Valve Maintenance

Valve Maintenance Overview Chapter 1 • Page 1

Chapter 1

Valve Maintenance Overview Experience has proven that periodic maintenance will make valves operate easier and seal properly. A small amount of the correct lubricant into the body or seat rings, fresh grease into the stem bearings, checking the stem packing and replenishing as necessary will add years, even decades to the service life of the valve.

Product loss because of stem leaks can be greatly reduced by simply tightening the gland packing or injecting a small amount of sealant. Cycling the valve, even partially, a few times a year will keep it from seizing in one position.

Practice valve sealing techniques by learning how to test valve seals through Block and Bleed and Double Block and Bleed procedures.

Before experimenting with dangerous on-line maintenance procedures, practice the routines on valves on the work bench. Get a good understanding of the capabilities of your equipment and the limitations of the valve you are working on.

Understand how to read a high-pressure injection gauge. Practice will teach you how to relate the gauge reading to what is physically happening inside the valve.

Always wear safety glasses when operating or servicing pressure-generating equipment.

The products and techniques presented have been developed by Sealweld Corporation over almost forty (40) years of practicing on-line valve maintenance. We strive to make the valve technicians job more productive through the development of effective products. We are constantly upgrading our sealant delivery systems by improving our pumps and adapters. Just as fuels such as gasoline have evolved over the years, so must our lubricant / sealants to remain insoluble. New products are constantly being developed to meet the demanding needs of pipelines around the world. As valve seals erode, heavier sealants must be injected in order to effect a seal. With the down-sizing of maintenance departments, valves are not topped-up as frequently; hence lubricant / sealants are expected to last longer before washing out or breaking down.

Page 2 • Chapter 1 Valve Maintenance Overview

The Valve Care Products referred to in this handbook have been developed to meet the specific needs of valve maintenance technicians. Similar products from other manufacturers may, or may not, be as effective. A common set of test standards is currently under development in order to more accurately compare the many brands of valve lubricants and sealants currently available. Copies of the technical papers presented at the 1990 and 1991 Offshore Technology Conferences can be obtained by contacting your nearest Sealweld® office.

ALWAYS consult the valve manufacturers owner’s manual prior to commencing work on any valve. Keep injection pressures below 4,000 PSI on cast iron and semi-steel valves. NEVER EXCEED the

working pressure of the valve you are servicing when filling the body cavity with grease.

Use EXTREME CAUTION before opening a valve body vent fitting. Know what product is in the valve. In cases of sour gas, wear emergency breathing apparatus and notify your fellow workers.

ALWAYS turn off your vehicle and work well down wind of all sources of spark or ignition.

When working around pressurized valves and pipelines, use extreme care and DO NOT take chances. Be prepared for equipment failure and have contingency plans. ALWAYS have a properly sized stabbing valve available in case of fitting failure. When working around valves containing sour gas, ALWAYS have your emergency breathing apparatus within arms reach as high-pressure injection may cause a damaged fitting to leak or break when you least expect it. Hydraulic pressure created inside the valve with a high-pressure grease gun can stretch bolts on bolted plug valves and cause leakage. Should this occur, simply release the pressure in the gun and hose assembly; the flange should sit back down and the leaking should stop.

ALWAYS use hearing protection when venting high-pressure gas valves.

Injection Gauge Reading Techniques Chapter 2 • Page 3

Chapter 2

Injection Gauge Reading Techniques In order to determine what is happening inside the valve, every gun or pump should be equipped with a working high-pressure gauge. Watch the gauge climb as sealant is injected; if the valve seat sealant system is empty, the gauge will build pressure with each stroke and drop off very quickly. As the seat sealant system fills, the gauge will drop off more slowly. The slower the gauge drops off, the tighter the fit between the seal faces. This is usually a good indication that the valve will seal when required. Cold weather will effect the viscosity of the sealing compounds and can give confusing signals. Practice pumping in all climates and conditions so you better understand by watching the movement of the gauge when the lubricant / sealant is moving into the valve passages.

High-Pressure Gauge

NOTICE how slowly the needle drops when pumping stops. This indicates how quickly sealant is moving into the valve. When the needle stops dropping or begins to fall more slowly, this usually

indicates the seat sealant system is full.

Gauge readings while injecting valve cleaner are often considerably lower than when injecting the lubricant / sealants because of its lighter viscosity. If the injection gauge climbs and does not drop off, this may indicate a plugged or restricted passage. Watch the gauge closely to see if the needle is moving at all. In cases where the sealant system is plugged, it is usually as a result of the drying and hardening of old sealant. Inject valve cleaner and leave it to soak from a few hours, to overnight in severe cases. Leave the gun attached to the valve and note the gauge pressure. Check the gauge periodically; a passage is cleared when the gauge begins to drop off. Cycle the valve to ensure complete coverage of the cleaner; continued injection will wash the residue downstream.

Page 4 • Chapter 2 Injection Gauge Reading Techniques

Sealant Injection Gauge

Air bubbles trapped inside the sealant hose or seat sealant system can cause the gauge to fluctuate wildly. When the gauge jumps from 2,000 PSI to 4,000 PSI and back again, this is usually an indication of trapped air. Remove pressure from the hose assembly by opening the release valve or by-pass valve and make sure the gauge reads (0 PSI) zero before disassembling the hose assembly. Compressed air bubbles in long hose assemblies may cause grease to spray with considerable force, disassembly of hoses or fittings to correct this problem should be performed with CAUTION.

ALWAYS wear eye protection when working around high-pressure equipment. A spray of grease which could not pierce skin can do severe damage to soft eye tissue.

Power Pumping Equipment Chapter 3 • Page 5

Chapter 3

Power Pumping Equipment Our field experience since 1969, has taught us that if you want the job done properly, you have to provide reliable and effective lubricant / sealant pumping equipment.

Most of the equipment used for servicing high-pressure valves is designed to build either 10,000 PSI or 15,000 PSI and can take a kick (flow back of line pressure due to sealant fitting failure). A simple automotive type grease gun can build-up to 8,000 PSI, but is not designed to take any flow back or kick of product. Because of this, low-pressure guns are not recommended for use on pressurized valves.

DO NOT USE LOW-PRESSURE GREASE GUNS FOR INJECTING SEAT SEALANT.

Low-pressure grease guns are used for greasing gearbox bearings only.

For best results use Sealweld® Eterna-Lube 1000 anti-seize and bearing lubricant compound.

DO NOT use in valve seat systems.

These guns are not designed to contain pipeline pressures in the event of fitting check valve failure.

Page 6 • Chapter 3 Power Pumping Equipment

Sealweld® ACTIV-8® The Sealweld® ACTIV-8® sealant injection pump is one of the most effective tools for servicing large diameter pipeline ball, gate and plug valves. It offers a very simple field repairable design. It is powered by compressed air, bottled breathing air or natural gas which is utilized to generate up to 10,000 PSI injection pressure instantly.

One of the more common problems with the old style Air Ram Bucket Gun was that because it has so many wearable parts, it is very difficult to repair and keep running in the field. The Air Ram Bucket Gun’s slower pumping speed usually meant the valve technician would start the pump and then go on to other tasks while the lubricant / sealant was being injected. In many cases the valve would be over-lubricated because the pump was left running too long or the valve was under-lubricated because there was a pocket of air in the can of lubricant / sealant and the pump air locked.

The ACTIV-8® has proven to be extremely effective on large diameter plug valves where hydraulic force is required to physically jack the tapered plug from its seat. A short quick shot of lubricant / sealant can often pop the plug from its seat. The high speed action can also wash contaminants from critical seal faces and will cut hours from the time spent when completely cleaning and re-lubricating large diameter valves.

Uni-Seal Pump The Uni-Seal Pump is a high speed hand-held pump that uses the same air / hydraulic motor as the Sealweld® ACTIV-8®. It is extremely effective for quickly servicing valves in hard to reach areas such as on towers or in tunnels. Its light weight makes it ideal for heli-portable work. Many operators power the pump with 125 PSI (maximum) natural gas.

ALWAYS use a filter and lubricator when utilizing natural gas as your power source.

The Uni-Seal will discharge sealant at up to 10,000 PSI and can empty a (1) one pound cartridge of sealant in less than (2) two minutes. In comparison, a hydraulic hand gun would require over 800 strokes and would need to be refilled once to discharge the same pound of sealant. A Sealweld® SuperGun® would require over 300 strokes to discharge a pound of sealant. It is easy to see why valves seldom receive sufficient quantities of lubricant / sealant.


Check your company policy regarding the use of natural gas.

Air Ram Bucket Gun The Air Ram Bucket Gun was developed over (30) thirty years ago and is capable of generating up to 15,000 PSI sealant injection pressure. It pumps directly from a (10 lb.= 5 quart) ten pound pail and the gun is wheel-mounted for easy transportation. It has a 100 to 1 ratio pump which uses air pressure to drive a reciprocating motor. The downtube assembly is a series of valve seats and ball checks which push the sealant through narrowing passages. As the passages narrow, the sealant pressure increases proportionally, up to 15,000 PSI. Any damage caused to the valve seats from dirt or grit in the grease pail will prevent the pump from building pressure. Care must be taken to keep the gun and sealant from becoming contaminated by dirt or sand.

One of the most common problems with the gun caused by trapped air in the downtube assembly. Care must be taken to expel all air from the top of a new pail when re-loading the gun. Peak the sealant in the center of the pail. Open the vent valve to expel the air as the follower plate moves down into the pail.


Operating Instructions 1. Open ram pull down valve # 1. This will allow

compressed air to escape the upper assembly.

2. Attach air hose to lower ram elevating fitting # 2 (keep clear of upper assembly of pump because it will rise rapidly).

3. After upper assembly has been raised, close valve # 1. This will allow the upper assembly to remain in the raised position. Detach air supply.

4. Attach container shield # 8 to (5) five quart = (10) ten pound pail # 9.

5. Remove the lid from can and peak the sealant to reduce trapped air.

6. Attach pail by tipping it approximately 45° while lifting it onto the follower plate to reduce trapped air.

7. Open pull down valve # 1. The pump assembly and pail will begin to lower. Watch that fingers do not get caught as the pail settles on the pump base and align pail in groove.

8. Make sure the groove which the pail rests in is clean and without buildup. The pail may rupture if it does not sit properly in the groove.

9. Open vent valve # 4 and by-pass valve # 5. This will allow air to escape as the pump assembly settles into the pail.

10. With ram pull down valve #1 open and throttle valve # 6 closed, attach air supply at air inlet nipple # 3. The upper assembly will begin to lower itself.

11. Once the pail has settled onto the base and follower plate has settled into the pail of sealant, open the throttle valve # 6 slightly and allow motor to run slowly. Sealant will begin to escape out vent valve # 4. Catch the escaping sealant on the pail lid or similar object.

12. Close both vent valve # 4 and valve screw # 5. Pressure should begin to move. Close release valve # 7, pressure should again begin to climb.

13. Open throttle valve # 6. Pump pressure should continue building to 100 times the inlet pressure. The motor will stall at this point. Discharge pressure will remain steady until release valve # 7 is opened.

14. To remove empty pail, elevate the pump assembly as in steps 1, 2 & 3 and tip pail until it breaks free of follower plate. If pail will not break free, remove as follows: Open vent valve # 4 and valve screw # 5. Connect air supply to the air nipple on vent valve # 4, the compressed air will blow the pail off the follower plate.

For repairs to this and any make of hand or power-operated lubricating equipment, contact: Sealweld Corporation in Calgary or Houston


Air Ram Bucket Gun Cut-Away View

Air Ram Bucket Gun Cut-Away View


Air Motor Parts Breakdown

Air Motor Parts Breakdown


Air Ram Bucket Gun Assembly

Air Ram Bucket Gun Assembly


Air Ram Bucket Gun Parts List Item # Description Part # KIT # Qty Req’d

1 Air Motor Complete R-RG-01 1 2 Retainer R-RG-02 1 3 Throttle Valve R-RG-03 1 4 Relief Valve R-RG-04 1 5 Air Tube R-RG-05 1 6 Male Connector R-RG-06 1 7 Air Nipple R-A8-15A 1 8 Ram Needle Valve R-RG-08 K-4 1 9 O-RING R-RG-09 K-4 1 10 Gasket R-RG-10 K-4 1 11 O-RING R-RG-11 K-4 6 12 Yoke R-RG-12 1 13 Hex Head Cap Screw R-RG-13 2 14 Socket Head Cap Screw R-RG-14 4 15 Lock Washer R-RG-15 3 16 Yoke Retain Screw R-RG-16 2 17 Air Coupler R-A8-14H 18 Base R-RG-18 1 19 Cylinder R-RG-19 2 20 Cylinder Head R-RG-20 2 21 Cylinder Gasket R-RG-21 K-4 2 22 Piston Rod R-RG-22 2 23 Piston Retaining Screw R-RG-23 24 O-RING R-RG-24 K-4 2 25 Piston Retaining Washer R-RG-25 2 26 Piston Packing R-RG-26 K-4 2 27 Retaining Ring R-RG-27 K-4 4 28 O-RING R-RG-28 K-4 2 29 O-RING R-RG-29 K-4 2 30 Restrictor Ell Assembly R-RG-30 1 33 Pump Body R-RG-33 1 34 Follower Plate R-RG-34 1 35 Follower O-ring R-RG-35 K-4 1 36 Down Tube Assembly R-RG-36 1 37 Roll Pin R-RG-37 K-5 3 38 Piston Rod R-RG-38 1 39 Rod / Valve Assembly R-RG-39 K-5 1 42 Tube Extension R-RG-42 1 43 Stop Washer R-RG-43 K-5 1 45 Steel Ball R-RG-45 K-5 1 46 Hex Nut R-RG-46 K-5 1


Item # Description Part # KIT # Qty Req’d 47 Primer Rod Pin R-RG-47 K-5 1 48 Cotter Pin R-RG-48 K-5 1 49 Steel Washer R-RG-49 K-5 1 50 Valve Seat R-RG-50 K-5 1 51 Gasket R-RG-51 K-5 1 52 Lock Washer R-RG-52 K-5 1 53 Extension R-RG-53 K-5 1 54 Primer Body R-RG-54 1 55 Piston & Cylinder R-RG-55 1 56 Coupling R-RG-56 K-5 1 57 Spring R-RG-57 1 58 Coupling R-RG-58 K-5 1 59 Piston Plug R-RG-59 1 60 Nipple R-A8-15A K-5 2 61 Gasket R-RG-61 2 62 Gasket R-RG-62 K-5 1 63 Yoke Retaining Washer R-RG-63 K-5 1 64 Piston Rod Packing R-RG-64 1 65 Piston Retaining Washer R-RG-65 K-5 2 66 Valve Screw R-RG-66 1 67 Vent Valve R-RG-67 K-4 1 68 Pressure Gauge R-RG-68 1 69 High-Pressure Hose S-120XHP 1 70 "L" Swivel H-SV-L1 1 71 Straight Swivel H-SV-ST1 1 72 Giant Buttonhead Coupler H-CPSG-2 1 75 Handle R-RG-75 1 76 Can Shield R-RG-76 1 78 Kick Stand R-RG-78 2 79 Axle R-RG-79 K-1 2 81 Spring R-RG-81 K-2 1 82 Retaining Ring R-RG-82 K-1 2 83 Release Valve H-RVAB K-2 1 84 Wheel R-RG-84 2 85 1/2" Lock Washer R-RG-85 K-2 2 86 3/8" - 16 x 1/2" Screw R-RG-86 K-2 2 87 5/16" Washer R-RG-87 K-2 1 88 3/8" Lock Washer R-RG-88 K-1 1 89 3/8" - 16 x 2" Screw R-RG-89 K-1 1 90 3/8" - 16 Nut R-RG-90 K-1 1 92 5/16" Lock Washer R-RG-92 K-1 3 94 5/16" - 18 Screw R-RG-94 K-1 1

100 Air Motor Body R-RG-100 1


Item # Description Part # KIT # Qty Req’d 101 Air Line Screw R-RG-101 K-1 1 102 Flat Washer R-RG-102 1 103 Cap Tube R-RG-103 1 104 Cap Tube Gasket R-RG-104 K-3 1 105 Air Cylinder R-RG-105 1 106 Piston Nut R-RG-106 K-3 1 107 Back-Up Washer R-RG-107 2 108 Doughnut Packing R-RG-108 1 109 Aluminum Washer R-RG-109 1 110 Packing Spacer R-RG-110 K-3 1 111 Motor Nut R-RG-111 1 112 Gasket R-RG-112 3 113 Cylinder O-RING R-RG-113 K-3 1 114 Toggle Cap R-RG-114 K-3 1 115 Toggle Cap Gasket R-RG-115 K-3 1 116 Toggle Spring R-RG-116 1 117 Plunger R-RG-117 K-3 1 118 Toggle R-RG-118 K-3 1 119 Shuttle R-RG-119 1 120 Slide Valve Screw R-RG-120 2 121 Lock Washers R-RG-121 2 122 Slide Valve Assembly R-RG-122 K-3 1 123 Valve Retainer R-RG-123 K-3 1 124 Slide Valve Gasket R-RG-124 K-3 1 125 Elbow R-RG-125 1 126 Compression Nut R-RG-126 K-3 1 127 Compression Sleeve R-RG-127 1 128 Cover R-RG-128 1 129 Cover Screw R-RG-129 1 130 Piston Rod R-RG-130 1 131 Nylon Washers R-RG-131 2 132 Lower Packing R-RG-132 1 133 Spacer R-RG-133 K-3 1 134 Brass Washer R-RG-134 K-3 1 K-1 Kick Stand Kit R-RG-K1 1 K-2 Wheel Repair Kit R-RG-K2 1 K-3 Air Motor Kit R-RG-K3 1 K-4 Minor Repair Kit R-RG-K4 K-6 1 K-5 Downtube Repair Kit R-RG-K5 K-6 1 K-6 Major Repair Kit R-RG-K6 K-6 1

Air Ram Bucket Gun Parts

Screw-Primed Hand-Held Sealant Injection Pumps Chapter 4 • Page 15

Chapter 4

Screw-Primed Hand-Held Sealant Injection Pumps

Sealweld® SuperGun® The SuperGun® is a hand-held manual sealant injection gun which can generate up to 15,000 PSI if required. The SuperGun® was developed in an effort to correct design deficiencies in the older styles of screw-primed guns.

