DUAL-SEAL BALL VALVE
Contents
1. MODEL 30 MODEL 30 D AND REVISION 4 SECTION DUAL SEAL LUBRICATION BALL VALVE PAGE 3 OF 5 3 Connect a high pressure 10 000psi grease gun to seat grease fitting on the pressure side of the valve 4 Pump lubricant into the valve seat The grease will travel around the entire annulus between the Primary and Secondary Seals filling the area up between the O D elastomers This will lubricate the seals and allow them to float as designed if you have determined that they are not sealing against the ball 5 Never exceed the working pressure of the valve when pumping grease into the seats Refer to Appendix E Table 2 1 from API 6D 6 Remove grease gun 7 Replace vent cap on grease fitting and lightly tighten C Draining the valve to remove moisture Depending on climate and your Company s standard operating procedures you may need to periodically drain accumulated water and contaminants from the center body cavity of the valve Choose the lowest body fitting to the ground depending on the orientation of the valve It will either be the center or middle body vent fitting or the lower trunnion fitting The lower trunnion fitting is typically a solid drain plug See Drawing C Drawing C Solid Cavity Drain Plug all valve sizes A429EN1 08 Rev 4 ETT OP M 31 6 X GIN MAINTENANCE MODEL 30 MODEL 30 D AND REVISION 4 DUAL SEA2. nn ae PAS NA OPERATING amp MAINTENANCE PROCEDURES FOR DUAL SEAL BALL VALVE FOR PRODUCTION PIPELINE TOP SIDE AND UNDERGROUND STORAGE SERVICES Manual Identification Number OPM 316 Rev 4 Revised February 2010 A429EN1 08 Rev 4 TABLE OF CONTENTS DESCRIPTION SECTION Operating Procedures for a Model 30 and Model 30 D Dual Seal Ball Veen una I Maintenance amp Lubrication for Model 30 and Model 30 D Dual Seal Ball Valve II Trouble Shooting amp Routine Functional Testing for Model 30 and Model 30 D Dual Seal Ball Valve Valve E EHSR Requirement of Warning amp Caution Appendices Maintenance Schedule aiite are A Assembly Boe C API Specification 6D Testing Procedures D General Design Standard cea E A429EN1 08 Rev 4 SECTION I OPERATING PROCEDURES OPM 316 MODEL 30 MODEL 30 D REVISION 4 DUAL SEAL SECTION 1 BALL VALVE PAGE 1 OF 5 Size All Pressure Class All Material Class All Mode of Operation All The Model 30 and Model 30 D Dual Seal Ball Valve use a trunnion mounted ball design to achieve an upstream seal The Model 30 Dual Seal valve is bi directional and incorporates W O M s patented Dual Seal d
3. II BALL VALVE PAGE 5 OF 5 0 DESCRIPTION Q m Gland Plate et 0 b 1 Thrust Washer NT y gt O Ring Seal e mon oo Stem Seal Detail amp Bill of Materials A429EN1 08 Rev 4 SECTION III OPM 316 TROUBLE SHOOTING AND MODEL 30 MODEL 30 D ROUTINE PUNCTIONAL TESTING REVISION 4 DUAL SEAL SECTION BALL VALVE PAGE 1 OF 4 Size All Pressure Class All Material Class All Mode of Operation All A Stem Packing Troubleshooting 1 If you see slight weepage of valve contents coming from around the stem this is an indication of a slight stem packing leak This may be corrected by injecting sealant into the stem packing fitting Use the same procedures as adding grease in the seat grease fitting instruction B Maintenance instructions for injecting lube sealant into this area See Figure 5 Keep in mind that the area to inject grease in to is very small and a single stroke from a high pressure grease gun should inject enough grease to affect a seal If the valve can be cycled open and close it several times to help distribute the grease around the O D of the stem A429EN1 08 Rev 4 OPM 316 TROUBLE SHOOTING AND MODEL 30 MODEL 30 D ROUTINE PUNCTIONAL TESTING REVISION 4 DUAL SEAL SECTION Ill BALL VALVE PAGE 2 OF 4 Grease Injection Fitting Upper Poly Pack Grea
