VALVEWORKS USA OPERATION AND SERVICE MANUAL FOR 7
Contents
1. Grease and insert the XLS bearing into Grease the inner surface of the ball screw housing the top of the ball screw housing and place the cover plate onto the greased surface Align the holes on the cover plate with the holes on the top of the ball screw housing insert amp tighten 4 4 20UNC socket head cap screws thru the cover plate into the ball screw housing Place the ball screw housing over the stem Remove the jack bolt and the final assembly adapter as shown above and push the housing should appear similar to the assembly above down until it rests on the bearing race set Insert a snap ring into the snap ring groove which After inserting the snap ring push the ball screw housing is located about 2 7 8 inches inside the ball screw onto the outer threads of the upper bonnet Then screw the housing ball screw housing onto the upper bonnet without explicit permission roprietary Booklet Valveworks US Jo not reproduc A ddre TESA n ea n PA F gues a 1 I H RRR AIK NIKK Eav 212_49 _NO2 VALVEWORKS USA Model FM1 Operation Manual Once the housing is on the threads you can use Insert a 4 20 UNC tap bolt into the ball a strap wrench to tighten it down Again you screw housing and tighten it with a will periodically rotate the stem adapter crescent wrench counterclockwise to allow the housing to move Lightly coat a 1 2 NPT grease fitting or 9 16 Tighten the grease fitting with an impact2. Autoclave for 15 kpsi with anti seize compound wrench and insert it into the upper bonnet NOTE Periodically turn the stem adapter counterclockwise to loosen the ball screw nut to allow the ball screw housing to screw on completely The finished upper bonnet assembly should appear as shown REPEAT THE STEPS FOR THE LOWER BONNET TOO Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 19 VALVEWORKS USA Model FM1 Operation Manual Place the hand wheel onto the stem adapter Tighten the hand wheel onto the stem adapter with a handwheel nut Place a 222 o ring onto the gland backseat Screw the gland backseat into the stem adapter Leave the stem adapter unscrewed about 0 500 Turn the hand wheel counterclockwise until it stops Screw the gland backseat into the stem adapter the rest of the way Measure the gap between the gland backseat Unscrew the gland backseat and have the distance and stem adapter with a Feeler gauge of the gap trimmed off the thread side of it VALVEWORKS USA Model FM1 Operation Manual Coat the trimmed gland backseat with Screw it back into the stem adapter anti seize compound completely PERIODIC MAINTAINANCE The Model FM1 gate valves are non lubricated valves in that they do not require the injection of lubricants or sealants to effectively seal Howeve
3. 1 4 TURN GATE SHOWN IN OPEN POSITION STUDDED END Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 6 VALVEWORKS USA Model FM1 Operation Manual BILL OF MATERIALS FLANGED OUTLET ITEM PART NO DESCRIPTION QTY I 290 FM1 77XY BODY FLANGED 291 FM1 77XY BONNET 380 FM1 7700 HANDWHEEL 313 FM1 77XY BONNET SEAL RING STEM OPERATING 341 FM1 77XY STEM BALANCING 2 3 4 5 340 FM1 77XY 6 7 8 356 FM1 7700 GATE NUT 351 FM1 7700 PACKING 9 352 FM1 7700 PACKING RETAINER NUT 10 353 FM1 7700 PACKING RETAINER LOCKNUT 11 306 FM1 77XY GATE SLAB 12 354 FM1 77XY GATE GUIDE 13 321 FM1 77XY SEAT FLOATING RC 14 334 FM1 77XY SEAT SEAL FLOATING RC NTR RT RID Rl RRL m m mej me IRI NINO Ie ININININI Nie Nj 15 343 FM1 7700 STEM PROTECTOR 16 155 FM1 7700 HOUSING BALL SCREW 17 397 7700 BALL SCREW LH THREAD 18 377 FM1 7700 BAERING SPACER LOWER 19 374 FM1 7700 BEARING SPACER UPPER 20 345 FM1 7700 COVER PLATE 21 346 FM1 77XY STEM ADAPTER 22 387 FM1 77XY GLAND BACKSEAT 23 381 FM1 7700 HANDWHEEL NUT 24 373 77XY BEARING INTERNAL NHTA 5280 25 369 77XY BEARING EXTERNAL 26 348 77XY SNAP RING SPIROLOX 27 349 77XY ROD WIPER 28 347 7700 O RING 29 096 7700 STUD