The added replaceable sleeve over the pump piston cuts repair costs by over 75% compared to similar equipment. The sealant barrel was enlarged 33% so that less refills would be required and so that it would hold the contents of a regular (16 oz.) sixteen ounce grease gun cartridge. Several other enhancements were added to make the gun more durable, easy to carry and pump faster. The SuperGun® will discharge (1 oz.) one ounce of lubricant / sealant with every (25) twenty-five strokes of the handle, making it the valve technicians favorite gun for routine topping-up procedures when only small quantities of lubricant / sealant are required.

Page 16 • Chapter 4 Screw-Primed Hand-Held Sealant Injection Pumps

Hydraulic Hand-Held Sealant Injection Pump The hydraulic hand gun has been improved recently by the addition of a locking handle clasp. This makes carrying the gun much easier and eliminates one of the main causes of the gun breaking down in the field.

There exists the risk for a dangerous problem with corrosion occurring on some hydraulic guns internal hydraulic relief valves. Some of the older styles of hydraulic hand guns utilized an internal relief valve which was not zinc plated. Over time, as air and water got into the hydraulic system, these un-plated relief valves would begin to corrode and then not relieve properly. This resulted in some guns building up to 20,000 PSI before thread failure would occur and the gun barrel blew out. Several valve technicians were injured before the problem was identified. All Sealweld® hydraulic hand guns have a zinc plated relief valve. If you suspect some of your existing hydraulic guns may have the old un-plated relief valve, Sealweld® can inspect or repair them and / or teach your personnel how to do their own gun repairs.

Another improvement included the introduction of a nylon sealant piston cup seal instead of the old hardened leather type. The nylon has superior wear resistance and sealing ability which prevents the hydraulic fluid in the gun from being contaminated by the lubricant / sealant.

Instructions for Re-Filling Hydraulic Hand Gun Fluid Bag This procedure will determine if your gun needs repair or is simply low on hydraulic fluid.

Many types of hydraulic fluids can be used, but you should not mix different types of oil in the same system. Guns operated in extremely cold climates require special cold temperature / high-pressure hydraulic fluid.

If the re-filling procedure does not solve your gun problem, we recommend you tag the gun for repair. Send the gun in for repair if you do not know the repair procedure; we can also provide an instructor to teach you how to repair your own equipment.


Fluid Bag Filling Instructions 1. Open by-pass valve # 4, check gauge to make sure all internal pressure has been relieved from the system.

2. Remove grease cap # 1 with hose assembly from gun. Unscrew the handle # 10 and use it as a lever if the cap # 1 is difficult to remove.

3. Push the barrel piston # 2 to the bottom of barrel # 3 with handle # 10. Be careful not to scratch the inside of the barrel with the handle.

4. Turn the gun over so that the grease barrel # 3 points down (towards ground). Secure in a vise if possible.

5. Close by-pass valve # 4 and replace pump handle # 10. Pump handle (50) fifty strokes.

6. Open by-pass valve # 4 to relieve pressure.

7. Remove end cap # 1 from fluid bag barrel. Some older versions have the end cap secured by small set screws. Remove the set screws before unscrewing end cap.

8. Remove Allen screw from the end of the fluid bag # 12. The hole in the fluid bag should be pointing straight up.

9. To top-up fluid bag # 12 with hydraulic fluid, use a squeeze bottle and add fluid slowly. Work your fingers around the top of the fluid bag in an attempt to dislodge air bubbles which may be trapped inside. Leave the Allen screw out while trapped air continues to escape; overnight is ideal.

10. Top-up the fluid bag and leave open until bubbles are no longer seen escaping.

11. Replace Allen screw and tighten. Replace end cap # 14 and tighten.

12. Reload the barrel with valve cleaner or lubricant / sealant. Replace end cap # 1 and tighten in place.

13. Close by-pass valve # 4. Attach gun coupler to valve fitting and begin pumping handle to build pressure. Read the high-pressure gauge to determine what is happening inside the valve.

Body Profile

Body Cross Section

Piston Assembly & Linkage Assembly

Handle Latch Assembly


Hydraulic Hand Gun Parts List Item # Description Part # KIT # Qty Req’d

1 Sealant Barrel Cap R-HG07 1 2 Piston Assembly R-HG08 1

2A Cap Screw R-HG08A 1 2B Washer R-HG08BA 1 2C O-Ring R-HG08B 2 2D Outer Washer Nut R-HG08C 1 2E Outer Nylon Cup R-A8-20C XX 1 2F Piston Body R-HG08E 1 2G Piston O-Ring R-HG08F X 1 2H Inner Leather Cup R-HG08H XX 1 2I Inner Washer Nut R-HG08I 1 3 Sealant Barrel R-HG09 1

3A Barrel Gasket R-HG10A XX 1 3B Body Barrel O-Ring R-HG10 X 1 4 Body Assembly R-HG11 1

4A Body (Bare) R-HG11A 1 5 Hydraulic Pump Cylinder R-HG11B XXX 1

5A Cylinder Neck O-Ring R-HG11C X 1 5B Bottom Cylinder O-Ring R-HG11D X 1 5C Pump Piston R-HG11E XXX 1 6 Check Valve Assembly R-HG11F XX 1

6A Copper Washer R-HG11FA 1 6B Ball R-HG11FB 1 6C Spring R-HG11FC 1 6D Check Valve Screw R-HG11FD 1 6E Check Valve Screen R-HG11FE 1 7 By-Pass Valve Assembly R-HG11G XX 1

7A By-Pass Stop R-HG11H 1 7B Cap Screw R-HG11I 1 7C O-Ring R-HG31 X 1 8 Hydraulic Relief Valve R-HG11J 1

8A Hydraulic Relief O-Ring R-HG11K X 1 9 Fulcrum Assembly R-HG12 1

10 Handle R-HG13 1 11 Linkage Assembly R-HG14 1

11A Link R-HG14A 2 11B Bolts R-HG14B 3 11C Washers R-HG14D 3 11D Lock Nuts R-HG14C 3

Hydraulic Fluid R-HOPINT XX 1 12 Fluid Bag R-HG15 XX 1

12A Fluid Bag Seal R-HG15A 1


Item # Description Part # KIT # Qty Req’d 13 Fluid Bag Barrel R-HG16 1 14 Fluid Barrel Cap R-HG17 1

15 * Set Screw (Optional) R-HG33 1 16 Handle Latch Assembly R-HG30 1

16A Stem & Knob R-HG30A 1 16B Latch Screw R-HG30B 1 16C Spring R-HG30C 1 16D Retainer R-HG30D 1 16E Latch Arm R-HG30E 1 16F Spring R-HG30F 1 16G Latch Sleeve R-HG30G 1 16H Cap Screw R-HG30H 1

X O-Ring Repair Kit R-HGOREP 1 XX Minor Repair Kit R-HGMIN 1

XXX Major Repair Kit R-HGMAJ 1 Latch Conversion R-HG-LC 1


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Gun Loading Techniques Chapter 5 • Page 21

Chapter 5

Gun Loading Techniques Loading viscous valve sealants can be a sticky proposition. Valve sealants in stick form were developed to keep the valve technicians hands clean. Experience has proven that stick type sealants have an extremely short service life in dry gas service and can make valves hard to turn in cold weather. Sealweld® sealants are unfortunately much stickier; however, once they are inside the valve they remain effective much longer. To help in loading the stickier sealants, Sealweld® has recently invented a device called the EZ-LOADER. It is used to transfer cartridge type lubricant / sealants into the SuperGun®, hydraulic hand gun or Uni-Seal Pump type guns. The EZ-LOADER loads cartridges quickly and easily with no mess or loss of product. One of the biggest complaints from customers are problems with stick greases becoming contaminated by dirt, sand and grime by leaving boxes of stick grease open in the back of a truck. By keeping the lubricant / sealant in cartridges, the risk of contaminants being accidentally pumped into a valve is greatly reduced.

EZ-LOADER for Stick Grease Cartridges

Some hydraulic gun manufacturers recommend the use of lubricant / sealant in plastic bags or Gun-Paks and that they can be loaded into the barrel by simply dropping the un-opened bag into the barrel. On some types of guns there is a special nipple for piercing the plastic bag and a screen for keeping the bag from being pumped into the valve. Unfortunately, not all gun manufacturers provide this feature and quite often these nipples and screens are removed during routine repairs and not replaced. Sealweld® recommends that the lubricant / sealant be stripped out of the plastic Gun-Pak bag and that the bag be thrown away so that there is no chance for the plastic to be pumped into the sealant fitting or valve.

Page 22 • Chapter 5 Gun Loading Techniques


High-Pressure Hose Assemblies Chapter 6 • Page 23

Chapter 6

High-Pressure Hose Assemblies High-pressure hose assemblies should ALWAYS be kept free from grease build-up and kept in good condition. Replace all broken, leaking or damaged connections.

Make sure all components are rated for at least 5,600 PSI working pressure in order to assure a reasonable safety margin. Be EXTRA CAREFUL whenever generating pressure in excess of 10,000 PSI, at these higher pressures old hose components are at their most vulnerable.

Extra long hose assemblies may provide too much friction when pumping viscous valve sealants. This results in excessive pressure drop by the time the sealant reaches the end of the hose. This is especially true when pumping in cold climates. ALWAYS use the shortest hose possible in order to achieve maximum performance from your pump.

ALWAYS bleed off all trapped air pockets caused by reloading guns and pumps before they get into long hose assemblies. It is very easy to trap air pockets in a long hose assembly even with light grease. Be suspicious of trapped air in the hose when the pump is running properly but no grease is coming out the end of the hose.

Many high-pressure hoses are connected with special high-pressure fine hydraulic thread. Be careful not to screw the wrong thread types together as they will fail under high-pressure pumping.

Page 24 • Chapter 6 High-Pressure Hose Assemblies

Be very careful of grease escaping through the vent hose on release valve # 6. DO NOT have your thumb or fingers over the hole when closing the valve and beware of spraying grease.

High-Pressure Hoses and Accessories Category Item # Description Part # Hose Assemblies A Sealweld® SuperGun® H-S-HOSE B Hydraulic Hand Gun H-H-HOSE C Uni-Seal Pump H-U-HOSE D Air Ram Bucket Gun H-R-HOSE E Sealweld® ACTIV-8® Gun H-A-HOSE Adapters 1A 1/8F X 1/8F Coupling H-AD-2F2F 1B 1/8F X 1/4F Coupling H-AD-2F4F 1C 1/8F X 1/2-27F Coupling H-AD-2F7F 1D 1/8M X 1/8M Nipple H-AD-2M2M 1E 1/8M X 1/4F Adapter H-AD-2M4F 1F 1/8M X 1/4M Adapter H-AD-2M4M 1G 1/8M X 1/2-27F Adapter H-AD-2M7F 1H 1/8M X 1/2-27M Adapter H-AD-2M7M 1I 1/4F X 1/4F Coupling H-AD-4F4F 1J 1/4F X 1/4M Elbow - 90° H-AD-4F4M-L90

1K 1/4F X 1/2F Coupling H-AD-4F7F 1L 1/4M X 1/2- 27M Adapter H-AD-4M7M 1M 1/4M X 1/4M Nipple H-AD-4M4M 1O 1/4M X 1/8F Adapter H-AD-4M2F 1P 3/8F X 1/4M Adapter H-AD-4M6F 1Q 3/8F X 1/4M Elbow - 90° H-AD-4M6F-L90

1R 1/2-27M X 1/8F Adapter H-AD-7M2F 1S 7/16-27M X 1/8F Adapter H-AD-9M2F 1T 7/16-27M X 1/4F Adapter H-AD-9M4F Couplers 2A Sealweld® Giant Buttonhead Coupler H-CPSG-2 2B Repair Kit for Sealweld® Coupler H-CPSGR 2C Sealweld® Screw-On Coupler H-CPSO 2E Nordstrom Coupler with Check H-CPRG 2F Repair Kit for Nordstrom Coupler H-CPRGR Low-Pressure Couplers 2G Alemite Giant Buttonhead Coupler H-CPAG 2H Repair Kit for Alemite Giant H-CPAGR 2I Alemite Small Buttonhead Coupler H-CPAS 2J Repair Kit for Alemite Small H- CPASR 2K Alemite Small Coupler without Adapter H-CPAS-B 2L Lincoln Small Buttonhead Coupler H-CPLS 2M Lincoln Small Coupler without adapter H-CPLS-B High-Pressure Gauges 3A Sealweld® 15,000 PSI Gauge H-GD-01 3B 15,000 PSI Gauge with Guard H-GD-01C 3C Gauge Guard 2.5" H-GG-2.5

High-Pressure Hose Assemblies Chapter 6 • Page 25

Category Item # Description Part # Hoses 4A 18" High-Pressure Hose H-HS-18"XHP 4B 28" High-Pressure Hose H-HS-28"XHP

Call Sealweld® 4C 10 foot High-Pressure Hose H-HS-120XHP for pricing 4D 5 foot High-Pressure Hose H-HS-60XHP

and 4E 15 foot High-Pressure Hose H-HS-180XHP availability 4F 20 foot High-Pressure Hose H-HS-240XHP

of these items 4G 30 foot High-Pressure Hose H-HS-360XHP 4H 18" Low-Pressure Hose - 1/8" H-HS-18"LP 4I 10 foot x 3/8" High-Pressure Hose H-HS-120HP Swivels 5A "Z" Swivel 1/4 X 1/2-27 H-SV-Z1 5B Straight Swivel 1/4 X 1/2-27 H-SV-ST1 5C "L" Swivel 1/4 X 1/2-27 H-SV-L1 5D Straight Swivel 1/4 X 1/4 H-SV-ST2 5E Straight Swivel 1/8 X 1/2-27 H-SV-ST3 Release Valve 6 1/4M X 1/4F H-RVAB Tee 7 1/4 X 1/4 X 1/4 H-T-444

Page 26 • Chapter 6 High-Pressure Hose Assemblies


Sealant Injection Fittings, Adapters and Special Tools Chapter 7 • Page 27

Chapter 7

Sealant Injection Fittings, Adapters and Special Tools

Identifying Dangerous Two-Piece Fittings There are several different styles of two-piece buttonhead fittings. The illustration below describes the differences between the most common styles. The drawing in the center illustrates the multi-rib style of pressed on top. This is the style which failed at a nearby compressor station at relatively low injection pressure (estimated 3,000 to 5,000 PSI). With this design, the ribs form a friction fit with the body section; there are no threads or additional ribs in the body portion. As there are no identifying marks on the samples we have in our failed fitting collection, we are unable to positively identify the manufacturer of this style of fitting.

Dangerous Two-Piece Fitting Designs

Two-piece fitting manufacturers distribute through a wide variety of industrial supply firms. It is possible that these types of fittings were introduced to the pipeline system many years ago and have been in service or in inventory since then. They could have also been purchased recently as old inventory from any number of sources, the supplier not realizing the potential danger of this style fitting when placed in high-pressure service.

Page 28 • Chapter 7 Sealant Injection Fittings, Adapters and Special Tools

The illustration on the left, is the other type of two-piece buttonhead fitting. The manufacturer's catalogue describes the fitting as being designed for heavy duty use, on industrial construction and earth moving machinery. Notice the single lip which secures the hardened buttonhead.

We encountered a failure of this style of buttonhead fitting several years ago. The top section separated at only 3,000 PSI while injecting sealant at approximately eighty 80° degrees Fahrenheit. This was on a twenty 20" inch ball valve manufactured in Scotland. The fitting had been provided as original equipment from the manufacturer. Upon further discussion with the manufacturer, they advised that they quit installing the two-piece buttonhead fitting in 1988 and now only utilize the one-piece design. Fortunately no one was injured when the fitting came apart because the buried inner check valve held back the 1000 PSI gas pressure.

Identifying One-Piece Fittings

One-Piece Sealant Injection Fittings

There is no doubt that the one-piece body is less likely to come apart under pressure. The weak point of the one-piece design is the use of a light crimp on the bottom of the fitting which holds the ball and spring in place. It is not difficult to collapse the spring inside the fitting when injecting cold or heavy sealing compounds (see Page 2 of the FLOW WOLF® brochure). This restricts sealant flow and can eventually plug off the fitting. Continued injection with high-pressure guns or pumps can straighten the crimp and the ball check mechanism is then blown into the valve body. This often results in the seat sealant system becoming completely plugged off. It can also result in gas or product escaping out through the fitting, which can be difficult to stop and may trigger an emergency shut-down if inside a compressor station.