4. OF 5 B Operation Instructions for Double Block and Bleed using the Bleed Fitting The W O M Dual Seal Ball Valve is a Double Block and Bleed valve DBB Double Block and Bleed can be verified by following API 6D test procedures With the line under pressure the valve center body cavity can be vented to the atmosphere and completely de pressurized with the ball in either the open or closed positions After venting if no additional line pressure enters the valve the seals have been proven to be intact Bleed the body cavity pressure through the vent bleeder fitting located in the upper quadrant of the ball valve s center section This fitting has two venting ports 180 degrees opposite each other Refer to Drawings A amp B NUT GROOVE PIN 1 2 20 L H THREADS 7 8 TO 1 3 8 HEX VENTING PORT 3 4 TO 1 NPT METAL TO METAL SEAL Drawing B 4 valve amp Up Body Vent Bleeder Fitting Figure 4 4 amp Larger Ball Valves A429EN1 08 Rev 4 OPM 316 PERATING PROCEDURE MODEL 30 MODEL 30 D e CEDURES REVISION 4 DUAL SEAL SECTION 1 BALL VALVE PAGE 3 OF 5 1 4 and larger valves To open the vent ports use a wrench on the upper smaller hex head stem of the fitting and turn the wrench counter clockwise This will allow any trapped pressure in the body to vent to atmosphere 1 4 SOCKET HEX SNAP RING 7 8
5. ENDIX E ATTACH DUAL SEAL BALL VALVE BROCHURE
6. Il PAGE 2 OF 5 Follow this sequence preferred but not essential to bleed off body pressure 1 Body vent fitting is the MIDDLE body fitting Note Use the instructions in Section C of the Operating Instructions to de pressurize the valve If you cannot de pressurize the valve you will need to use sufficient grease gun pressure to over come the pressure in the valve plus the pressure required to move the grease out of the grease gun In cold weather grease will thicken and require more pressure to pump through the gun Caution Never remove any fitting or plug that appears to be threaded into the body without first making sure there is no pressure beneath the fitting There may be trapped pressure underneath the fitting that could eject it out of the threads with deadly consequences 2 When body cavity is completely vented remove the vent cap from the grease fitting See drawing E on the pressure side seat Do not remove the entire grease fitting which is threaded into the valve end connection A ball check inside the fitting prevents pressure loss but will accept grease input VENT CAP 1 1 4 HEX 1 14 UNS BALL TO 1 5 1 SPRING RETAINER V4 TO 1 NPT THREAD Drawing E Vented Cap Body Grease Fitting 1 6 WRENCH HEX Note There is no buried check valve beneath ANY grease fitting of a WOM Valve A429EN1 08 Rev 4 OPM 316 MAINTENANCE
7. L LUBRICATION SECTION II BALL VALVE PAGE 4 OF 5 As an option this plug can be replaced with a quarter turn drain valve Removing solid drain plug allows water and sediment to drain from valve Be sure this plug or a valve is re installed prior to commissioning valve Do not remove this plug without first venting valve body cavity to the atmosphere D Storage a Place the valve in the full open position b Inject grease in to each seat grease fitting until you see excess grease oozing out from between the ball and seat on the inside of the valve cavity see instruction B under Seat Lubrication Coat the end connection seal surfaces with grease to prevent rust Use flange covers to keep out debris e The valve should remain in the open position until installed NOTES 1 Always follow your Company s specified operating instructions for the media being produced Assembly drawing of Model 30 Ball Valve Details of stem sealing area Bill of Material for Ball Valve Stem Packing Tag Drawing P EMERGENCY STEM SEALANT INJECTION FITTING IN CASE OF STEM LEAK SLOWLY INJECT SEALANT INTO FITTING UNTIL LEAKAGE SUBSIDES OR STOPS REPAIR VALVE AS SOON AS POSSIBLE STEM SEALANT FITTING IS FOR INJECTION OF EMERGENCY SEALANT ONLY Stem Packing Tag A429EN1 08 Rev 4 TZ OPM 316 MAINTENANCE MODEL 30 MODEL 30 D AND REVISION 4 DUAL SEAL LUBRICATION SECTION
8. TES 1 Always follow your Company s specified operating instructions for the media being produced 2 Assembly drawing of Model 30 Ball Valve 3 Details of stem sealing area 4 Bill of Material for Ball Valve A429EN1 08 Rev 4 OPM 316 MEI LEN NS N TROUBLE SHOOTING AND MODEL 30 MODEL 30 D ROUTINE PUNCTIONAL TESTING REVISION 4 DUAL SEAL SECTION Ill BALL VALVE PAGE 4 OF 4 ITEM DESCRIPTION Gland Plate Stem OR 7 10 14 15 16 Stem Detail amp Bill of Materials a 3 oo e A429EN1 08 Rev 4 SECTION IV ARAS OPM 316 LVL WIN 7 L 7 CAUTION For handling and or lifting the lifting equipment fasteners hooks etc must be sized amp selected white talking into account the valve weight indicated in the packing list Do not use the lifting points located on the actuator if any to lift the valve Caution must be taken during the handling to avoid that this equipment passes over the workers or over any other place where a possible fall could cause damage Every employee should aware about the safety regulations during handling of the valve 1 1 Preparation and Preservation for Shipment All valves are properly packed in order to protect the parts that are subjected to deterioration during transportation and storage on site In particular precautions should be followed as