4. 0934 14 VALVEWORKS USA Model FM1 Operation Manual BALL SCREW SUB ASSEMBLY Raise the gate up until the stem is back seated Place a 350 o ring on the lower bearing Then lay the valve down The operating stem spacer as shown above should protrude as shown above Place the snap ring onto the other side Place the lower bearing spacer snap ring end first over of the lower bearing spacer the operating stem Be careful not to scratch the stem Place the upper bearing spacer on the ball The ball screw should rest in the recess screw as shown above area on the spacer as shown Place a bearing race set over the travel screw Screw the travel screw onto the top threads and onto the upper bearing spacer of the operating stem as shown above roprietary Booklet Valveworks US o not reproduce wit explicit permission A AA es PEED ea a PA F gues g 1 Hh H QQR_ADS_NIGK Bay 212_A95_NO2A AUUIL CSS LOUSY OWadll LAKE NOdaG DUDSDSICI 4 Ll I 11l 1 T O0O TAJ UU ia T JLO TLI UP VVALVEWORKS USA Model FM1 Operation Manual If it is not already unscrew the ball screw with the Adjust Lower Bearing Spacer where milled slot upper bearing spacer and bearing race set to reveal 2 is in line with spring pin Use a 3 8 spring pin to holes for socket set screws as shown above hold it in place Roll the ball screw nut upper bearing spacer and Screw the stem adapter onto the ball bearing race set back onto the lower bearing spacer
5. 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 27 VVALVEWORKS USA Model FM1 Operation Manual Place a test flange with a grease fitting Lightly coat the exposed threads of the pad installed onto the studs stud with anti seize compound Screw a hex nut onto each of the exposed Tighten the hex nuts with a certified pad studs impact wrench Repeat the above steps to install the other test flange NOTE A test flange is shown in this manual but the service flange will use the same nuts and bolt circle Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 28 VALVEWORKS USA Model FM1 Operation Manual VISUAL INSPECTION Before installing a Valveworks USA Model FM1 valve in the field here are a few items to visually inspect Be sure the upper bonnet grease Be sure the upper bonnet grease fitting cap is on and tight fitting cap is on and tight Be sure the Alemite fittings are on Be sure the Hand wheel Nut is and tight tight Be sure the gate is in the fully open or fully closed position Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 29 VALVEWORKS USA Model FM1 Operation Manual FIELD HOOK UP INSTRUCTIONS Grease and i
6. 425 0266 Fax 318 425 0934 VALVEWORKS USA Model FM1 Operation Manual ORDERING INFORMATION The following information should be provided with any request for quote or order placement of Valveworks USA 7 1 16 FM1 Gate Valves VVVVVVV API 6A Requirements PR PSL Temperature Rating API 6A Material API 6A Any Special Test Requirements Any Special Material Requirements Any Special Coating or Protection Requirements Other Specifications and or Certifications OPERATION The Valveworks USA Model FM1 gate valves are Ball Screw operated valves The gate of the MODEL FM1 Valve is a one piece slab gate that uses two floating seats to generate a highly reliable seal The slab gate eliminates the chance of trapping pressure within the body cavity which can cause pressure locking Fully open the valve before installing or shipping The sealing area of the gates in the full open position is protected by the body and is less likely to be damaged Do not remove the molybdenum disulfide coating from internal parts This coating serves as a lubricant and corrosion inhibitor To hydrostatically test the valve body to full API test pressure the valve must be in a partially open position When testing the valve in the closed position seat test do not exceed the working pressure stamped on the valve identification plate During storage always leave the valve in the fully opened or fully closed position This will tightly wedge the gate aga
7. Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 12 VALVEWORKS USA Model FM1 Operation Manual Sas 2 The completed gate assembly should appear similar to the one above BODY SUB ASSEMBLY Coat the threads of the body bonnet stud holes Insert the studs into the top of the valve body Tighten the studs onto the body using a stud Grease the back and backside of the seats grease tightening bolt and a certified impact wrench and insert the external seal rings into the seal ring grove of each of the seats Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 13 VALVEWORKS USA Model FM1 Operation Manual Insert the greased end of the seat into the seat Insert the gate guides on top of the seats as shown pockets as shown NOTE The flat side should be on the top x a Insert the bonnet seal ring The body cavity should appear as shown with the seats gate guides and the bonnet seal ring Lower the gate assembly into the body It should fit The operating stem should stand up as shown above between the seats and gate guides while the balance stem travels thru the hole in the lower bonnet Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425
8. TE 6 9A PLASTIC 9B STELLITE 3 oo N 9A COATING NONE PHOSPHATE MOLY STANDARD PAINT COATING POWDER COAT NITRIDE QPQ PHOSPHATE EXCEPTION FC BODY BUSHING DO NOT NITRIDE HARDFACE STELLITE 6 SPRAY amp FUSE HARDFACE TUNGSTEN CARBIDE HARDFACE COLMONOY 5 ELECTROLIS NICKEL WELD ON HARDFACE ZINC PLATE XYLAN COATING 4130 INCONEL 625 CLAD 4130 SS 316 RING GROOVE Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 VALVEWORKS USA Model FM1 Operation Manual ASSEMBLY INSTRUCTIONS The following steps have to be followed before assembly of any component of the FM1 gate valves Assembly work area must be clean and free of dirt metallic shavings and wood particles Surface preparation of work area should be metallic or covered with a layer of corrugated cardboard All lubricants and utensils used in assembly must be clean All tools used in assembly must be clean and in good working order Clean all components metallic prior to assembly Keep all elastomers and plastic base materials in bags or boxes until needed for assembly Inspect all components for burrs dings marks scrapes nicks and etc prior to assembly VVVVVVV UPPER LOWER BONNET SUB ASSEMBLY Insert a packing set into the bonnet as shown and push it down Apply anti seize compound to the in
9. VALVEWORKS USA OPERATION AND SERVICE MANUAL FOR 7 1 16 INCH MODEL FM1 GATE VALVES 7 1 16 Model FM1 Studded 7 1 16 Model FM1 Flanged Outlet 10 000 20 000 W P Outlet 10 000 W P VALVEWORKS USA Model FM1 Operation Manual INTRODUCTION In appreciation to our customer for purchasing our product we have prepared this Operation Manual to assist you in the Operation Maintenance Assembly and Installation of the Valveworks USA API 6A 7 1 16 inch FM1 Gate Valve We encourage you to follow recommendations in this booklet to attain the best possible service from our product which is designed and proven to offer the service one can expect of a quality product If you need to contact a representative for more specific information pertaining to a special problem you should contact VALVEWORKS USA 1650 SWAN LAKE RD BOSSIER CITY LA 71111 PHONE 318 425 0266 FAX 318 425 0934 TOLL FREE 888 425 0266 EMAIL SALES VALVEWORKSUSA COM WEBSITE WWW VALVEWORKSUSA COM CONTENTS APPLICATIONS sssisscssvasnssasvasessassnswoeasvacwssacoascsscsscgescassaacaanssassnessoasensssvasessn sade seuebsdeweuedsvecesecsussesescdecossssussessessecosd TEMPERA TURE RA TING iss cesscisscesusssssuscousessscoudoussdsuscedadvscbussevsboesacvsbossd vesoaledvensesscvesesaceshoondevessovsnvopecvedvevasvsbvonden 3 TRIM CHAR Toi sisietsnsasescascodcessasvasenssswasucsaswaboasacoddocsaswapodsaswasonsascanvavaduasussansasansanaadensondavansacsnsosdosansecassansososansasade