Should this occur, the Sealweld® FLOW WOLF® Leak-Lock # 1 adapter can be attached to the leaking giant buttonhead fitting and the top section tightened to make a seal. Once the leak is stopped, cleaner and / or sealant can still be injected into the valve. During the next scheduled shut-down, the pipeline can be de-pressurized and the damaged fitting can be safely replaced.

Dangerous 1/4" One-Piece Fittings Another weak point of most one-piece styles is the risk of the fitting snapping in two as a result of inadequate wall thickness on 1/8" NPT and 1/4" NPT sizes. The failure usually occurs at the transition zone between the threaded portion and the body shoulder. It can be caused by dropping a wrench on the fitting or by standing on the fitting while climbing to examine the actuator. Occasionally the buttonhead coupler can become locked onto the buttonhead fitting if the pressure is not relieved from the sealant hose assembly. Inexperienced maintenance people have been known to use a hammer to remove the coupler from the fitting and the striking blow has been known to cause these smaller sized fittings to break in two.

With the one-piece design there must be sufficient clearance through the bottom of the fitting to insert a ball check and spring mechanism. Many of the 1/4" and larger one-piece giant buttonhead fittings feature a

Sealant Injection Fittings, Adapters and Special Tools Chapter 7 • Page 29

double ball check system. These types require an even larger internal passage which further reduces the wall thickness in the threaded area. This lowers the burst rating of the fitting and offers little if any safety margin.

Unfortunately most valve manufacturers have cut only a 1/4" NPT thread into the body of the valve for sealant fittings. We strongly recommend that you urge the valve manufacturers to use a 3/8" NPT or 1/2" NPT thread to reduce the risk of this type of fitting failure on all new valves. For valves that must use a 1/4” NPT fitting, standardize with a .316 stainless steel material for increased mechanical strength.

Special Uses and Safety Advantages of the FLOW WOLF® Fitting Many of the valves currently in service have only a 1/4" NPT thread for sealant fittings. To safely re-fit these valves, we suggest the use of a 1/4" FLOW WOLF® sealant injection fitting made from .316 stainless steel or a 1/4” NPT male x 3/8" or 1/2" NPT female stainless steel adapter. The .316 stainless material is readily available from Parker or Cajon or similar sources and offers burst rating of 18,000 PSI to 24,000 PSI which provides a comfortable safety margin. Because these adapters do not have check valve mechanisms, there is adequate wall thickness in the threaded area and increased material strength. Install a 3/8" or 1/2" NPT FLOW WOLF® style sealant injection fitting into the adapter. Remember to advise maintenance staff to completely de-pressurize the pipeline leading up to the valve as well as the valve body before attempting to remove a sealant injection fitting. Do not rely on the buried inner check valve to hold back line pressure, they are notoriously unreliable.

The special single ball check feature in the FLOW WOLF® fitting allows the valve technician to attach the SO-BV Tool to the fitting which can un-seat the ball check. The technician can then test if the buried internal check valve is in place and working or if it has been damaged or removed. If the seat sealant system is plugged or if solid contaminants become trapped behind the valves seat rings, proper use of the SO-BV Tool enables the technician to back flush these contaminants out through the tool.

A 1/2" 3000 PSI stabbing valve should always be screwed into the SO-BV Tool before the stinger un-seats the ball check in the fitting. Hydrates or contaminants may prevent the ball check from re-seating when the stinger is retracted after the back flushing or venting is complete. With the ball valve attached to the SO-BV Tool, simply close the valve to contain the leakage. The leaking ball check can usually be properly seated by injecting a small amount of Sealweld® # 5050 ball valve sealant back through the 1/2" ball valve, SO-BV tool and fitting.

Page 30 • Chapter 7 Sealant Injection Fittings, Adapters and Special Tools

Suggested Actions There are such a wide variety of designs and styles of sealant fittings it is difficult to recommend that any particular fitting be withdrawn from a pipeline system without close examination. The best way to judge if it is one-piece or two-piece construction is to examine the bottom of the fitting. If the fitting is installed into a pressurized valve, it would be extremely dangerous to remove it to examine the bottom in an attempt to determine whether or not it is of one-piece construction. DO NOT rely on the buried inner check valve to hold back line pressure. ALWAYS blow down the pipeline both upstream and downstream before removing any sealant injection fittings on ball and gate valves. As this is impractical in most situations our best advice would be to NOT service the valve if the technician has any doubts if the fitting is safe or not.

Call Sealweld® for on-site valve maintenance training seminars, available worldwide.

When examining sealant fittings; if a crimp is obvious then you can be almost certain that it is of one-piece construction. If the bottom is flat and no crimp is present, then it is probably a two-piece fitting and should be discarded. The FLOW WOLF® design is obvious by its threaded cage (with Allen head) screwed into the bottom of the fitting and FLOW WOLF stencil on the wrench flats. Sealweld® valve maintenance technicians tour the many miles of pipeline on a regular basis. We would be glad to stop in at any location and examine any fittings in question to make a determination. By spending a little time with your valve technicians, we can show them some of our many failed fitting samples and teach them how to make their own determinations regarding the integrity of fittings.

Sealweld® FLOW WOLF® Valve Maintenance Adapter Kit Chapter 7 • Page 31

Sealweld® FLOW WOLF® Valve Maintenance Adapter Kit A collection of the most commonly used adapters for servicing all makes of valves.

FLOW WOLF® Leak-Lock # 1 FLOW WOLF® Leak-Lock # 1 Adapter for leaking or damaged giant buttonhead fittings Stops leakage to atmosphere and allows for the safe injection of valve cleaners and sealant.

Order Part Number - D-FW-LL1-SS

FLOW WOLF® Leak-Lock # 2 FLOW WOLF® Leak-Lock # 2 Adapter for leaking or damaged small buttonhead fittings. Converts a small buttonhead fitting to a giant buttonhead fitting for easy servicing.

Order Part Number - D-FW-LL2-SS

Page 32 • Chapter 7 Sealweld® FLOW WOLF® Valve Maintenance Adapter Kit

FLOW WOLF® Leak-Lock with Metal Seat FLOW WOLF® Leak-Lock with Metal Seat designed for all types of giant buttonhead fittings with a metal cap. Converts non-standard buttonhead connections to North American standards for connecting guns and pumps.

Order Part Number - D-FW-LL1-MS-SS

FLOW WOLF® - Cameron® Adapter FLOW WOLF® - Cameron® Adapter - Use in Cameron® Ball Valves that are equipped with a small capped fitting. Threads onto cap thread connection.

Order Part Number – D-FW-CAM-SO


Screw-On Body Vent Tool The SO-BV Tool - Screw-On Body Vent Tool threads onto fittings with a metal cap and sends a stinger down to un-seat the ball check. Ideal for preventing pressure lock in W-K-M® gate valves.

Order Part Number - D-SO-BV

FLOW WOLF® - Screw-On to Buttonhead Adapter FLOW WOLF® - Screw-On to Buttonhead Adapter

Converts W-K-M® fittings without a buttonhead flange to accept a standard slip-on giant buttonhead coupler.

Order Part Number - D-FWSO-BH


FLOW WOLF® - Packing Injector Adapters FLOW WOLF® - Packing Injector Adapters for threaded stem plug valves. Remove Allen head screw and install a buttonhead adapter to inject valve cleaner and loosen the old hardened packing.

Order Part Number - D-PIT-KIT

FLOW WOLF® - Orifice Fitting Adapter FLOW WOLF® - Orifice Fitting Adapter - Inject valve cleaner to soften old stick grease follow-up by injecting a soft sealant such as Sealweld® Total-Lube # 911 will fit most types of standard packing injectors.

Order Part Number - D-FWOA1/4 T


FLOW WOLF® - Packing Injector Relief Stinger The Packing Injector Relief Stinger features a special tip on stinger and groove along threads for relieving excess packing pressure that may be causing increased torque in gate valves.

Order Part Number - D-PI-RLF

FLOW WOLF® - Small Screw-On Connection Small Screw-On to Standard Screw-On Connection - Use in W-K-M® / IKS ball valves with small capped fitting. Connect to the D-FWS0-BH adapter.

Order Part Number - D-SSO-SO



Instructions for Installing Auxiliary Fittings Chapter 8 • Page 37

Chapter 8

Instructions for Installing Auxiliary Fittings Due to the possibility of extreme high pressures being generated while servicing pipeline valves, these fittings are designed with a one-piece body.

DO NOT remove fittings from pressurized valves.

The threads which connect the fitting to the valve are found on the body of the fitting. Wrap these threads with thread tape or other suitable thread lubricant. DO NOT use Lock-Tite or similar thread locking material as it may adversely effect the ball check device inside the fitting.

Attach the proper size wrench to the fitting body only when tightening and removing auxiliary valve fittings.

DO NOT tighten the fitting into the valve by the bolt or cap.

Screw the fitting into the valve tightly, being careful not to cross thread the fitting. Should the threads begin tightening prematurely, back the fitting out and inspect for thread damage. Re-tape the threads and repeat as necessary.

Once tightly installed, service fittings as described below.

Body Vent Fittings

Turn the bolt in and out several times and lubricate thread with penetrating oil or similar light oil. Brush the threads with Sealweld® Eterna-Lube 1000 anti-seize compound or equivalent. Leave the bolt screwed in and tighten down snugly with a wrench. Use a back up wrench on the body

To open: Place wrench on bolt and turn counter-clockwise, making sure to use a back up wrench on the fitting body. DO NOT unscrew the bolt from the body. Once the valve is pressurized, beware of escaping product from the valve. Follow company safety regulations for venting pressurized valves.

NOTE: DO NOT OVER-TIGHTEN.

Page 38 • Chapter 8 Instructions for Installing Auxiliary Fittings

Capped Sealant Injection Fittings

Lubricate the cap threads with penetrating oil or similar light oil, then tighten. ALWAYS put a back-up wrench on the body wrench flats when tightening and when removing cap.

Capped Sealant Injection Fitting

Giant Buttonhead Sealant Injection Fittings

Once the fitting is installed, place a plastic cap over the buttonhead flange to keep dirt and grit away from the fitting.

Part Number F-BHCAPS - Giant Buttonhead Sealant Injection Fitting

Packing Injectors

Back the bolt all the way out of the body then lubricate threads with penetrating oil or similar light oil. Insert screw bolt back into body and tighten. Be sure to use a back up wrench on the body when tightening and removing.

Packing Injector

Different Styles of Sealant Injection Fittings and Specialty Adapters Chapter 9 • Page 39

Chapter 9

Different Styles of Sealant Injection Fittings and Specialty Adapters The next biggest obstacle after you get your pumping equipment loaded and operating properly is being able to connect your pump or gun to the valves sealant injection fitting. Due to the lack of any industry standards regarding fittings, the valve technician has no idea what type to expect when he travels into the field to service valves. Not even the valve manufacturer can tell you because they quite often install many different types of fittings depending on the service, pressure rating or what the fitting manufacturer had on sale that week. Fittings are often replaced by contractors during turn-around and in the absence of a specific company policy; the contractor will often supply whatever is available at the local industrial supply house.

Sealweld® has produced a wall chart which illustrates the most popular sealant fittings and accessories. Actual sized photographs make it easy to order the proper replacement. Call your nearest Sealweld® office for a free copy of the Fitting Poster and Gun & Adapters Poster.

In order for Sealweld® valve technicians to be prepared for every different fitting possibility, we carry up to 100 different styles, sizes and grades of fittings and adapters in our vehicles. Just the other day we discovered a new valve manufacturer that featured a new make of fitting which would have no possible way of being utilized without manufacturing another unique adapter. This fitting would also have met the new CSA specification because it featured a one-piece body, giant buttonhead flange and independent internal check valve. The buttonhead flange was too thick so a standard buttonhead coupler (located on the end of the sealant gun hose) would not fit. The threads on the cap were metric so the alternative screw-on style coupler would not fit either. Unfortunately this situation is more often the rule than the exception.

Cutaway View of a Sealant Injection Fitting

Page 40 • Chapter 9 Different Styles of Sealant Injection Fittings and Specialty Adapters

Sealant Injection Fitting Terminology

During plant and pipeline construction one of the more common mistakes is installing a combination fitting with an NPS thread into a valve body or extension with NPT threads. The illustration below shows the long neck fitting. In many cases the valves are insulated and the long neck NPS fitting was installed in order to extend the buttonhead out through the insulation. If you discover this problem in some of your valves, ALWAYS WAIT for the pressure to be reduced to (0 PSI) zero in the pipeline leading up to the valve before attempting to remove the NPS fitting. Chances are that if the fitting has been in the valve for some time, there is no immediate requirement for replacement. Use extreme caution if injecting lubricant / sealant into valves with this problem. There are probably only (2) two or (3) three poorly fitting threads holding the fitting in place. If there is any obstruction in the fitting, high injection pressures may be required. The use of high injection pressure could result in the threads failing and the fitting blowing out of the valve body, which may result in an uncontrolled leak and / or the risk of personal injury. In this case, you should NOT attempt any maintenance, but wait until the fitting can be safely replaced.

Conventional NPT Type Fitting Conventional NPS Type Fitting

Common Tapered Thread Fitting Common Straight Thread Fitting

Valve Cleaners, Lubricants & Sealants Chapter 10 • Page 41

Chapter 10

Valve Cleaners, Lubricants & Sealants In order to avoid any confusion surrounding the use of the words grease, lubricant and sealant, all are words used to describe a grease-like substance. There are those who believe that the more viscous greases make better sealants. In truth, the best sealants are greases which are insoluble in the product flowing through the valve and have special additives to bridge off a leak path. Throughout most of this manual we describe all of these products as lubricant / sealants to avoid confusing the reader with terminology.

Body Filler Greases Commonly used in wellhead gate valves and other larger gate valves where hydrates may be present. The body cavity is filled with this light grease to prevent the hydrates (which would otherwise collect in the valve's body cavity) from freezing when throttling or when the outdoor temperature drops below freezing. These greases also prevent other contaminants from collecting in the bottom of the valve body. Body filler greases will lubricate the metal seating surfaces and prevent galling. The grease should also prevent internal corrosion of unprotected metal surfaces and reduce torque required to cycle the valve. These light greases are made from petroleum oil and thickened with clay fillers; corrosion inhibiting agents are commonly added. These types of greases are often used by ball and gate valve manufacturers to keep internal components from rusting during shipment and storage. These light greases should be washed out of the seat sealant system or displaced through the injection of the proper lubricant / sealant prior to installation.

Gate Valve Body Filler Grease in (10) ten pound pail - Part Number S-GV-10

Page 42 • Chapter 10 Valve Cleaners, Lubricants & Sealants

Valve Cleaning Compounds Were developed to serve many functions. The dry nature of dehydrated natural gas can rob most lubricant / sealants of much of their lubricating ability. When left too long in the valve, some types of lubricant / sealants will completely break down and leave behind the solid fillers which had been used to thicken the base oil into a grease-like compound. In this instance, the valve cleaner must re-moisturize the dried lubricant / sealant in order for it to flow out of the sealant channel system. It is not unusual to have a varnish-like build-up on critical seal faces on valves in gas service. Valve cleaners must also include solvents which can remove this build-up and detergents which will help carry away the dissolved material. A good quality cleaner should include a dry lubricant such as graphite so that when critical seal faces are cleaned, the metal surfaces do not gall or score by cycling the valve in a dry condition. It is extremely important that the cleaning agents be compatible with gaskets, packings and O-rings in the valve body or stem. Improper cleaners may cause O-rings to swell or crack and lead to seat and body leakage. Sealweld® Valve Cleaner Plus is approved for use in all types of valves.

Valve Cleaner Plus in (10) ten pound pail - Part Number S-VC-10

Valve Lubricants Are made from materials which are insoluble in whatever gas, or liquid is inside the valve. Modified vegetable oils are often blended with synthetic oils, special corrosion inhibiting agents and other additives to give the lubricant its sticky texture. These viscous and sticky lubricants will provide some sealing ability and are generally recommended for new valves or valves with very little wear. It is very important that a good quality valve lubricant be resistant to breakdown or shearing of the gel structure under high-pressure injection and the enormous load forces commonly seen across seal faces. It must also be stable over a broad temperature range and not break down or harden when pumped at freezing temperatures and in higher temperature service such as may be seen in compressor discharge applications.

Sealweld® Equa-Lube Eighty in (10) ten pound pail - Part Number S-EQ-10

Valve Lubricants / Sealants Are generally formulated with much of the same ingredients as valve lubricants. Special additives are blended in which enhance the sealing characteristics of the compound. Lubricant / sealants are generally more viscous. Many manufacturers add finely powdered PTFE or P.T.F.E. flakes. These have been found to seal minor scratches and shallow corrosion pits. Some manufacturers of valve sealants use finely ground mica or asbestos as bridging agents. EXTREME CARE must be taken to ensure large PTFE particles are not introduced that can plug the sealant injection fittings and passages.

The Sealweld® paper Theory, History, and Results of Sealant for Subsea Service explains in greater detail some of our earlier investigations into valve sealant testing. Offshore Technology Conference Paper # 6697 is also available on request; this paper details our further research into valve sealant testing.