9. TO 1 3 8 HEX PORT 1 2 i METAL TO METAL SEAL 2 Drawing A 2 amp 3 valve Figure Se Scu Bal Valves Body Vent Bleeder Fitting 2 2 and 3 valves same procedure as for 4 and larger but the vent fitting uses an allen head wrench to open and close the ports 3 Close the vent fitting by turning the small hex head stem or allen head clockwise until it snugs tight This fitting must be in the closed position at all times other than for block and bleed tests Caution When turning the smaller hex head make sure the threaded body of the fitting does not unthread out of the ball valve center section You may need to put a back up wrench on the larger hex head See Figures 3 amp 4 ALWAYS USE EYE PROTECTION DURING THIS PROCEDURE C VENTING No WOM ball valve can trap pressure in the body All valves are self relieving A429EN1 08 Rev 4 OPM 316 OPERATING PROCEDURES MODEL 30 MODEL 30 D REVISION 4 DUAL SEAL SECTION 1 BALL VALVE PAGE 4 OF 5 In the Model 30 the excess pressure bleeds to the side of the valve with the lowest pressure For example if you have 1000 psi on the upstream side of the valve and 500 psi on the downstream side the excess pressure in the body cavity will bleed to the low pressure downstream side See Figure 1 1000 PSI Figure 1 Figure 2 In the Model 30 D with the Third Sea
10. below a The valves must be packed with the ball in the open position b The valve ends surface shall be protected with suitable protective The ends shall be closed with plastic rubber disc c All actuated valves must be carefully securely palleted or crated in order to ensure that the parts of actuator don t extent beyond the crate d The type of packing must be defined in the Customer s order amp shall be appropriate to ensure safe transportation to final destination amp eventual conservation before installation 1 2 Handling Requirements A Packed Valves Crates Lifting amp Handling of the packed valves in crates will be carried out by a fork lift by means of appropriate lifting slings Cases The Lifting of packed valves in cases should be carried out in the lifting points and at the center of gravity position which have been marked The transportation of all packed material must be carried out safely with safety measures A429EN1 08 Rev 4 OPM 316 LS B Unpacked Valves 1 The lifting amp the handling of these valves must be carried out on pallets protecting the machined surface to avoid any damage 2 For big sizes valves the sling amp hook must be carried out by using the appropriate tools brackets hooks fasteners ropes and load balancing tools in order to prevent them from falling during the lifting amp handling 1 3 Storage and Preservation before Installation In case the valves
11. erating Conditions and the Company s own Preventative Maintenance Program 2 The stem seals are lubricated at the factory No maintenance needed for normal operation 3 Model 30 and Model 30 D uses two sets of dry permanently lubricated bearings the upper trunnion and one on the lower trunnion These bearings do not require lubrication under normal operating procedures 4 Worm gear The worm gear operator needs annual additions of heavy non pourable grease to lubricate the worm gear shaft Grease can be injected thru the grease zert located on the gear housing or you can unbolt the gear box and pry off the cover plate Add grease until the area is nearly full Grease will help keep water from accumulating in the gear box NOTE In freezing weather any water in the gear box can freeze and damage the box B SEAT LUBRICATION It is not necessary to lubricate the seats during normal operations of this valve The seats are designed for the resilient seals to float against the ball without requiring grease Caution There will be some trapped pressure in the body cavity from the last open close cycling If the valve is handling H2S or similar toxic materials appropriate safety precautions and protective equipment should be used Consult your safety coordinator if unsure A429EN1 08 Rev 4 MODEL 30 MODEL 30 D DUAL SEAL BALL VALVE MAINTENANCE AND LUBRICATION OPM 316 REVISION 4 SECTION