10. W NUT B7 24 30 101 0000 BODY GREASE FITTING 2 31 109 0001 ALEMITE GREASE FITTING 3 32 1173261 SET SCREW 1 4 X 3 4 LG 3 33 1173303 SET SCREW 3 8 X 3 4 LG 4 34 1173462 CAP SCREW 1 4 X 1 LG 4 35 64313 PIN SPRING 1 400 0002 GREASE 25 LBS The last two digits in the part no s vary with X Material Type and Y Coating The table below gives the different available material types and coatings Please refer to the valve tag to know the material type and coating on the valve parts Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 VALVEWORKS USA Model FM1 Operation Manual STUDDED OUTLET ITEM PART NO DESCRIPTION QTY 1 298 FM1 87XY BODY STUDDED 1 2 291 FM1 87XY BONNET 2 30 103 0000 AUTOCLAVE FITTING 2 The Bill of Material for the flanged outlet and the studded outlet is the same except the ones tabulated above The body and bonnet vary for the tow products and the studded outlet valve uses Autoclave Fittings instead of Body Grease Fittings MATERIAL TYPE 1 4130 1A 4140 1B 1040 1C 1018 1D 1020 1E SA285 C 1F 1026 2 410SS FORGED 2A S42400 3 1748S 3A NITRONIC 50 4 316SS 4A 316 304SS 4B 3048S 5 BRONZE 6 INCONEL 718 6A INCONEL 725 6B INCONEL X750 7 MONEL 8 A487 4D 8A A487 4C 8B CA15 8C CF8M 8D CF3M 8E CA6NM 9 STELLI
11. al Valveworks USA 7 1 16 FM1 gate valve unit can be applied to the following sizes and working pressures APPLICATION OPTIONS AVAILABLE Gate valve size 7 1 16 Valve working pressure 10 000 20 000 psi Temperature range 60 C to 121 C 75 F to 250 F The flanged outlet gate valve is rated for 10 000 psi work pressure and the studded outlet gate valve of this product line is rated for 10 000 psi 15 000 psi and 20 000 psi TEMPERATURE RATING Temperature classification Operating Range TRIM CHART Material class AA General service BB General service CC General service DD Sour service EE Sour service FF Sour service HH Sour service Minimum Material Requirements Body bonnet end and outlet connections Carbon or low alloy steel Carbon or low alloy steel Stainless steel Carbon or low alloy steel Carbon or low alloy steel Stainless steel CRAs Pressure controlling parts stems and mandrel hangers Carbon or low alloy steel Stainless steel Stainless steel Carbon or low alloy steel Stainless steel Stainless steel CRAs As defined by NACE MR 0175 gt In compliance with NACE MR 0175 As shown by API 6A For specific details consult Valveworks USA Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888
12. asing tool into the fitting forcing the ball check off its seat The valve will vent and drain once the ball check is unseated Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 22 VALVEWORKS USA Model FM1 Operation Manual A program of regular draining and body venting is the most positive way to prevent problems caused by foreign matter in the valve However if a regular draining program cannot be followed it is recommended that valves be drained after the following operations gt After a well has come in and has been cleaned up gt After a mudding operation gt After a cementing operation gt Anytime the valve seems hard to operate by hand and will not fully open or close by the required number of hand wheel turns gt When the valve is hard to operate from the fully open or fully closed position because it is pressure locked or Iced up Pressure locked is a condition that may exist with any dual seat expanding type gate valve when body pressure greatly exceeds line pressure It occurs only in fully closed position and is a positive indication that sealing surfaces are in good condition Tced up is a condition caused by a restriction in the flow or a differential in the pressure of gas flow at high pressure which produces extremely low temperatures These restrictions or differentials in pr
13. ced to zero and close the pressure release tool gt Raise the pressure back up to the test pressure for the secondary pressure holding period of at least three 3 minutes gt Bleed off the pressure until it s reduced to zero Then close the pressure release tool and the valve The hydrostatic body test pressure shall be determined by the rated working pressure of the equipment Hydrostatic test pressures shall be as given as tabulated below Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 25 VALVEWORKS USA Model FM1 Operation Manual HYDROSTATIC BODY TEST PRESSURE PSI MPa Working End and Line Pipe Pressure Outlet and Tubing Rating PSI Mpa Connections PSI Mpa Threads PSI Mpa 2 000 13 8 4 000 27 6 4 000 27 6 3 000 20 7 6 000 41 4 6 000 41 4 5 000 34 5 7 500 51 7 7 500 51 7 10 000 69 0 15 000 103 4 15 000 103 4 15 000 103 4 22 500 155 2 20 000 138 0 30 000 207 0 Hydrostatic Seat Test gt With the valve closed apply the rated working pressure gt Hold and monitor at that pressure for at least three 3 minutes gt Open the valve and bleed off the pressure until it s reduced to zero Then close the valve and the pressure release tool gt Repeat the steps above Switch the sides of your f