Sealweld® Total-Lube # 911 Lubricant / Sealant in (10) ten pound pail - Part Number S-TL-10

Sealweld® # 5050 Sealant in (10) ten pound pail - Part Number S-VS-10

Valve Cleaners, Lubricants & Sealants Chapter 10 • Page 43

Extra Heavy Sealants Are heavier sealants which have an extra quantity of PTFE particles and often feature much larger PTFE particles and flakes. These types of materials should only be used in an emergency as a last chance alternative to removing the valve from the pipeline. Sealweld® Extra Heavy # 5050 and Double Extra Heavy # 5050 would fall into this category.

Emergency Sealants

Sealweld® XH # 5050 Sealant in (10) ten pound pail - Part Number S-XS-10

Sealweld® XXH # 5050 Sealant in (10) ten pound pail - Part Number S-XXS-10

When using the heavier emergency sealants, ALWAYS open the valves body vent fitting (if possible) in order to draw the sealant over the damaged seal face.

Remember to wait (10 - 20) ten or twenty minutes with the body vent open to ensure the seal is holding.

DO NOT be fooled by the viscosity of the sealant. Heavy and / or cold sealants will take time to extrude through the tiny leak paths before the valve starts to leak again. Watch the injection gauge very closely to see if the sealant is pushing into the valve or if the seal is holding.

Once a reliable seal is achieved, leave the gun hooked up and under pressure. Remember to check the gauge periodically. Leave the valve alone; DO NOT cycle the valve or the seal will be lost. Leave the body vent fitting open, otherwise pressure will build-up in the valve's body cavity and there is a risk that the gas or liquid will escape downstream. By watching and / or listening to the leakage through the body vent fitting you are able to judge how the seal is holding.

Gap Bridging Ability of Sealants

Page 44 • Chapter 10 Valve Cleaners, Lubricants & Sealants

We draw your attention to the graph illustrated above and on the last page of Offshore Technology Conference Paper # 6697. Notice that sealants "B" and "E" demonstrated some initial sealing ability then failed abruptly after approximately (6) six minutes. This would indicate that the valve technician should always wait some time before assuming it is safe to work downstream of any valve in which sealant has been injected.

"H" is Sealweld® # 5050 Ball Valve Sealant

Knowing when to stop injecting sealant is an important part of being successful. Quite often that one more stroke that you think will get you a perfect seal will cause the seat ring to lift off the seal face and the seal will be lost.

The emergency sealing compounds (Sealweld® XH # 5050 and Sealweld® XXH # 5050) should always be displaced from the seat sealant system after use to eliminate the possibility of future plugging problems. This is done by injecting equal amounts of a lighter lubricant / sealant, such as Sealweld® Total-Lube # 911 and cycling the valve a few times. If it is not possible to cycle the valve completely, we recommend that the ball, gate or plug be rocked off the closed or open position to accomplish the cleaning or purging operation.

Recommended Valve Care Products Chapter 10 • Page 45

Recommended Valve Care Products

Sealweld® Valve Cleaner Plus Specifications Base Oil: Mineral Oil Color: Black Temperature Range: -73° C to +121° C or -100° F to +250° F Texture: Thin Paste Pressure: 10,000 PSI ASTM Penetration: 270 - 320 Dropping Point: None Solvent Resistance: N/A Special Additive: Graphite Compatibility: Dispersant Particle Size: Micronized Composition: Semi-liquid Application: Used as an internal valve cleaning compound for use in ball, gate and plug valves

as well as orifice fittings. Use in wellhead valves, at pump and compressor stations and distribution systems. Ideal for use on valves with plugged sealant fittings, seat leakage problems or valves which are hard to turn. Leave in valve for at least (30) thirty minutes. Purge from system with regular lubricant / sealant after use.

Sealweld® Equa-Lube Eighty Specifications Base Oil: Synthetic

Color: Natural / Opaque

Temperature Range: -37° C to +148° C or -35° F to +300° F

Texture: Tacky

Pressure: <10,000 PSI

ASTM Penetration: 220 - 250

Dropping Point: None

Solvent Resistance: Excellent

Special Additive: No TFE Fluorocarbon

Compatibility: Excellent

Particle Size: N/A

Composition: Semi-Liquid

Application: Used as an all purpose synthetic valve seat lubricating compound. Ideal for use in new ball, gate and plug valves for reducing torque, preventing galling of mated seating surfaces and keeping contaminants from entering the valve sealant system. Insoluble in oil, natural gas and water related services. Use in wellhead valves, pump and compressor stations and distribution systems.

Page 46 • Chapter 10 Recommended Valve Care Products

Sealweld® Total-Lube # 911 Specifications Base Oil: Synthetic Color: White Temperature Range: -28° C to +232° C or -20° F to +450° F Texture: Tacky Pressure: 10,000 PSI ASTM Penetration: 165 - 195 Dropping Point: None Solvent Resistance: Excellent Special Additive: PTFE Fluorocarbon Compatibility: Excellent Particle Size: Micronized Composition: Semi-Liquid Application: Used as a premium grade synthetic lubricant / sealant for ball, gate and plug valves

as well as orifice fittings. Insoluble in oil, natural gas and water. Use in wellhead valves, at pump and compressor stations and distribution systems. Proven to reliably seal a leak path of up to 0.10”. Ideal for sealing damage to O-rings, chevron seals and U-Cups. Designed specifically as a premium grade synthetic valve lubricant / sealant to provide the longest service life for valves that cannot be serviced frequently. Valves serviced with Total-Lube # 911, require less frequent maintenance than valves serviced with conventional lubricants.

Sealweld® Total-Lube # 911 - 12 (light) Specifications Base Oil: Synthetic Color: White Temperature Range: -31° C to +232° C or -25° F to +450° F Texture: Tacky Pressure: 10,000 PSI ASTM Penetration: 200 - 225 Dropping Point: None Solvent Resistance: Excellent Special Additive: PTFE Fluorocarbon Compatibility: Excellent Particle Size: Micronized Composition: Semi-Liquid Application: A slightly less viscous formulation than regular # 911 ideal for outdoor applications,

block valves and automatic lubricators on suction and discharge valves.


Sealweld® # 5050 Sealant Specifications Base Oil: Synthetic Color: Green Temperature Range: -34° C to +232° C or -30° F to +450° F Texture: Tacky Pressure: 10,000 PSI ASTM Penetration: 165 - 195 Dropping Point: None Solvent Resistance: Excellent Special Additive: PTFE Fluorocarbon Compatibility: Excellent Particle Size: Micronized Composition: Semi-Liquid Application: Used as a synthetic sealant for ball, gate and plug valves. Insoluble in oil, natural

gas and water related services. Use in wellhead valves, at pump and compressor stations and distribution systems. Proven to reliably seal a leak path of up to 0.30”. Ideal for scratches, scarring or pitting on critical seal faces. Use for sealing stem and seat seal damage when Total-Lube # 911 fails to hold a reliable seal.

Sealweld® Extra Heavy # 5050 Sealant Specifications Base Oil: Synthetic Color: Green Temperature Range: -31° C to +232° C or -25° F to +450° F Texture: Tacky Pressure: 10,000 PSI ASTM Penetration: 200 - 220 Dropping Point: None Solvent Resistance: Excellent Special Additive: PTFE Fluorocarbon Compatibility: Excellent Particle Size: Micronized Composition: Semi-Liquid Application: Used as an emergency sealant for ball and gate valves Insoluble in oil, natural gas

and water related services. Use in wellhead valves, at pump and compressor stations and distribution systems. Not recommended for use in plug valves except in an emergency. The excellent sealing ability of this compound may restrict internal sealant passages and / or plug them completely. Purge from system after use.

Sealweld® XXH (Double Extra Heavy) # 5050 Sealant Specifications Application: Hydrocarbon - Natural Gas, Oil, Related By-Products Use in ball and gate valves with

EXTREME leakage problems.


Chameleon Emergency Sealant Specifications Application: Emergency Sealant - Designed for application by professional valve maintenance

technicians only. Call Sealweld® for assistance. Use only in valves with severe leakage as a last alternative to draining the pipeline for valve replacement. Provides a reliable temporary seal in ball and gate valves.

Sealweld® Slick Sticks Specifications Temperature Range: -40° C to +260° C or -40° F to +500° F Texture: Moldable Dropping Point: None Solvent Resistance: Excellent Special Additive: PTFE Fluorocarbon Composition: Putty Application: Injectable valve stem packing for gate valves and plug valves in hydrocarbon service.

Sealweld® D-1014 Sealant Specifications

Also available without PTFE as a low temperature lubricant.

Base Oil: Synthetic Color: Gray Temperature Range: -59° C to +204° C or -75° F to +400° F Texture: Tacky Pressure: 10,000 PSI ASTM Penetration: 310 - 340 Dropping Point: None Solvent Resistance: Excellent Special Additive: PTFE Fluorocarbon Compatibility: Excellent Particle Size: Micronized Composition: Semi-Liquid Application: Lubricant / sealant - Use in all sizes of ball and gate valves with minor seat leakage.

Use in plug valves larger than 6”, as well as in orifice fittings. Designed for use in LPG / NGL, low temperature service.

XH (Extra Heavy) D-1014 Sealant Specifications Application: Emergency Sealant - Use in ball and gate valves with SEVERE leakage problems.

Call Sealweld® for assistance. Do not use in small diameter plug valves.


Sealweld® Eterna-Lube 1000 Lubricant Specifications Base Oil: Synthetic Color: Silver Temperature Range: -40° C to +1093° C or -40° F to +2000° F Texture: Tacky NLGI: 1 ASTM Penetration: 295 - 320 Dropping Point: None Solvent Resistance: N/A Special Additive: Proprietary blend Compatibility: Excellent Particle Size: < 4 microns Composition: Semi-Liquid Application: Use in valve stems and gearboxes to prevent corrosion, extend bearing life and

reduce torque. Use in ball, gate and plug valves in high-temperature service.

Sealweld® Gate Valve Body Filler Grease Specifications Base Oil: Synthetic Color: Blue Texture: Buttery Dropping Point: None Application: Used as a lubricant for gate valve bodies. Fill the body with this inexpensive

lubricating grease. Contains corrosion inhibitors and antioxidizing ingredients.



Valve Maintenance Techniques Chapter 11 • Page 51

Chapter 11

Valve Maintenance Techniques Reliable valves are one of the most important safety components in the plant or pipeline.

It is the responsibility of the valve technician to make sure that every valve turns easily and seals in an emergency.

Turning or cycling the valve periodically is just as important as injecting lubricant. External stem corrosion can dramatically shorten the service life of the valve. ALWAYS examine for evidence of rusting, periodically apply rust penetrant and anti-seize type grease to achieve extended service life.

You can build a safe, cost and time effective, Valve Maintenance Program with the Sealweld® ValvePro® series of software solutions.

Perform an audit on every valve and build a data base describing each valve, its performance and preventative maintenance history.

ALWAYS read the valve manufacturers owners manual before commencing any maintenance procedure.

Page 52 • Chapter 11 Valve Maintenance Techniques

Valves have different types of internal sealing mechanisms. Some key points to remember are:

• Gate valves are typically downstream seating. API or wellhead-type gate valves typically DO NOT have any provision for internal seat pressure relief. Always use extreme caution when injecting grease or sealant into these types of gate valves. DO NOT over-fill the valve with grease or the valve body may rupture. Some of the larger pipeline type gate valves may have a self relieving upstream seat ring and may be equipped with a seat sealant system similar to ball valves.

• Floating Ball Valves (without internal trunnion) are typically downstream seating. These valves typically DO NOT have a provision for de-pressurizing the body cavity.

• Trunnion Mounted Ball Valves come in a variety of seat sealing configurations. The term Double Block and Bleed has been misinterpreted by valve manufacturers and pipeline operators alike. Most trunnion mounted ball valves feature bi-directional sealing, meaning the valve will isolate line pressure in either direction. Some valves have the capability to test the seat seals by depressuring the body cavity in either the full open or full closed positions. Other valves such as the Grove B-5 can only de-pressurize the body cavity in the full closed position. Trunnion mounted ball valves are typically upstream seating. The two most common seat sealing designs are those that have a self-relieving downstream seat ring, and those that have a bi-directional or independent sealing (not self relieving) downstream seat ring, like the Grove B-5. These differences can become important when sealing a valve in an emergency.

The addition of the body vent fitting feature in pipeline ball and gate valves has enabled the valve technician to determine the effectiveness of his maintenance techniques. By evacuating the body cavity between the two valve seats, the technician can determine if the valve seats are holding a seal. If leakage persists, the technician can usually judge which seat is passing by listening or waiting for the leak to diminish as sealant is injected into each seat ring.

For valves in gas service, Sealweld® has recently developed and is field testing a turbine gas meter which connects to the valves body vent fitting. This new tool enables the valve technician to take an accurate metered reading of gas volumes out through the valves cavity. The test can be performed both before and after servicing each valve and is used to determine the effectiveness of your current maintenance program. A hard copy printout is provided which can be collected over a period of months or years for long term maintenance analysis.

To Grease or Not to Grease, Is Often the Question Some valve manufacturers (usually the ones who do not manufacture their own line of lubricant / sealants) claim that you do not need to lubricate a valve until it leaks. This would be similar to waiting for a bad compression test before changing the oil in your new car. By the time the problem is realized the damage is done.

By filling the valves seat sealant system with an insoluble valve lubricant / sealant, you accomplish several things.

First of all, by filling the series of grooves, channels and passages you reduce the possibility of foreign materials and other contaminants finding their way behind the seat rings and becoming trapped there. On many seat ring designs the lubricant / sealant can also act as a hydraulic medium and actually force the seat ring hard against the ball, thus improving the technicians ability to achieve a seal. Should contaminants become trapped against the seal face they will do considerably less damage if they are lubricated than if you cycle the valve against them in a dry condition. Torque values will be greatly reduced through the periodic introduction of fresh lubricant. As a result, there will be less wear on seals and actuators It is very difficult for a dry seal to hold for a long period of time. Water can also act as a sealant if the leak path is small enough. Even a small leak can cut out soft PTFE or nylon seating materials if allowed to leak long enough.

Seat ring inserts and O-ring materials can become stuck to seal faces and may tear when the valve is cycled if not properly lubricated. By keeping the seat sealant system full, you greatly reduce the risk of methanol or other corrosion inhibiting chemicals affecting the seat sealing O-rings which can shrink, crack or otherwise fail and lead to uncontrollable leakage.


Typical Seat Ring Sealant System

The argument against the introduction of valve lubricant / sealants is that they may eventually break down and that in some cases this can lead to seat leakage. In other words, once you begin using lubricant / sealants you can not stop. The injection of a very small amount of lubricant / sealant each time the valve is cycled will prolong valve service life dramatically while preventing the hardening or drying of old lubricants.

You may notice that many small diameter valves DO NOT have a seat sealing system. Because of this, these valves either are repaired or replaced when they begin to leak. This would be an undesirable alternative when working with expensive large diameter pipeline valves. Just the cost of draining the product in the pipeline leading up to the valve makes this an uneconomical proposition. The price of periodically injecting a small amount of lubricant / sealant is a mere fraction of what the repair or replacement would cost.

The cost of the sealant and manpower required, is insignificant compared to the cost of shutting down the line, draining, excavating and replacement valve costs. Sealweld® presented a discussion paper on this subject at the Onshore Pipeline Cost Reduction Conference & Exhibition in Amsterdam in April of 2000. Contact Sealweld® for a copy of the Study of the Economic Benefits of Valve Commissioning During Pipeline Construction.

There can be problems caused by using the wrong type of lubricant / sealant in some services. In a worst case, we have seen examples of a lubricant / sealant (in high temperature service) polymerize and bake hard into a rubber-like substance. When the lubricant / sealant goes hard it can prevent the seat rings from traveling like they should which can make the valve hard to turn and / or not seal properly. If you have any concerns over which lubricant / sealant you should be using contact your nearest Sealweld® office for product suggestions.

Routine Maintenance Procedures Routine valve maintenance often consists of periodically topping-up the valves sealant system in order to keep fresh lubricant / sealant at the seal face. The illustration below details the route the cleaner or lubricant / sealant must travel in order to reach the seal face passage.

The quantity of lubricant / sealant required to top-up can vary greatly depending on how long it has been since the valve was last serviced, the type of lubricant / sealant being used, the type of valve, cycle frequency, the product flowing through the valve and its temperature.


Many companies wait for a problem to occur before considering servicing a valve. Waiting for a problem to occur may take several years and during that time many brands of lubricant / sealant may have dried out, decomposed or simply washed away. The lubricant / sealant can also polymerize. This hardened grease can restrict seat travel and hold the seat ring away from the seal face. This may result in an increase in torque and damage to soft seating materials and O-rings. If the lubricant / sealant has washed away, the void behind the seat rings could be filled with solid contaminants such as sand, dirt, slag, line scale, plastic coatings and even pieces of pipeline scraper pigs.

Valve Sealant System

Full Service Maintenance If topping-up the valve seat sealant system does not achieve the desired results, this is usually an indication that it is time to clean the valves seat sealant system. Sealweld® Valve Cleaner Plus is a combination of light oils, solvents, detergents and graphite particles with a minimum of thickeners. When injected into the valve, it softens and re-moisturizes the old dried greases, cleans important passages and channels and removes the varnish-like buildup which can occur on valves while in service. Allow the valve cleaner to soak in the valve for (30 – 60) thirty to sixty minutes. On problem valves which are seized or which have plugged sealant passages, allow the cleaner to soak overnight. To ensure proper cleaning action, cycle the valve a few times (where possible) and top-up the cleaner a few times to push contaminants away from seal faces.