12. esign of two independent seals on each side of the ball for extended valve life and additional safety The Model 30 D use the same upstream Dual Seal design but the addition of a modified secondary seal on the downstream side now gives the valve a third seal on the downstream side of the ball The 30 D also has a preferred direction of flow arrow indicated by a stainless steel tag mounted on the side of the body A GENERAL OPERATING INSTRUCTIONS Ball valves should never be used to throttle line fluid Throttling any ball valve will result in seat and or ball damage This valve should be fully opened and fully closed To Operate 1 To OPEN rotate the lever or gear box handwheel counter clockwise the valve has moved 90 degrees and strong resistance is felt There is a shoulder the end stop on the valve which gives the valve a positive stop in the open position Worm gear operated valves will have a position indication cast on to the top plate of the worm gear These valves will travel only turn 1 4 turn or 90 degrees Reverse direction to CLOSE 2 Power opening with an electric actuator use the open closed stops on the valve or on the gear box to fully open and close the valve The electric actuator should be set to stop with torque limits A429EN1 08 Rev 4 OPM 316 OPERATING PROCEDURES MODEL 30 MODEL 30 D REVISION 4 DUAL SEAL SECTION 1 BALL VALVE PAGE 2
13. have to be stored before installation the storage has to be carried out in controlled way and has to perform in accordance with following way 1 The valves have to be stocked in a closed clean and dry area 2 The ball must be in the open position and the faces must be protected with plastic or rubber discs with straps 3 Periodical checks have to be carried out in the storage area to verify that the above mentioned conditions are maintained For actuated valves in addition to the above refer the warnings in the actuator manufacturer manual Note Storage in the open area for limited period can be considered only in case the valves have appropriate packing Do not place consignment packages directly on the ground Do not expose consignment packages to the weather or directly to the sun Check the packaging every two months A429EN1 08 Rev 4 SECTION V ARAS OPM 316 VA WIN 7 SA L 7 EHSR REQUIREMENT A Sm WARNING amp CAUTION BALL VALVE PAGE 1 of2 1 Verify the direction of the flow in the line corresponds to the arrow indicated on the valve body If valve has a flow direction arrow this is the PREFERRED DIRECTION of flow but the valve will seal in either direction and is bi directional Every valve that WOM makes is bi directional 2 Refer the actuator user manual for the actuator operated valve Verify the overpressure relief device in case of gas amp liquid service Caution If piping
14. l the valve will vent excess pressure to the upstream or pressure side of the valve At zero line pressure it could hold approximately 200 psi to 300 psi inside the body cavity Precaution should be taken to bleed off this retained pressure by a Opening the vent fitting b Using a pressure relief tool see below on one of the body grease fittings or c By cycling the valve to bleed the body cavity pressure to the line See Figure 2 above A429EN1 08 Rev 4 OPM 316 OPERATING PROCEDURES MODEL 30 MODEL 30 D REVISION 4 DUAL SEAL SECTION 1 BALL VALVE PAGE 5 OF 5 Pressure Relief Tool for use with grease fittings NOTES 1 Always follow your Company s specified operating instructions for the media being produced 2 Assembly drawing of Model 30 Ball Valve 3 Details of stem sealing area 4 Bill of Material for Ball Valve CO TU u TEM DESCRIPTION Bal 2 GlandPlate 3 Upper Trunnion 7 PrimarySeal Secondary Seal 5 Stem Seal Details amp Bill of Materials A429EN1 08 Rev 4 SECTION II OPM 316 MAINTENANCE MODEL 30 MODEL 30 D AND REVISION 4 DUAL SEAL LUBRICATION SECTION II BALL VALVE PAGE 1 OF 5 Size All Pressure Class All Material Class All Mode of Operation All A GENERAL INSTRUCTIONS 1 Preventive Maintenance is based on Op