14. ect and Test Annually TEST PROCEDURE Grease and insert a BX 156 ring joint into one of Be sure that the test flange has a tightened grease the body flanges Note Refer to the end of the fitting all of its studs and a nut on each with all manual for studded outlet to prepare for testing of the nuts on the grease fitting side as shown Align the test flange studs with the body flange Screw the each hex nut on the vacant side of a holes Then push the test flanges its studs and stud as shown until all of the studs have a nut on their hex nuts onto the body flange the test flange and the valve flange Tighten the hex nuts on the test flange side A finished flange should appear as shown with an impact wrench until they are tight Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 24 VALVEWORKS USA Model FM1 Operation Manual NOTE Repeat the above steps for the opposite flange Remove the grease fitting cap from one test flange Remove the grease fitting cap from the opposite and attach a pressure release tool as shown above test flange and attach the flow line as shown above Hydrostatic Body Test gt With the pressure release tool and flow line connection tight open the valve partially and apply the test pressure for at least three 3 minutes Bleed off the pressure until it s redu
15. ensoniees 3 ORDERING INFORMATION cccccccscsscscsssccsscssccsesccssccesscsscsssccsssccssscsscsssssssecsecscessecsssccsecessoececssssessesecsecsesessesensess 4 OPERATION onune nE RERE ER ENRAIAR 4 ASSEMBLY DRA WING cccrircicisaerioniyenioiironit ayeni EN EERE NAi NEE NEE N A AEE R 5 BICL OF MATERIALS ssssasisoisuisasiassesdsoas0ssu0sus05sds0u0000080000 0050050 80005s000ud0ddessan0seunseensoudsoncoseovessasuasonesoeavesudsobeosedvossaes one 7 ASSEMBLY INSTRUCTIONS cccccscscsssscsssscsssccsscsssccssessscccsecsecccsessececsecsecessessesessessececsecsecceessesessesecsessesecsesseseesess 9 UPPER LOWER BONNET SUB ASSEMBLY c sseecccceseeccccsscececcecececceseececceeececcseesecceseecseneneeceeaeners 9 BALL SCREW PREPARATION ssccccccsececcccesceccassceccacesccccasseccesssecccausceceaaeseeceaueseeceaaeseeccauteeeeeans 11 GATE SUB ASSEMBLY oocccoocg ees olec ects ce cere ENNE rE EIAN ENEE LANE VEEE EN AEI AEE ria R aE 12 BODY SUB ASSEMBLY sorssriissrrsrisdravt ni sack Ekas S NEENA ENEE S NEEE AES AEA EE ee 13 BALL SCREW SUB ASSEMBLY itcccsiccccascossccossedeciacconsceceeued ceacdeedcacsuesccaceowedeacesecceaceesscceudedsciadeeaveecens 15 PALAS SEMBIGY oa E AAAA AAT 17 PERIODIC MAINTENANCE wissssssseusssiassasescasessescasensesessssesteseatenceneasctessendesdesossebeasedcassuccsebbendaseosdeecnsesdaventensooasessedss 21 BALL SCREW LUBRICATION cccccssssssceccecccccsssssesccccsceessuusescccccccessuaenececceseesuausessceceeseeauauenen
16. essure may be caused by throttling through a valve by leakage of a closed valve or by Leakage through the stem packing Valves in service on gas containing hydrates or in fresh water service exposed to low external temperatures may also iced up In this case it is advisable to inject alcohol or glycol into the valve body through the drain fitting to combat these conditions The same procedures are used for injecting alcohol or glycol as are used for valve body lubrication Do not operate the valve immediately after injecting as these fluids should be retained in the body to perform the Antifreeze effect TROUBLESHOOTING PROBLEM CAUSE SOLUTION Leakage when closed Seats Disconnect from service and check for the condition of the seats Leakage when open through Bonnet Seal Disconnect from service and replace body bonnet connection Ring the bonnet seal ring Leakage when partially open Packing Disconnect from service and replace thru top of bonnet the packing Leakage at flange Flange Seal Disconnect from service and replace Ring the flange seal ring Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 23 VALVEWORKS USA Model FM1 Operation Manual MAINTAINANCE INTERVALS Procedure Recommended Interval Vent or Drain See Page Cycle Open to Close Semi Annually Disconn