Valve Sealant Capacity Chart


The quantity of cleaner required is detailed on the above sealant capacity chart. Ball valves generally require one (1 oz.) ounce per inch of valve size into each seat ring. Riser pipe quantities are extra, generally (2 ozs.) two ounces per foot or (16 ozs.) sixteen ounces per eight foot riser. In other words, a thirty six 36" inch ball valve would require (36 ozs.) thirty-six ounces (= 2.25 pounds) into each seat ring plus an additional (16 ozs.= 1 pound) sixteen ounces into each of (4) four riser pipes. This quantity can be reduced by the quantity required to fill the riser pipes. Injecting (36 ozs.) thirty-six ounces of cleaner would fill the sealant riser lines, the seat ring passage and the sealant channel. Switch the pump back over to the lubricant / sealant and continue injecting (16 ozs.) sixteen ounces of lubricant / sealant. Stop the pump and allow the cleaner to soak in the seal face passages for up to (1) one hour. When you are satisfied that the cleaning action is complete, continue injecting (20 ozs.) twenty ounces of lubricant / sealant to displace all the cleaner. By opening the valves body vent fitting during the cleaning operation the cleaner is drawn over the seat insert and allowed to clean the important seal faces.

How Much is Enough? Over-lubricating can lead to problems downstream if the line can not be pigged from time to time. Under-lubricating can lead to the deterioration of lubricant / sealants and the build-up of decomposed grease residue.

Ideally, the valve technician wants to keep the sealant passages filled with soft sealant as well as the area behind the seat ring, through the valve body, riser lines and sealant fitting. To accomplish this the technician must top-up the valve from time to time. In order to obtain the longest possible maintenance interval and to prevent over-lubrication, the lubricant / sealant must be resistant to breakdown from high-pressure injection, temperature variances (freezing), resistant to dehydration from natural gas and / or insoluble in the product flowing through the valve.

Typical Ball Valve Seat Sealant System


Notice on the illustration, that the seal face passage and sealant channel are exposed directly to line pressure. This is the most vulnerable portion of the seat sealant system. The lubricant / sealant can be scraped off by the seat insert as the valve is cycled washed away by high-pressure jetting action of the line pressure flowing through the valve and also contaminated by foreign materials flowing along the pipeline (scale, rust and internal plastic coatings).

By injecting sufficient quantities to replace the lubricant / sealant in the seal face passage you have probably displaced the foreign materials and refilled the area up to the seat insert. The quantity can vary depending on the exact seat ring design, generally 1/4 to 1/3 of the sealant system capacity. In other words, if a 36" ball valve holds (36 ozs.) thirty-six ounces into each seat ring then 1/4 would be (9 ozs.) nine ounces or 1/3 would be (12 ozs.) twelve ounces. By injecting these top-up quantities at least once a year most valves will operate and seal properly. Valves which cycle frequently or are closer to the compressor (because of increased temperature) should be topped-up more frequently.

Another good indication of the seat sealant system becoming full is to watch the injection gauge while topping-up. One of the best ways to practice getting the feel for when the seat sealant system is full, is to fill valves for the first time from a dry condition. As the passages become full, the lubricant / sealant will have more difficulty escaping, the injection gauge will begin to climb rapidly and will fall more slowly when pumping is stopped. This is not always a reliable method in cold climates where the increased lubricant / sealant viscosity can send confusing signals.

Plug Valve Maintenance Chapter 12 • Page 57

Chapter 12

Plug Valve Maintenance

Servicing Threaded Stem Lubricated Plug Valves

Introduction Hard to turn valves are usually a result of:

• A build-up of old dried sealant in sealant passages restricting plug travel

• Lack of sealant

• Improper adjustment

• Rusted stem threads underneath the stop collar at the outboard end of the stem

• Hard / dried out old stem packing

• Any combination of the above

In order to determine which of these problems are the likely source of the difficulty, the following steps must be taken.

Locate the sealant injection fitting on the top of the valve (see illustration). Inject Sealweld® Valve Cleaner Plus using a high-pressure sealant injection pump in sufficient quantities to completely displace the old sealant.

ALWAYS watch and read the injection pressure gauge to judge what is happening inside the valve.

In most cases, as the cleaner is injected, the pressure will increase until a rapid de-pressurization or blow will occur as the old sealant is pushed out of the valve. The cleaner will then run in smoothly with very little increase in pressure. The plug valve should be cleaned in the fully open or fully closed position in order to get all the old sealant out from under and around the plug. Cycle the valve several times to ensure complete coverage of the cleaner.

Once the cleaning is complete, inject Sealweld® Total-Lube # 911 plug valve lubricant / sealant in equal quantities as the valve cleaner. The plug should be in the fully opened or fully closed position. As the sealant is injected, the pressure gauge will increase and slowly decline as the sealant enters the sealant grooves. When pumping stops, the gauge will begin to drop. The more slowly the gauge drops, the tighter the fit between the plug and valve body. The tighter the fit, the better chance you have of achieving a seal. Too tight a fit and the valve may be difficult to cycle.

Page 58 • Chapter 12 Plug Valve Maintenance

The plug can be adjusted in order to improve the valve sealing and turning ability. Look on the bottom of the valve and you will notice a cap tack welded to the body of the valve. The plug position is set at the factory and the cap is tack welded to prevent unnecessary tinkering. If the cap weld is intact then the setting should be correct. If the weld has been broken some adjustment may be necessary. Consult the proper valve manufacturer's service manual for proper setting adjustment advice.

Threaded Stem Plug Valve

If the valve is still stuck or very hard to turn after it has been cleaned and lubricated, assuming that the plug setting is correct, you can suspect problems in the stem packing area.

Original Stem Packing The original stem packing in a threaded stem plug valve consisted of short asbestos fibers in a graphite bonding material. After many years the packing usually becomes hard and looses its lubricity, resulting in an increase in torque required to turn the valve. Replacement of the stem packing and / or introduction of a suitable thread lubricant will normally solve this problem.

Upper Stem Lubrication Remove the stem indicator stop collar. It may be necessary to use two (2) wedges or a two-prong pulley puller to pry off the collar. Examine the area on and around the stem for visible rusting. Spray with penetrating oil and clean with a wire brush. Mark the stem position and cycle the valve open one complete turn to expose the stem threads. Liberally spray the threads with penetrating oil and use a wire brush to clean them. Cycle the valve to its original position and pour penetrating oil into the depression surrounding the stem. If necessary make a dam of modeling clay or heavy sealant around the stem to contain the penetrating oil. Cycle the valve and note if the movement is any easier.

It will probably be necessary to repeat this procedure several times. This is not an instant fix.

Types of Threaded Stem Plug Valves Chapter 12 • Page 59

Types of Threaded Stem Plug Valves There are two types of threaded stem plug valves. One has a pipe (packing) plug on the neck of the valve located 180° degrees opposite the stem packing injector fitting. The other type of valve does not have a pipe (packing) plug.

Plug Valve Cross Section

Stem Packing Removal - Procedure # 1 Wait until the next scheduled shut-down when the line and valve can be de-pressurized. The valve technician should only attempt the procedure on a pressurized valve if there is no alternative. Before attempting to replace the stem packing on a valve under pressure we recommend the valve technician practice with a valve (or two) on the workbench first. Get familiar with the procedures required to safely change the stem packing before heading out to the field.

Equipment Requirements: • Set of buttonhead adapters for packing injectors (available from Sealweld®)

• (1) each - High-Pressure Sealant Injection Guns

• Allen key set

• Open end / box end wrenches

• Adjustable wrench - 6"

• Stabbing Valve (Class 600) with schedule 80 nipple (see sketch)

• Sealweld® Valve Cleaner Plus, Sealweld® Total-Lube # 911 and Sealweld® Slick Sticks Stem Packing

• Penetrating oil

• Varsol and rags

• Foaming type leak detector (for use on valves in gas service)

The objective is to safely remove the old stem packing and replace it with Slick Sticks valve stem packing. This packing is a special preparation for pipeline valves and includes special inhibited grease and a variety of PTFE particles which bridge to form a durable, rebuildable seal. The stem seal can then be rebuilt by simply injecting additional Slick Sticks or Super Stem Packing compounds through the packing injection fitting.

Page 60 • Chapter 12 Types of Threaded Stem Plug Valves

Replacement of Stem Packing on Hypreseal Plug Valves

This procedure should only be performed by trained and certified Valve Maintenance Technicians.

The valve being serviced should not be pressurized in order to avoid risk of personal injury. Always assume the stem packing gland contains trapped line pressure and that extreme caution should be exercised. Work cautiously and use liberal amounts of foaming type leak detector before completely unscrewing any threaded fitting to check for trapped gases.

Read this handbook and the corresponding valve manufacturer's manuals completely before starting any maintenance routine.

Mandatory Safety Equipment • Hard Hat

• Safety Glasses

• Steel-Toed Boots

• Nomex® (or equivalent) fire retardant coveralls

• Hearing Protection

• Emergency Breathing Apparatus (depending on product, location and climatic conditions)

• A full port stabbing valve of the same thread and internal dimensions as the plug opposite the packing injector. An XH Nipple (schedule 80) should be thread taped and tightened into the valve. The other end of the nipple should also be thread taped. Keep the stabbing valve in the open position and within arms reach in case of kick through the stem packing gland while the plug is removed. The stabbing valve must be full port.

ALWAYS notify your supervisor or the control room before attempting this procedure.

In the worst case, if the valve is under pressure the following procedure could expose the Valve Maintenance Technician to full line pressure escaping through the stem or packing injector or packing plug (once removed). Depending on the product in the line, the location of the valve and wind direction, this can present serious consequences. Additionally, when removing the packing plug opposite the packing injector - if pressure has entered the stem packing area, the plug will blow out at great velocity once the last engaged thread is unscrewed. Due to the excellent sealing ability of most packing compounds and valve sealants, the threads may not leak until the last engaged thread is unscrewed. This is why a stabbing valve must be ready before the procedure begins. The check valve devices installed in most sealant fittings and packing injectors are unreliable and prone to leakage and / or failure.

Always use EXTREME CAUTION when working with valves under pressure.

Use liberal amounts of foaming type leak detector when unscrewing any fitting on pressurized gas valves. If at any time line pressure is suspected to be entering the stem packing area, stop this procedure and proceed only after you are sure all sources of pressure have been eliminated.

Have an evacuation plan discussed and ready for implementation in case of emergency.

Types of Threaded Stem Plug Valves Chapter 12 • Page 61

Assuming the plug has been cleaned with valve cleaner as previously discussed, inject valve lubricant / sealant such as Total-Lube # 911 through the sealant fitting on the top of the valve. Keep pressure on the fitting in excess of line pressure. If the lower threads on the stem have failed it is possible to have a kick once the plug is removed. By having the valve charged these threads should seal themselves with the sealant. Also, by watching the pressure gauge you can better judge if the lower threads have failed by a corresponding drop in gauge pressure as the plug is unscrewed.

Carefully back the Allen screw out of the packing injector body and replace it with the proper sized buttonhead fitting from the stem servicing kit. It may be necessary to wrap the threads with thread tape. Always check for leakage before completely unscrewing.

Carefully begin to unscrew the plug opposite the packing injector. Being a tapered thread you should be able to unscrew it by hand after (1 - 2) one or two turns. If the plug still requires a wrench, it may be a sign that line pressure is evident in the stem area. The packing will be in compression and will expand once the plug is unscrewed. This can send confusing signals to the technician.

Quickly install the stabbing valve and tighten in place. Working through the open stabbing valve, remove as much of the old packing as possible with a packing puller or screw driver. As the packing is normally in compression, a certain amount of expansion is going to occur once the plug is removed. This is normal. Watch the gauge on the sealant gun for signs of sealant entering the stem area. Should a leak or kick occur - quickly remove the packing puller or screw driver from the stabbing valve and close the stabbing valve to contain the leak.

Inject Sealweld® Valve Cleaner Plus through the buttonhead adapter on the packing injector fitting. As the cleaner is injected, the old packing should begin to extrude through the open stabbing valve. At this point you will be most vulnerable to a kick as most of the packing has been removed. Watch the gauge pressure on the sealant gun for any sign of pressure drop. Should the packing begin to blow, simply close the stabbing valve to contain the leakage.

Close the stabbing valve and pressure up the stem area with valve cleaner. This will force the cleaner into the stem threads and moisten the old packing. By repeatedly pressuring up the stem area and quickly opening the stabbing valve, the old packing can be carried out with the cleaner. If possible, cycle the valve partially or fully to distribute the valve cleaner up and down the threaded stem.

You may now begin to replace the packing. Remove the buttonhead adapter in the packing injector and insert Sealweld® Slick Sticks. The Slick Sticks are injected by screwing in with the original Allen screw. When the Allen screw bottoms out, back it out and repeat the procedure. Leave the stabbing valve in the open position while additional Slick Sticks are added. The Slick Sticks will push out the old packing and valve cleaner as it enters the packing gland. When Slick Sticks are evident in the stabbing valve, the stabbing valve can be removed and the plug replaced.

Cycle the valve several times to ensure it has returned to its normal condition and that it turns easily with the original wrench provided. Inject additional Slick Sticks until the Allen screw becomes harder to turn. Check the valves torque requirements to ensure the packing material is not over-compressed.

Return the valve to its original position (fully opened or fully closed).

Return to the valve site and inject additional Slick Sticks if necessary over a period of (2 – 3) two or three days. For this period additional Slick Sticks may be required as the valve cleaner and lubricating oil in the Slick Sticks is displaced. Be careful not to apply excessive force to the Allen screw as a great deal of pressure can be generated with even a short wrench.

Additional Slick Sticks can be added if necessary as part of a maintenance routine on an annual or semi-annual basis. If stem leakage is still a problem, a heavier grade of Super Stem Packing is also available.

Stem Packing Removal - Procedure # 2 This procedure is applied to those valves which do not have a plug on the neck of the valve, 180° degrees opposite the stem packing injector. In this case it is not possible to force out the old stem packing. However,

Page 62 • Chapter 12 Types of Threaded Stem Plug Valves

it is beneficial to introduce a lubricant such as Sealweld® Valve Cleaner Plus into the stem area to reduce the valve operating torque and moisten the old dried packing.

• Remove the Allen screw from the packing injector, dig out as much of the old hard packing as possible. Install the proper sized stem servicing buttonhead adapter.

• Attach the sealant gun, filled with valve cleaner, to the buttonhead adapter on the packing injector.

• Apply pressure by means of the sealant gun until the gauge reads 4000 PSI. Stop pumping and observe whether there is a drop in the gauge reading. Maintain a 4,000 PSI pressure for (10) ten minutes. Check the valve turning torque. Turning the valve, even a small amount, will help to distribute the valve cleaner around the stem threads.

• Repeat until the valve turns in a normal manner.

• Remove the stem servicing adapter and insert Slick Sticks stem packing before re-installing the Allen screw in the packing injector. Inject a sufficient quantity of Slick Sticks to sufficiently seal the stem and still provide minimal torque requirements.

• Return to the valve site and inject additional Slick Sticks if necessary. Be careful not to apply excessive force to the Allen screw as a great deal of pressure can be generated with even a short wrench.

Additional Slick Sticks can be added as part of a maintenance routine if necessary. If stem leakage is still a problem a heavier grade of Super Stem Packing is also available.

Summary If these procedures are not successful at reducing torque and eliminating stem leakage, the valve has more serious mechanical damage and should be repaired or replaced at your earliest opportunity.

This document has been prepared in order to provide valve maintenance personnel with a better understanding of some of the procedures which can be utilized in order to make plug valves easier to turn or seal. If you do not clearly understand the procedures being described, contact Sealweld® Services for an explanation or on-site demonstration.

Threaded Stem Plug Valve

Welded Body Ball Valve Maintenance Chapter 13 • Page 63

Chapter 13

Welded Body Ball Valve Maintenance The welded body ball valve is very popular in the oil and gas industry for several reasons:

• Welded body construction (as compared to a bolted body design) is more compact.

• The body draining feature allows the valve maintenance technician to test each seat rings sealing ability with the ball in either the full open or full closed positions. This is accomplished by opening the body vent fitting which de-pressurizes the valve body cavity (inside each seat ring). By learning how to properly use the valve body vent fitting the technician can judge how effective the present maintenance program is and whether or not additional maintenance is necessary.

• Sealant injection fittings access directly to each seat ring. This enables the technician to top-up the quantity of lubricant inside the valves sealant injection system on a periodic basis. Valve cleaner can also be injected into these fittings to flush out the old grease in the valve and to clean critical seal faces on the ball. Heavier sealants are also injected through the sealant injection fittings during an emergency when a critical seal is required.

• Ratcheting seats are unique to the Cameron® welded body ball valve. A cog attached to the valve stem reacts with teeth cut on each seat ring which rotates both seat rings each time the valve is cycled to the closed position. After (24) twenty-four closings each seat ring has rotated 360° degrees. This feature is an advantage to the technician. If an acceptable seal can not be achieved after cleaning and relubricating the valve, rotate the valve a few times. This ensures the seat ring and ball face seal at new positions. If a wire draw is present across the seal face, the cut on the seat ring and ball face would not realign for (24) twenty-four more cycles. The ability to achieve a seal through the use of heavier sealants is significantly increased if the technician can reduce the size of the leak path by 50% by simply cycling the valve.