15. ntain the W O M warranty the above maintenance schedule should be followed B In the event of abnormalities see Troubleshooting Guide for possible cause and recommended repair A429EN1 08 Rev 4 APPENDIX B APPENDIX C APPENDIX D MODEL 30 30 D BALL VALVE GENERAL HYDROSTATIC PROCEDURES SHELL TESTING When the valve needs to be Shell tested it has to be in PARTIAL OPEN position If Shell testing is done in full open or full closed position there is a possibility the seal assemblies may get damaged Consult the factory or the latest edition of API Specification 6D for Shell Test maximum pressures for the valve you are testing The shell test will verify if the following seal points are intact and functioning property 1 to bonnet gasket seal 2 All body bleed fittings 3 seat sealant fittings 4 Stem injection fittings 5 Stem seals In any of the above seal points appear to be leaking or weeping consult the factory representative SEAT TESTING When the valve needs to be Seat tested it has to be in FULLY CLOSED position Consult the factory or the latest edition of API Specification 6D for Seat Test maximum pressures for the valve you are testing See Table 5 1 from API Spec 6D The seat test will verify if the following seal points are intact and functioning property 1 The face seal of the seat against the ball 2 outside diameter elastomer seal on the seat assembly A429EN1 08 Rev 4 APP
16. se Pack Lower Stem Seals Upper Thrusr Washer Stem Seal Details Figure 5 A429EN1 08 Rev 4 OPM 316 TROUBLE SHOOTING AND MODEL 30 MODEL 30 D ROUTINE PUNCTIONAL TESTING REVISION 4 DUAL SEAL SECTION Ill BALL VALVE PAGE 3 OF 4 2 lf you see a steady flow of valve contents coming from around the stem this may indicate significant damage to the stem seals Use the same instructions above but Inject enough sealant into the stem packing fitting to reduce the amount of the leak until an authorized service representative can be consulted B Shell Testing The valve is to be shell tested in the PARTIAL OPEN position The test is to be done as per API 6D latest edition The shell test is to verify if the following seal points are intact and functioning properly 1 Body to Upper Lower Trunnion gasket seals 2 All Body Bleed Fittings 3 Stem Seals If any of the above seal points appear to leak or are weeping consult the WOM factory representative See Stem Seal Trouble Shooting at the beginning of this section C Seat Testing The valve must be in the FULLY CLOSED position The Seat Test is done in accordance with API 6D latest edition The Seat Test will verify if the following seal points are intact and functioning properly 1 The face seal of the seat against the ball 2 seat to body seal where the outside diameter elastomer seals between the body and the seat assembly NO
17. system is pressurized with water for testing and in case the piping system has been shut down after testing for a long time the following steps should be followed 1 Use the corrosion inhibitor with water to pressurize the piping system 2 After testing the piping system should be depressurized and test water completely drained A429EN1 08 Rev 4 OPM 316 TO N III 17777 27 EHSR REQUIREMENT 2 WARNING amp CAUTION BALL VALVE PAGE 2 of 2 Depressurize the line before starting any seals replacement of the valve or maintenance of the valve Failure to do so may cause serious personal injury and damage to the valve If the valve needs to removed from the line for some reason the user should ensure the following 1 The valve is depressurized 2 the pipe shall be cut as far away from the valve as possible AN Warning Depressurize the line before starting anv maintenance Failure to do so mav cause serious personal injurv and damage to the valve A429EN1 08 Rev 4 APPENDIX A MAINTENANCE SCHEDULE FOR BALL VALVES LUBRICATION amp GENERAL AS BI MONTHLY SEMI MAINTENANCE NEEDED WEEKLY ANNUALLY 1 Lubricate Body amp Seats x 2 Pressure Test X 3 Inspect for Stem Packing Leaks X 4 Inspect for Smooth Valve Operation X 5 Inspect Flanges for Leaks X 6 Inspect gear box X 7 Inspect Grease Fitting amp Inj Ports X A In order to mai
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