Fitting Identification

Page 64 • Chapter 13 Welded Body Ball Valve Maintenance

Cameron® has a reputation for manufacturing a high quality valve. The welded body design means the valve must be cut open in order to replace damaged seat rings and balls. This type of repair is very expensive and the valve must be returned to the factory for repair. Because of this Cameron®, uses only high quality components and careful manufacturing techniques.

Routine Maintenance Procedures Applying a small quantity of fresh lubricant / sealant and cycling the valve periodically can add years to the effective service life of the valve.

When valves leave the factory they are often filled with a light petroleum grease containing inhibitors to prevent corrosion to the internal components of the valve during shipping and storage. Quite often the valve will sit on the ground at the construction site for months or even years before being installed in the pipeline. The valve is then installed and the line hydrostatically tested and pigged to clean the construction materials, line scale and other contaminants from the pipeline system. Most seat and seal face damage has occurred even before product has been introduced to the pipeline.

The proper lubricant is one which is insoluble in the product flowing through the valve. It must be stable over a broad temperature range and resistant to shearing of the gel structure because of the high injection pressures usually required to push fresh lubricant to seat rings.

Sealant System Cross Section

Routine maintenance often consists of topping-up the sealant system with a small quantity of fresh lubricant / sealant. The valves sealant injection system is a system of grooves, channels and riser pipe assemblies through which the lubricant / sealant travels. Each time the valve cycles, a small amount of lubricant / sealant is lost downstream. By keeping the sealant system topped-up at all times, the risk of contaminants finding their way behind the seat ring is greatly reduced. Learn how to properly read the injection gauge on the gun or pump to judge when the sealant system is full. Once filled, the lubricant / sealant will act as a hydraulic medium and force the seat ring hard against the ball. At this point the injection gauge will rise rapidly. Stop pumping and watch how slowly the gauge settles back down. Gauge pressure will eventually equalize with line pressure.

The quantities required to top-up the sealant system vary greatly depending on how often the valve cycles, the product flowing through the valve, temperature and the type of lubricant / sealant selected. Some pipeline companies have deemed a quantity equal to 1/8 of the capacity of the sealant system injected twice annually sufficient for most pipeline block valves in clean natural gas service. Because compressor suction and discharge valves cycle more frequently, they require more maintenance. Compressor discharge valves should see even more maintenance due to the higher operating temperatures.


Proper Cleaning Techniques When topping-up the sealant system fails to achieve the desired results, rotate the valve a few times so the seat rings are realigned, then top-up again. If the body cavity still will not blow down, it may be time to inject valve cleaner.

The best results are achieved by cycling the valve to the closed position. Make sure the valve is fully closed as the seat ratchets do not engage until the valve is 7/8 closed. The last 1/8 turn usually becomes more difficult as the ratchets engage and the seat rings begin to turn.

When valve is fully closed, begin injecting valve cleaner. Rock the valve on and off the full closed position to ensure the valve cleaner cleans critical seal points evenly. The sealant capacity for Cameron® ball valves is approximately (1 oz.) one ounce per inch of valve size into each seat ring. Remember to include the quantities contained in the riser pipe assembly (generally (2 ozs.) two ounces per foot on each 1/2" I.D. riser). A (10") ten inch valve would require (10 ozs.) ten ounces of cleaner into each seat ring. If the valve were buried (8') eight feet an additional (16 ozs.= 1 pound) sixteen ounces would be required into each riser pipe. When the sealant system becomes completely full with valve cleaner, the injection gauge will begin to drop and will fall more quickly when pumping stops.

Many Cameron® valves have sealant fittings on both sides of each seat ring. In this case inject 1/2 the required quantity into each sealant injection fitting. If buried, remember to add the riser pipe quantities (generally (2ozs.) two ounces per foot on each 1/2" I.D. riser).

Leave the valve cleaner in the valve from (30) thirty minutes to a few hours or even several days on problem valves. Remember to rock the valve while continuing to inject additional quantities of valve cleaner to clear obstructed channels inside the valve.

Be patient; the valve cleaner often takes time to clean seal faces thoroughly.

If the sealant fitting or buried inner check valve is plugged from old dried sealant, it may take some time for the valve cleaner to soften the old material. If plugged, the gauge will climb quickly and will not drop off. If this occurs, keep the gauge pressure under 8,000 PSI and come back every few hours and try to push a little more cleaner into the sealant injection fitting. Many hand-held injection guns are capable of injection pressures of up to 15,000 PSI. If too much pressure is applied, the high pressure may blow the slug of sealant and the ball check out of the fitting and into the valve body. If this has occurred, as you attempt to remove the grease gun from the fitting you may be exposed to full line pressure. To reduce the risk of this occurring, install a Leak-Lock on the plugged sealant fitting so that if the ball check in the sealant fitting is lost, you can stop line pressure from escaping with the ball check in the Leak-Lock. Leak-Locks are available for both small (Part number D-LL#2) and giant buttonhead fittings (Part number D-LL#1) A special Cameron® adapter (Part number D-CAM-SO) is available which screws onto the Cameron® small buttonhead with cap fitting and adapts it to a giant buttonhead so you can use your regular grease gun coupler. This will keep line pressure from escaping.

NEVER attempt to remove a sealant injection fitting from a valve which is under pressure.

The sealant channel accesses the seat ring area upstream of the seat insert. This means that the sealant fitting accesses the pipeline upstream of the ball / seat sealing interface. Even if the valve is closed and the valve body vented to atmosphere, there is still pressure under the sealant fitting if there is pressure in the pipeline. Make sure there is no pressure in the pipeline upstream and downstream of the valve before attempting to remove the sealant injection fitting.

DO NOT rely on the inner check valve located under the sealant fitting to hold back line pressure. These small check valves become damaged easily and are seldom reliable.


Adding Fresh Lubricant / Sealant Once the cleaning function is complete it is necessary to refill the sealant system with the required lubricant / sealant. The same calculations used for injecting valve cleaner are applicable (one ounce per inch (1oz. / in.) of valve size into each seat ring plus riser pipe quantities). When the seat sealant system is full, the injection gauge will climb steadily and drop off more slowly when pumping stops.

Open the valve body vent fitting and de-pressurize the body cavity to judge the results of cleaning and re-lubricating. When working in high-pressure gas service use of ear protection is recommended while doing this procedure. Open the body vent fitting slowly and as the noise pitch drops, continue opening the body vent fitting in small increments. Occasionally a piece of ice or sealant may obstruct the passage in the body vent fitting. ALWAYS open and close the body vent fitting several times before assuming the body cavity has been de-pressurized.

REMEMBER to close the body vent fitting BEFORE cycling the valve.

If cleaning, re-lubricating and cycling the valve have not stopped the leakage, check that the valve stops are clean of dirt, rust, paint or other foreign materials and that the valve is truly open or closed. It should not be necessary to adjust the valve stop adjustment screws found on many gearboxes after the initial setup or when the valve is first installed. When the technician is sure the valve has been cleaned, re-lubricated and the valve stops clean, if leakage is still a problem it is then time to inject a heavier sealant.

Seat Sealing Procedures With the valve in the full open or full closed position the body vent fitting can be opened and the body cavity of the valve drained. This enables the technician to test each seat rings sealing ability.

If testing with the valve in the open position, inject lubricant / sealant very slowly. If possible leave the body vent fitting open so that the lubricant / sealant is drawn over the damaged seat ring insert.

Sealweld® Services Division offers valve seat leakage testing. Leakage into the valves body cavity is measured using a small turbine gas meter attached to the valves body vent fitting. The turbine gas meter is attached to a hand-held computer which calculates volumes in cubic feet, liters or cubic meters at time intervals of minutes, hours or days. A print-out from the computer provides before and after servicing leakage volumes. We developed this system of calculating valve leakage rates for customers overseas as a method of accurately designing an effective preventive valve maintenance program.

In order to acquire accurate meter readings we have designed a new style of body vent / drain valve which features a threaded vent hole so the meter can be attached with no leakage. The threaded vent hole also allows us to pipe the leakage outside the building so that emergency shut-down equipment is not triggered by escaping gas.

By opening the body vent fitting, the technician exposes himself to the product in the pipeline. This often creates a dangerous situation and extreme caution should be exercised. ALWAYS consult your companies operations manual for safe procedure advice before opening a body vent fitting. If in a building, this will probably trigger emergency shut-down equipment. ALWAYS notify the control room before attempting this procedure, turn off all vehicles and power sources and extinguish any open flames before opening a body vent fitting.

Maintaining a Seal Achieving and maintaining a reliable seal is often a question of confidence which is only acquired through experience. When a problem leaking valve is found in the system, use this valve to practice your sealing techniques.

A typical situation is one in which the downstream side of the valve is de-pressurized and full line pressure is being held upstream of the closed valve. The valve has been cleaned and re-lubricated, still some leakage is still being realized through the open body vent fitting. At this point a heavier sealant can be injected.


Cameron® valves are trunnion-mounted or in other words the ball is in a fixed position and the spring loaded seat rings are allowed to float. In this application, the upstream seat ring is being pushed hard against the ball by line pressure. With the body vent open, the downstream seat ring is being pushed against the ball by the force of the seat ring springs.

The lubricant / sealant must be displaced before the heavier sealant fills the sealant system. The same calculations used for injecting valve cleaner are applicable (one (1 oz.) ounce per inch of valve size into each seat ring plus riser pipe quantities). Concentrate sealing efforts on the upstream seat ring at first. Inject sufficient quantities of sealant slowly so that the PTFE particles are distributed evenly. When the sealant reaches the seat ring, open the body vent fitting so that the PTFE particles are drawn over the damaged seat ring insert. Listen, as the leak diminishes stop pumping. The leak should decrease until it is a mere whisper.

Seat Ring Cross Section

Quite often a small amount of leakage will have to be tolerated. Efforts are now underway to use gas meters connected to the body vent fitting to arrive at some hard numbers as to how much leakage can be tolerated while keeping it safe to work downstream of the valve. At the present time the industry is dependent on the experience of the valve maintenance technician and his judgment as to whether or not it is safe to work downstream. When an acceptable seal is achieved, wait (10 – 20) ten to twenty minutes to make sure the seal is going to hold. The technician may wish to leave the body vent fitting open so that any upstream seat ring leakage is vented to atmosphere instead of downstream.

ALWAYS notify fellow workers of the leak and flag the area where the product is being vented.

Where possible, a blind flange should be installed downstream of the valve to ensure no product escapes into the section of pipeline being serviced.

More severely worn valves can be successfully sealed by using even heavier sealing compounds. These compounds often contain increased quantities of PTFE in various sized particles. The object being to build a small dam of PTFE particles which will stop the leakage. One of the consequences of using the extra heavy and double extra heavy sealants is the risk of plugging the sealant injection fitting or buried inner check valve with PTFE particles. The patented FLOW WOLF® sealant injection fitting and in-line check valve have been designed so they will not plug, even with these heavier sealing compounds. These fittings have to be installed before the valves are pressurized. Heavier sealants should be displaced with a lighter sealant or lubricant / sealant after the critical seal is no longer required to avoid plugging problems associated with the old style fittings.

When piping is used to vent the body vent fitting or to equalize body pressure, it is important to be sure that pressure can not enter the valve body through these sources if workers downstream are depending on this


valve to hold. It is important to be sure that all the small valves on the piping system DO NOT leak or pressure could enter the valve body. On many designs the downstream seat is self relieving. This is a built-in safety feature so that the valve body will not rupture if over-pressurized (usually caused by the thermal expansion of liquids trapped in the valve body). This can also present dangerous problems for workers downstream of the leaking valve. If pressure is introduced into the body cavity, the springs holding the downstream seat will lift off at approximately 200 PSI in excess of line pressure, sending the leakage downstream. As long as the open body vent fitting can vent all the leakage into the body cavity, the downstream seat should remain intact.

Valves which require sealant in order to achieve an acceptable seal must be topped-up each time a seal is required. Once the valve has been cycled, the seal will be lost until sealant is re-injected and the seat testing procedure is repeated.

Stem Lubrication The stem seals on a Cameron® valve are designed for many years of service with little or no maintenance. The stem area is sealed top and bottom with rigid graphite / PTFE type seal rings. Only small quantities of lubricant / sealant or sealant, if any, are required on a periodic basis.

Attach the gun onto the stem seal fitting and watch the injection gauge very closely. DO NOT EXCEED 2,000 or 3,000 PSI in the stem area. Usually (1 – 2) one or two strokes of a manual gun is all that is required. Stop pumping and watch how slowly the gauge falls. If both upper and lower seals are holding, the gauge should not drop at all. If the gauge drops slowly, give it another stroke of sealant and watch the results. If the gauge continues to fall, look at the top of the stem to see if sealant is present. If sealant is escaping from the top of the stem, tighten the cap screws that hold the top seal ring in place. If sealant continues to escape, the top stem seal ring should be replaced during the next shut-down. If sealant is not present and the gauge continues to fall, you may suspect the lower seal is damaged. If this is the case, slowly inject a heavier sealing compound until the leak reaches acceptable limits.

ALWAYS consult the proper Cameron® maintenance manual before attempting any mechanical repairs.

Gearbox Maintenance Many Cameron® valves come equipped with manual gearboxes. Keep the gearbox filled with a high quality waterproof lubricant such as Sealweld® Eterna-Lube 1000. Replace damaged seals and O-rings as soon as they are discovered to prevent water from entering the gearbox and causing corrosion.

Keep the gearbox lubricant topped-up by injecting through the Zerk nipples located on the top, side or back of the gearbox. Be careful not to over-fill the gearbox or the weather seals can be blown out.

If high torque is twisting the gearbox and seals are failing to hold the gearbox oil or lubricant, Sealweld® D-1014 lubricant / sealant has been used successfully as a year-round gearbox lubricant / sealant.

Manual Gearbox


Instructions for Manual Operation of the Bettis® Rotary Gas / Hydraulic Actuator with Mode Selector

Bettis® Gas / Hydraulic Operator, Two Way Manual, Shown In Power Gas Mode

Switch To “Manual” position to lock out remote switching signal before proceeding with local manual operation

With Power Gas:

• Press upper left relay handle and hold to close line valve

• Press upper right relay handle and hold to open line valve

With Hand-pump (No Power Gas):

• Turn lower left valve handle and operate hand-pump to close line valve. Return valve handle to vertical

• Turn lower right valve handle and operate hand-pump to close line valve. Return valve handle to vertical


To Disarm Operator:

• Shut off power gas supply

• Press either upper relay handle to partway to bleed power gas

• Switch to Auto position and ensure lower valves handles vertical and gas supply valve open to resume unattended automatic operation

General Care and Appearance Many companies like to keep their valves painted and looking new. Advise paint crews to tape over the nameplate before painting so that important information is readily available. Plastic caps are available from Sealweld® for giant buttonhead fitting protection. Keep paint, dirt and grime away from these important fittings. Tape up body vent fittings and oil the threads so they continue to operate reliably. Keep paint away from gearbox seals and exposed valve stems.

Clean up excess valve cleaner and lubricant / sealant from sealant fittings and valve bodies. Remove all rubbish from the valve site.

Report any external leakage to your supervisor immediately.

If valves are to be wrapped or insulated, extensions to facilitate the lubricant / sealant fittings may be required. These extensions must be made from XH (schedule 80) pipe of a suitable grade depending on the service the valve is in. Make sure all connections are NPT. Many contractors have accidentally installed NPS (non-tapered) fittings by mistake.

Before Moving to the Next Valve Return the valve to its original position. DO NOT jam the handle or gearbox back it slightly off the full open or full closed position so there is a little play in the gearbox.

Replace the caps onto the sealant injection fittings and stem sealant fitting then tighten firmly with a small wrench. Make sure the body vent fitting is closed before cycling the valve or introducing pressure to the system.

Mark your maintenance chart accordingly. If problems are discovered, mark the valve number and location for more attention during the next shut-down. If serious problems are discovered, note all the nameplate information (including the country where the valve was manufactured) and contact the manufacturer for additional information.

In Summary Whenever servicing valves, rock the valve off its full open or full closed position (only when safe to do so) to keep the valve from being seized in one position. Rotate the valve fully closed at least once a year to move the seat rings to a new position.

The pressure MUST BE equalized on both sides of large diameter valves before they can be cycled.

NEVER remove a sealant injection fitting or stem seal fitting from a pressurized system. The sealant injection fittings enter upstream of the seat rings. With the valve closed and the valve body de-pressurized, there is still full line pressure immediately under the check valve in the sealant injection fitting. DO NOT rely on the buried inner check valve to hold if the sealant injection fitting becomes damaged. Wait for the pipeline system to become de-pressurized before attempting to replace fittings. Beware of trapped pressure inside valve bodies, valve stems and sealant systems especially riser pipe assemblies. Remember, threads do not always weep or leak like they should in the presence of sealants.


If valve leakage continues to be a problem, check the valve stops to ensure that the valve is fully open or closed. Occasionally dirt, grime and rust can build-up on valve stops and keep them from closing or opening fully. Cameron® normally provides plugs on the riser assembly which can be removed to visually examine the stops for build-up. If the riser is filled with oil or anti-freeze, this will need to be caught as the plug is removed.

Learn the capacities for topping-up and completely replacing the lubricant / sealant in the valves sealant system, including riser assemblies. DO NOT OVER-LUBRICATE. If topping-up does not accomplish the desired results, it may be time to clean the valve or switch to heavier sealant.

Cameron® uses a unique sealant injection fitting which is uncommon to industry standards. These small capped fittings should be replaced with Sealweld® fitting (Part number F-SC1/4BH) capped sealant injection fitting with giant buttonhead or a FLOW WOLF® (Part number F-FW1/2BH) with a reducing adapter to 1/4" NPT the next time the system is down and all pressure removed. When ordering new valves from Cameron®, insist on Sealweld® FLOW WOLF® fitting (Part number F-FW1/2BH) and in-line check valve be installed at the factory.

Older Cameron® valves have 1/4" NPT plugs screwed into the valve body where the sealant fittings should be. There is usually a buried inner check valve located under the plug. DO NOT remove the plug if there is pressure inner check or product in the pipeline. Wait until the pressure can be taken off the pipeline and remove the plug carefully. Install a new fitting instead of the 1/4" plug (Part number F-FW1/4BH-SS). Begin by injecting valve cleaner very slowly. Quite often the inner check is plugged and it may take some time to open a passage to the seat ring.

Buried Ball Valve

ALWAYS consult the appropriate Cameron® manual for advice on repair or parts information. Copies of most manuals are available from Sealweld® Services ValvePro® Reference Library at no

charge.


Neglect is the principal cause of valve leakage. Once a valve is put into service a maintenance program should be started. Remember to keep topping-up the valves at regular intervals and inject valve cleaner whenever the valve will not seal or becomes hard to turn. A small amount of routine maintenance can keep ball valves operating reliably for years and even decades.

Bolted Body Ball Valve Maintenance Chapter 14 • Page 73

Chapter 14

Bolted Body Ball Valve Maintenance There are many manufacturers of bolted body ball valves and many different styles and designs. As far as the valve maintenance technician is concerned, there are two basic designs which require periodic maintenance. The two-piece and three-piece bolted body ball valve manufacturers generally do not provide seat sealant injection systems except in valves larger than 4" (unless the valves are custom ordered).

The two-piece body is commonly found on small diameter valves (under 6" six inch) although some of the early designs were made considerably larger. In other words, the ball is secured at the top with no bottom trunnion.

NOTICE that there are no springs associated with the seat rings. In this design the seat rings are in a fixed position, and the ball is allowed to float.

Two-Piece Bolted Body Ball Valves In order to seal this type of valve, first cycle the valve to the closed position. The line pressure will push the ball hard against the downstream seat ring. Because the upstream seat ring and body cavity are exposed to the upstream line pressure, there is no provision to bleed the valve body cavity to test the valve seat ring seal integrity.

Some two-piece bolted body ball valves have either a trunnion mounted ball or a floating ball design. Obtaining a seal can be somewhat tricky with the floating ball style. In cases where there are (2) two sealant injection fittings and they appear to be accessing each seat ring, proceed as follows. The seal is obtained by line pressure forcing the ball against the downstream seat ring. Where the sealant actually enters the seat ring becomes very important (see illustration). Assuming the sealant enters upstream of the PTFE insert as with a conventional ball valve, any sealant injected into the downstream seat ring would be lost downstream of the seal face and would be ineffective. When injecting sealant into the upstream seat ring we can assume the ball has lifted away from the upstream seat ring as it is forced hard against the downstream seat ring. In order for the sealant to be effective, it MUST travel around the circumference of the ball in order to find the downstream seal face. It may take a considerable quantity of sealant before any results are obtained, but a seal should eventually be achieved.

Page 74 • Chapter 14 Bolted Body Ball Valve Maintenance

Floating Ball Valves

In cases where there is just one sealant injection fitting and it appears to be accessing the body cavity, the seal will be achieved in much the same way. In this instance less sealant will be required because the injection point is closer to the downstream seal face.

If the valve continues to leak, it may be because the valve seal faces require cleaning. Inject the valve cleaner into the sealant fittings. Substantially more will be required upstream of the seal face. The best results are achieved by allowing the cleaner to soak for a few hours to overnight in problem valves. Again, considerable quantities will be required in order to have any effect. Displace the cleaner by cycling the valve a few times. The cleaner will be washed downstream. The cycling action should scrape the softened build-up away from the seal face area. Follow up by injecting your regular lubricant / sealant into the upstream fitting. If the regular sealant is not effective, cycle the valve a few times, then inject a heavier sealing compound such as Sealweld® # 5050 Ball Valve Sealant.

Sealweld® # 5050 Ball Valve Sealant is very effective at obtaining a reliable seal when the regular lubricant / sealant is no longer effective. If the valve leak does not diminish after injecting # 5050 it may be that the seat ring is not aligning against the ball properly. This is a more common occurrence on valves with O-rings as opposed to valves with ridged PTFE or Nylon seals. Occasionally one hard blow with a rubber mallet against the top of the upstream flange will cause the seal ring to realign properly.

It can be confusing when there is equal pressure both upstream and downstream of the valve being serviced. When the valve is closed and the body cavity is vented, then both seat rings act the same as the upstream seat ring.

Line Pressure Pushes The Ball Onto The Downstream Seat Ring

Maintenance Instructions For the Grove B-5 Ball Valve Chapter 14 • Page 75

It is possible to lock-up the valve after venting the body cavity. This is caused by the line pressure pushing both seat rings hard against the ball. This is a more common problem on high-pressure or large diameter valves. To unlock the seat rings, equalize the pressure in the body cavity by introducing line pressure into the body cavity through an auxiliary inlet. It is possible to jack the seats off the ball by injecting grease into the body cavity. It will take a substantial quantity because the hole in the ball must be filled as well.

NOTE: Be very careful not to over-pressure the body cavity as it could rupture the body casting.

Maintenance Instructions For the Grove B-5 Ball Valve

Introduction to Ball Valves in Natural Gas Pipelines BEFORE commencing work on any valve that is under pressure obtain the required “Hot Work” permit from the control room supervisor or similar authority.

Cross Section of Grove B-5 Ball Valve

Find out the nature of the product in the pipeline, does it contain hydrogen sulfide gas or other toxic components? Are you working in a confined space, is emergency breathing equipment required? What is the pressure in the pipeline? Do you have the authority to interrupt flow when cycling the valve to the closed position? Who is working downstream, do you have permission to open valves that are normally closed? What other workers are in the immediate area, are they aware that you may be releasing gas to atmosphere, is there a spark hazard from the other workers activities? Ask these specific questions and write down the response.

Organize a “Tail Gate” Safety Meeting with your fellow workers to discuss the job, the objectives, safety concerns and emergency response activities. Discuss the use of hand signals so that communication can continue while the venting procedure is in progress. Determine the direction of the prevailing wind in relation to gas venting activities.

Page 76 • Chapter 14 Maintenance Instructions For the Grove B-5 Ball Valve

On Arrival at the Valve Site

NOTE: A sealant injection fitting is normally installed in conjunction with an opposed U-cup type stem seal. A Grove vent plug or slotted plug is normally installed in conjunction with dual O-ring

stem seal configuration.

1) Identify the valves to be serviced.

2) Record the nameplate information from the manufacturers nameplate on the side of the valve and power operator in the valve report.

3) Locate and identify the different external fittings on the valve:

a) Stem sealant fitting, Grove vent plug or slotted plug

b) Seat sealant injection fittings

c) Giant buttonhead without steel cap

d) Giant buttonhead, with threaded steel cap (metric or American Standard)

e) Body vent fitting

i) with Allen head screw

ii) bolt head type

iii) small diameter ball or plug valve

f) Pressure relief valve - at or near the top (stem end) of the valve. In natural gas service the relief valve may be replaced with a threaded pipe plug. Replace only with written authorization from your Engineering Department and only if safe to do so.

g) Threaded plugs at different locations

4) Make a sketch of the valve layout at the valve site, number each valve. Make notations of the direction of gas flow to orient yourself to upstream and downstream valves and seats. Make a notation of the compass directions (define which direction is north).

Routine Maintenance Procedures If the seat sealant injection fitting is leaking gas to atmosphere, or before injecting valve cleaner, attach a Sealweld® Leak-Lock device to the leaking buttonhead fitting. Should the original check valve and / or internal check valve fail or leak, this adapter will stop any leakage to atmosphere and provide an auxiliary check valve device.

Flow Wolf Leak – Lock #1


Inject a small quantity of synthetic valve lubricant sealant such as Sealweld® Total-Lube # 911 or Sealweld® Equa-Lube Eighty into the seat sealant injection fittings with a high-pressure sealant injection pump.

Cross Section of Seat Sealant Injection System

Watch the high-pressure gauge on the sealant pump very closely. Normally the gauge will climb steadily as pumping continues. Keep injection pressures below 6,000 PSI. Stop pumping (between strokes if using manual injection pumps) and watch the needle on the gauge drop. The needle should drop slowly. If the gauge drops rapidly, this may be an indication that the seat sealant system is empty or low of sealant. Inject additional sealant and continue watching the gauge.

If the seat sealant system or sealant fitting is plugged, the gauge will climb rapidly and not drop off when pumping stops. If the viscous sealant is cold, it will not flow rapidly, be patient and watch the needle closely. If plugging is suspected, discontinue injecting sealant and switch to valve cleaner to clear the obstruction from the seat sealant system.

When the seat sealant system is full, the gauge will climb rapidly and drop very slowly when pumping stops.

Before cycling any valve - ALWAYS request permission from your supervisor, maintenance department and pipeline operations department. DO NOT cycle the valve while injecting cleaner or sealant. Stop pumping and relieve sealant pressure before cycling the valve.

Lubricate the bearings in the gear-set before cycling valve. Use a low pressure grease gun and inject a small quantity of Sealweld® Eterna-Lube 1000 anti-seize compound through the grease nipples at various locations on the gear-set.

Cycle the Valve It is recommended to periodically cycle (rotate from closed to open or vise versa) every valve to keep it operating effectively. Verify with a supervisor that it is safe to do so.

Cycle the valve several times to spread the sealant around the seal face area. If the valve can not be fully closed (or opened) because of operational considerations, request permission to cycle the valve at least thirty 30° degrees (1/3 closed) and back to the full open (or closed) position.

Before opening the body vent fitting make sure the procedure is approved by supervisors. Inspect the work site, take notice of wind direction. Move all ignition sources upwind of the work site (welders, trucks, cars and other vehicles). Extinguish all sources of ignition, no open flames or cigarettes.

Wear good quality leather gloves as the escaping gas can cut skin quite easily. ALWAYS wear eye protection (goggles or safety glasses) and ear protection (ear plugs or ear muffs).


Notify your fellow workers that venting is about to begin. Wait for all workers get to a safe area with appropriate safety equipment and to indicate proceed by showing the thumbs up hand sign.

Draining the Body Cavity Water (hydrates), compressor oil, gas condensate, and solid residue may collect in the body cavity from time to time.

It is recommended to open the body vent / drain fitting to bleed out these contaminants on a regular (annual) basis.

Draining the body cavity may take from several seconds to several minutes depending on the valve size and vent hole size in the body vent fitting. For large diameter valves a full port ball valve or plug valve is recommended or more rapid depressurization.

Keep in mind that the Grove B-5 valve is designed with a hole drilled through the top of the ball. This means that the ball must be in the fully closed position in order to drain the body cavity. If the body vent fitting is opened with the ball in the open position, high-pressure gas will escape to atmosphere from the pipeline through the 1/4” hole drilled through the top of the ball.

ATTENTION! - If hydrates are present in the gas, the body vent fitting or riser assembly may freeze off during high-pressure gas venting procedures. This may confuse the technician into mistakenly thinking the valve body has been completely de-pressurized. ALWAYS work the closing mechanism in the body vent fitting open and closed repeatedly, with zero leakage, before assuming the body cavity has been de-pressurized. Ice blockages may take time to thaw before a passage is re-opened. Work slowly and patiently to be sure the valve body is truly de-pressurized before disassembling any blow-down assembly components.

Drain the liquids into a portable scrubber or similar vented container or drum to avoid releasing these materials into the environment. Dispose of materials collected in a responsible manner.

Testing the Seat Seals The internal sealing ability of the valve can be tested by cycling the valve to the closed position and opening the body vent / drain fitting.

This will usually take from several seconds to several minutes. As gas pressure drops the sound or pitch will also fall. If the seals are perfect, the body cavity will vent to (0 PSI) zero pressure and (0 CFM) zero gas leakage. If the valve has been in service for a number of years, a perfect seal may not be achievable. If the leak is small and steady, a small leak may be tolerated in certain situations.

Manual Seat Testing Methods Be very careful and always wear good quality leather gloves. If the gas leakage is excessive you will not be able to hold your hand over the vent hole in the body vent / drain valve. Use common sense, if gas pressure is excessive do not place your hand into the gas stream. Escaping high-pressure gas will freeze the moisture in the surrounding air into tiny ice slivers that can pierce your skin causing great pain and discomfort.

A simple yet effective test is to place your gloved hand firmly over the open body vent fitting and stop all gas from escaping. Use only a reasonable amount of force when stopping gas flow, do not wrap your fingers around the body vent fitting. Now time the build-up of pressure by counting the seconds required before accumulated pressure forces your hand away from the vent hole.

If you can count to ten before your hand is pushed away, this is a very small leak, approximately 1 cubic foot per minute. If you can count to one before your hand is pushed away, this is a leak of approximately 10 cubic feet per minute.

Leakage rates below (30) thirty CFM are acceptable in many situations depending on the application. Use a gas measuring or metering devise to verify leakage rates that are close to the maximum allowable leak rate.


Sealing Leaking Valve Seats Valve seat leakage may be due to a number of factors:

• The valve stops may be out of alignment. Inspect the valve stops and make sure the valve is fully closed. Misalignment by more than two or three (2 – 3°) degrees may expose the bore hole through the ball to the pipeline pressure resulting in continuous leakage.

Remember…it's a ninety 90° degree rotation from open-to-closed.

• Old sealant and other pipeline debris may have built-up contaminants in the seal face area.

• This build-up could prevent proper contact of the seal face between the ball and seat ring, resulting in seat leakage.

• The ball, seat ring or seal O-ring (elastomer) may be scratched, scared or otherwise physically damaged.

Troubleshooting Tips for Valve Leakage The first step should be to visually examine the valve stops or valve position indicator. Notice the position of the indicator, it should be exactly ninety 90° degrees perpendicular to the orientation of the pipeline. If you are not sure if the valve is fully closed, loosen the lock nut on the valve position set screw and back off the set screw. ALWAYS mark the current position of the indicator then take the valve beyond its normal closed position.

Open the body vent fitting or leave the body vent fitting open when performing this procedure. Listen for the sound of escaping gas to increase, then decrease as the correct closed position is located.

When the leak rate is at its smallest, lock the valve stop adjusting screw nuts in position.

If the valve continues to leak at this point, inject a small quantity of sealant into the sealant injection fittings, one seat ring at a time.

The leakage could be caused by not having a sufficient quantity of sealant in the seat ring. A good rule of thumb is (1 oz.= 28 grams) one ounce of sealant per inch of valve size per seat ring. In other words: a (16") sixteen inch diameter valve would require approximately (16 ozs.= 1 pound) sixteen ounces of sealant into each seat ring to fill from empty. If the valve is buried, add (2 ozs.) two ounces of sealant per foot of 1/2” diameter riser pipe. Depending on the number of sealant risers and the design of the riser assembly, this can vary the quantity of sealant required.

Inject sealant slowly, it must pass through a series of machined grooves and narrow passages around the circumference of the seat ring before reaching the seal face. Listen for the leak rate to slow down as sealant reaches the leak point. This may help identify which side of the valve is damaged.

If injecting additional sealant is not successful it may be necessary to clean the seal face area.

The inside of the pipeline may be contaminated by left over construction debris such as welding slag, sand, dirt and sand blasting materials. Hydrostatic testing operations may introduce dirty water, sand and small stones into the pipeline. During the installation of actuators, and during hydrostatic testing operations the valves are cycled. Any dry contaminants will scratch and scar the sealing surfaces causing tiny leak paths.

Solid contaminants may become lodged in the small space at the back of the seat ring or inside the seat ring through the sealant passages. These contaminants can inhibit proper seat travel and even wedge the seat ring in an unusual position so that the seat insert is not making proper contact with the ball.

The valve seats could have a varnish-like build-up caused by leaking oil from turbine / compressor seals or old dried valve grease or sealant. Sealweld® Valve Cleaner Plus has been specifically designed to soften the debris and varnish-like build-up that can occur inside natural gas pipeline valves.

Inject valve cleaner in sufficient quantity to displace the old sealant inside the seat sealant system (one (1 oz.) ounce per inch of valve size per seat ring). Allow the valve cleaner to soak inside the valve from one hour to


overnight if possible. Cycle the valve at least three (3x) times to distribute the cleaner around the seal face area. Top-up repeatedly to push the softened contaminants out of the tiny sealant passages and into the pipeline.

After soaking with valve cleaner, open the body blow down fitting and observe if the leak as diminished or increased. If the leak was caused by a build-up of varnish, the leak may be completely eliminated by cleaning. If the leak was caused by scars to the seating surfaces, the leak rate may increase as a result of cleaning.

Replace the valve cleaner by injecting fresh lubricant / sealant such as Sealweld® Total-Lube # 911. Inject the same quantity of sealant as valve cleaner (one (1 oz.) ounce per inch of valve size per seat ring plus riser pipe quantities). Cycle the valve at least (3x) three times to distribute the sealant around the seal face area. Inject very slowly, do not exceed 6,000 PSI injection pressure. It will take more time for the viscous sealant to fill the sealant passages.

If the damage is due to very small scars or seal face O-ring damage, Total-Lube # 911 will provide an effective seal for small scars to .010” and O-ring damage.

If the leak appears to stop, then kicks and becomes a larger leak or sputters, it may be necessary to inject a heavier sealant such as Sealweld® # 5050 Ball Valve Sealant. Inject the same quantity of sealant as you injected Sealweld® Total-Lube # 911 (one ounce per inch (1 oz. / inch) of valve size per seat ring plus riser pipe quantities). # 5050 Sealant will seal scars up to .030” through the use of specially processed PTFE flakes.

Sealweld® # 5050 is also available in XH (Extra Heavy Grade) and XXH (Double Extra Heavy Grade) for extreme seat scarring damage.

It is always recommended to start with a light grade sealant and gradually work up to the heavier sealants.

Additional Sealing Procedures for Emergency Situations Because of the unique seat ring design, the Grove B-5 ball valve can have a special sealant compound (Sealweld® Chameleon Sealant) injected directly into the body cavity in order to effect a seal in an emergency.

You must keep in mind that this may require a substantial quantity of sealant, for instance a 16” diameter ball valve would require approximately (100) one hundred pounds of Chameleon Sealant to completely fill the hole in the ball and the body cavity. It is possible to over-pressure the body cavity, this procedure should only be performed by experienced professionals. Contact Sealweld® Services for additional information.

Stem Sealing Procedures The B-5 ball valve may be equipped with any of a variety of stem seal configurations.

Stem Sealant System


The most common design features (2) two O-ring seals (see illustration). There may be a Grove vent plug or a vented plug (threaded plug with a slot cut along the threads) located between the (2) two O-rings. The plug may be unscrewed (1 – 2) one or two turns, if gas escapes this would indicate that the lower stem seal is worn or damaged. Tighten the plug back in place to energize the upper O-ring.

Notice if gas is escaping out through the upper O-ring seal and into the gear-set or actuator. This would indicate that both O-rings are worn and / or damaged.

It may be possible to stop this type of stem leak by removing the vented plug and installing a sealant injection fitting. To accomplish this safely, the valve should be cycled to the closed position and the body cavity vented to (0 PSI) zero. It may be possible to remove the vented plug in the stem if a very small leak is present.

Use extreme caution and common sense.

With the body cavity vented and body vent fitting open, slowly remove the vented plug in the stem. Relieve the gas pressure slowly, work the vented plug in and out repeatedly until the plug can be safely removed.

Install a Sealweld® FLOW WOLF® type sealant injection fitting (part number F-FW 1/4 BH SS) into the valve stem where the vented (this fitting features a 1/4” NPT thread, different connecting thread sizes are also available). Tighten the new fitting in place.

Inject sealant (Sealweld® Total-Lube # 911 for small leaks, # 5050 Sealant for larger leaks) into the sealant fitting on the stem. Watch the pressure gauge on the sealant pump closely DO NOT EXCEED 3,000 PSI when injecting sealant. Excess pressure may force one or both of the O-rings out of the machined groove and lead to uncontrollable leakage.

Grove Vent Plug 1/4" NPT with Allen head

When the gauge reaches 3,000 PSI; stop pumping - then close the body vent fitting.

Cycle the valve back into the full open position to re-pressurize the body cavity and stem seal area. Watch the gauge on the injection pump closely. If pressure drops off, inject additional sealant, DO NOT EXCEED 3,000 PSI. It may be necessary to inject a heavier sealant such as Sealweld® XH # 5050 or XXH # 5050 if leakage persists.

Before Leaving the Valve Site Use a penetrating type oil to spray the body vent fitting and any external moving parts. If the oil residue turns orange in color this may be an indication of rusting and corrosion. Clean up the affected area then apply Sealweld® Eterna-Lube 1000 anti-seize compound to prevent further deterioration. Make sure the body vent fitting is closed and sealing properly. Lubricate the bearings in the gear-set or actuator with Eterna-Lube 1000.

• Cycle the valve back to its original position.

• Tighten the steel caps back on the sealant injection fittings.


• Pick up your hand tools, sealant pump and adapters, secure in tool box.

• Clean up any sealant that may have been spilled or leaked.

• Clean up any rubbish at the valve site.

• Test for gas leakage to atmosphere from valves, fittings and flanges.

If the valve or valve yard is normally chained and locked, replace these items to their original position. If padlocks are used, spray the padlock with penetrating oil and open / close repeatedly to ensure easy operation.

Store and retrieve all preventative valve maintenance procedures in ValvePro®, a Series of Software Solutions from Sealweld®.

Report Writing Before leaving the valve site prepare your written report including the valve detail, work performed and results achieved. Refer to the samples for Service Report worksheets. Write down all results clearly so they can be read by all personnel.

Use the areas of the report marked "Comments" to detail any additional work to be performed. Use extra pages as required.

Keep copies of the reports in a binder that can be taken to the field by the valve technician during the next maintenance interval or during a pipeline emergency.

For additional information including spare parts lists and repair procedures consult the “Grove Series B-5, B-4B and B-4C Ball Valve Installation & Maintenance Manual Bulletin No. B-IRM 1/94 (2.5M)”

Gate Valve Maintenance Chapter 15 • Page 83

Chapter 15

Gate Valve Maintenance The gate valve is an old proven design. Many of the smaller, simpler gate valves require stem seal maintenance only. Some of the more elaborate and larger diameter gate valves in high-pressure and / or sour service have provisions for seat sealant injection.

The simplest design is the typical forged steel gate valve as illustrated below.

Typical Forged Steel Gate Valve

Periodic maintenance consists of inspecting the stem for leakage and tightening the gland nut as required. Keep the threaded stem oiled to prevent rusting and clean up any dirt or sand which adheres to the stem. Cycle the valve (if possible) to keep the valve from seizing in one position. Keep paint away from the stem threads, as it can build-up and increase torque and may keep the valve from seating properly.

Forged and cast steel gate valves are generally simple and inexpensive. Most styles are designed so that the gate and seats can be easily replaced. This style of valve does not have any provision for seat sealant injection. Stem packing can be made from braided rope packing or soft plastic type packing such as: Sealweld® Slick Sticks or Pak-King compound.

Page 84 • Chapter 15 Gate Valve Maintenance

Should stem leaks develop after the packing gland has been fully compressed it is possible to have professional leak sealers come in and effect repairs. It is done simply by hot tapping into the packing chamber and injecting Sealweld® Pak-King compounds.

Wellhead Gate Valves The W-K-M® POW-R-SEAL gate valve illustrated below is the most copied gate valve in industry today. At last count there were over (25) twenty-five copy-cat manufacturers of varying quality. The working principles are all identical; the seat rings are fixed to the body and the gate is split and held together with a strong spring.

Maintenance on this style of valve consists of adding more plastic stem packing putty sticks as stem leaks develop. Be careful while removing the bolt or stinger of the packing injector. Occasionally the ball check in the body of the packing injector will not seat properly and gas or liquid can escape under high pressure. Remove the bolt slowly, it should unscrew by hand after one or two turns if there is no pressure behind it. There is a small vent hole near the top of the packing injector body which should vent leakage as the bolt is unscrewed if the ball check has failed. Exercise extreme caution while injecting stem packing. The fine threads on the bolt portion of the packing injector can generate up to 30,000 PSI without much effort with a short wrench. Turn the screw in slowly until the leakage stops.

NOTE: DO NOT OVER-TIGHTEN or the valve may become difficult to operate.

The body cavity is often filled with body filler grease to lubricate the gate and seats, prevent internal corrosion and keep hydrates from collecting in the valve body. Always consult the proper W-K-M® (or other manufacturers) manual for advice on body filling instructions before starting. Quantities required to fill the body are approximately (1) one pound of grease per inch of valve size, a two (2") inch gate valve requires about (2 lbs.) two pounds of body filler grease. For best results select a grease which is insoluble in the solution flowing through the valve. Extreme care must be taken, DO NOT exceed the maximum working pressure of the valve being serviced when filling the body cavity. Attach the SO-BV Tool to one of the (2) two body grease fittings to vent leakage and to prevent over-pressuring the body cavity while filling.

The stem bearing should be lubricated periodically with a high quality water resistant bearing compound such as Sealweld® Eterna-Lube 1000. Care should be taken not to over-lubricate the stem bearings.

Types of API Gate Valves


In order to get this style of gate valve to seal properly, it may be necessary to operate the valve several times. Use of heavy sealing compound is generally NOT recommended due to the large quantities which must be injected. The seat design does not have provision for seat sealant injection; however, in an emergency, filling the body cavity with an insoluble seat sealant may achieve the desired results.

McEvoy® Gate Valves The McEvoy® gate valve is considered by many to be the Cadillac of wellhead gate valves. It is designed for many years of rugged reliable service. It has many design features which make it ideal for severe service such as high-pressure and corrosive conditions. Because it is a more expensive valve, extra care should be taken to ensure many years of reliable service.

The main advantage of the McEvoy® design is the provision for automatic seat sealant injection. Every time the valve is operated, the sealant reservoir discharges a small amount of sealant into each seat ring. There is sufficient quantity of sealant for approximately (100) one hundred operations. The sealant reservoir is refilled through the (2) two capped fittings adjacent to each seat ring. Because the valve seats feed from a reservoir, use of valve cleaner is generally not recommended except in an emergency. There is no assurance that the valve cleaner can be completely displaced from the reservoir unless the reservoir is emptied by operating the valve over (100) one hundred times.

McEvoy® Three Fitting Style


The smaller capped fitting located near the bottom of the valve body is used for the injection of a body filler grease. As with other wellhead gate valves, the body filler grease will lower operating torque, prevent corrosion and prevent hydrates from collecting in the valve body.

Stem packing consists of a series of chevron packing rings in the bonnet assembly. The packing and stem bearing can be replaced with the valve under pressure by following the instructions as detailed in the owners manual. The bleeder plug can be removed to check if the stem back-seating was successful.

The stem bearing should be lubricated periodically with a high quality water proof lubricant such as Sealweld® Eterna-Lube 1000.

As with any valve, the valve should be cycled at least once or twice a year to keeping from seizing in one position.

Pipeline Gate Valves Pipeline gate valves are designed so that the gate is in a fixed position and the seats are spring loaded and allowed to float. The seat sealing principles are very similar to pipeline ball valves. Gate valves in liquids service are usually equipped with a body relief valve. The relief valve will prevent the body from rupturing as a result of liquids expansion with the valve in the closed position.

Typical Through Conduit Pipeline Gate Valve

There are many different manufacturers of pipeline gate valves. The working principles are all generally the same. Where they differ is in the seat sealing and stem packing areas. See the illustrations of the most common stem packing designs. Some valves use different combinations of the these designs. Each style has its advantages depending on the service conditions.

Because of the long travel of the valve stem, pipeline gate valves are prone to stem leakage.

In the case of O-ring seals, the O-rings will roll as the stem rises which can lead to pinching and tearing of the O-ring. Valves with O-ring type stem seals generally use a buttonhead fitting to allow for the injection of valve sealant such as Sealweld® # 5050 if leakage develops. Care should be taken when injecting sealants into a valve stem. Because it is an enclosed chamber there is no where for excess sealant to go. Continued high-pressure injection may extrude the O-ring stem seals out of their recess and make the leakage worse. Usually (1 - 2) one or two strokes of the gun handle is sufficient to put a small amount of pressure (2,000 PSI to 3,000 PSI) into the stem gland in order to charge the seals. Valve cleaner should never be injected into a buttonhead fitting on a valve stem with O-ring type seals because there is no way to displace the cleaner.


Gate Valve Stem Packing

In the case of plastic putty type packing, the long travel of the stem shaft has a tendency to pull some of the packing out as well. This means additional packing must be added on a regular basis to replace the lost packing.

Chevron ring type packings are available in a wide variety of exotic grades for valves in extreme services such as hard to hold liquids and gasses. When chevron packing fails, it may require a system shut-down to replace the packing safely. Valves equipped with chevron rings with an emergency sealant backup (either buttonhead or packing injector) are generally more reliable. With the dual system, most leakage can at least be slowed considerably if not stopped completely.

Stem bearings and weather seals are generally lubricated with a light-weight water resistant grease such as Sealweld® Eterna-Lube 1000. The grease provides a protective coating over metal parts which would otherwise rust and corrode. Be careful not to over-lubricate or build excess pressure with the grease gun as this could pop the weather seals. Some valve manufacturers use a Zerk fitting with a relief slot to ensure excess pressure can not be built up. Oil seeping from the stem or gearbox may indicate that the stem seal has failed and that the lubricating grease has broken down back into its oil base. If this occurs, tag the valve for stem seal or gearbox seal replacement during the next shut-down. Make sure all the old grease residue is removed before replacing with fresh grease. Eterna-Lube 1000 is effective in this application because of its resistance to breakdown as a result of temperature fluctuations. Weather seals can often be replaced safely with the valve under pressure.

ALWAYS consult the owners manual before attempting any repair procedure.

The body cavity should be drained periodically to get rid of contaminants which may have collected in the bottom of the valve. Many pipeline valves are designed with seat seals that will allow for body draining with the line under pressure and the valve in the open or closed position. Block and Bleed is described as closing the valve and draining the body cavity. Double Block and Bleed is described as being able to drain the body cavity with the valve in the full open or full closed position. If the valve does not operate properly, it may be as a result of contaminants which have collected in the bottom of the valve.

Seat sealing systems vary from one manufacturer to another. In principle they are very similar to a typical pipeline ball valve. The sealant does not generally travel the circumference of the seat ring like most ball valves. Rather, it enters through only (1 – 2) one or two small holes near the seal face area. It is essential to operate the valve several times to ensure complete coverage of the valve cleaner or lubricant / sealant being injected. Quantities of lubricant / sealant required to fill the seat sealant system are 25% to 50% less than similarly sized ball valves. Use approximately 0.50 ounces to 0.75 ounces per inch of valve size into each seat ring. A ten (10") inch gate valve will require five to seven (5 – 7 ozs.) ounces to completely fill the seat sealant system. Quantities required to top-up the seat sealant system will be considerably less as well.

Valves with double block and bleed provisions should have their seat seals tested as part of maintenance routines.


ALWAYS cycle the valve several times before switching to heavier sealants.

Grove® G-12 Gate Valve Sealing Principles

Grove® G-12 Gate Valve Sealing Principles


Grove® G-12 Gate Valve Cut-Away View

Grove® G-12 Gate Valve Cut-Away View



In Conclusion Chapter 16 • Page 91

Chapter 16

In Conclusion Valves are used to re-direct product flow and for basic on-off service. It is the valve maintenance technician’s responsibility to keep these valves in good operating condition and sealing properly.

The products, techniques and procedures detailed in this program have been developed over many years of pipeline experience. Always consult the proper manufacturers operating and maintenance manual before starting any repair procedure. Sealweld® has a large library of such manuals, many dating back (20 - 30) twenty or thirty years. Photocopies are available on request.

Keep copies of all the owner’s manuals on the many valves at your facility readily available for easy reference. Make a record of your maintenance activities and keep it up to date. Make notations on any alterations you have made to the original configuration (changes in stem packings, the removal of inner check valves, etc.). Be sure to include comments on any special procedures required to get the valve to seal, this could prove invaluable in an emergency.

We trust you will find the procedures detailed in this program useful when maintaining the valves at your facility. Should you have any question regarding any of these procedures, or if you know of any successful procedures you would like to share, please contact us at:

Sealweld Corporation – Canada # 106, 4116 – 64 Ave. S.E. Calgary, Alberta CANADA T2C 2B3 TOLL FREE 1-800-661-8465 PHONE 1-403-236-0043 FAX 1-403-236-5487 EMAIL [email protected] URL http://www.sealweld.com

Page 92 • Chapter 16 In Conclusion

Sealweld (USA), Inc. 6450 Skyview Drive Houston, Texas USA 77041 TOLL FREE 1-800-624-4301 PHONE 1-713-466-7373 FAX 1-713-466-7778 EMAIL [email protected] URL http://www.sealweld.com

ValvePro® Technical Support TOLL FREE 1-800-661-8465 PHONE 1-403-236-0043 FAX 1-403-236-5487 EMAIL [email protected] URL http://www.valvepro.com

After Words The HANDBOOK of Valve Lubrication and Maintenance is written from the maintenance departments point of view and in the language of service people responsible for safe and efficient operation of lubricated plug, ball and gate valves.

The information in this handbook is intended as a guide only. Always consult the valve manufacturers recommended maintenance procedures. No warranty is written or implied.

Use of product and / or company names is for reference only.

Sealweld®, ValvePro®, ACTIV-8®, SuperGun® and FLOW WOLF® are registered trademarks and / or patents of Sealweld Corporation.

Glossary of Valve Terms - Copyright© Grove Valve & Regulator Company, 1980, 1993.

Cameron®, W-K-M®, and McEvoy® are registered trademarks of the Cooper Cameron Corporation.

Microsoft® is a registered trademark and Windows and Word 97 are trademarks of Microsoft Corporation.

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