17. inst the seats and prevent damage to the sealing area of both the gate and seats Always remove the valve from service before work is performed on the stem bearings When lubricating the body do not exceed the maximum API working pressure stamped on the identification plate The valve should be fully closed or fully opened during lubrication of the body or seats Seat lubrication pressures should not exceed the maximum allowable API test pressure This method of operation will prevent damage to the sealing surfaces of the gate and seats and will increase the life of the valve Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 4 VALVEWORKS USA Model FM1 Operation Manual ASSEMBLY DRAWING OF MODEL FM1 GATE VALVE MODEL FM1 7 1 16 10 000 P S I HANDWHEEL OPERATED OPERATION BI DIRECTIONAL SLAB GATE TO OPEN AND CLOSE BACKOFF HANDWHEEL 1 4 TURN GATE SHOWN IN OPEN POSITION FLANGED END Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 5 VALVEWORKS USA Model FM1 Operation Manual GOYA HO OW BO OOO Q 000000000000000 00A MODEL FM1 7 1 16 15 000 P S I HANDWHEEL OPERATED OPERATION BI DIRECTIONAL SLAB GATE TO OPEN AND CLOSE BACKOFF HANDWHEEL
18. l screw to unscrew from the ball screw nut in either direction This will cause the ball screw to de ball itself When assembling more than one valve it is a good Mark the location of 2 socket set screw holes idea to label or number the travel screw and its with a hammer and transfer punch specific operating stem to ensure that the two will assemble correctly Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 11 VALVEWORKS USA The transfer punch will leave an indentation in two places like the one shown above GATE SUB ASSEMBLY Align the balance stem into the slot of the gate screw on the gate nut and tighten it with an oil filter wrench Model FM1 Operation Manual al Unscrew the operating stem from the ball screw assembly and drill 2 drill point depth holes at the marked locations with a 0 25 drill The finished stem should appear similar to the one shown above Insert the balance stem into the gate nut j Insert 4 4 20UNC socket screws around the gate nut and tighten them with an allen wrench NOTE The placement of balance stem depends on whether the valve will be direct operating or reverse acting REPEAT THE STEPS FOR ASSEMBLY OF OPERATING STEM Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan
19. low and pressure release connections bleed off the new pressure release side and repeat steps above to perform a seat test on the new flow side The valve is acceptable if no leakage is visible during the holding period While holding the hex nuts on the body flange loosen each of the test flange hex nuts After removing the body flange hex nuts you can remove the test flange its studs and their hex nuts Pass a drift mandrel through the valve bore after the valve has been assembled operated and pressure tested Remove the upper bonnet grease fitting cap and attach a flow line from the grease pump to the grease fitting as shown above Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 26 VALVEWORKS USA Model FM1 Operation Manual Remove the lower bonnet grease fitting cap and After the valve is accepted it is tagged with a attach a pressure release tool as shown above green or blue tag before being painted STUDDED OUTLET INSTALLATION TESTING Coat the threads of each hole with anti Screw the 1 50 thread length side of each pad seize compound stud into an empty coated hole Grease and insert the BX156 ring joint Tighten each stud with a pipe wrench into the valve ring groove Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address
20. ner threads of the bonnet Tighten the packing retainer with an expanding wrench Screw in the packing retainer locknut Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 9 VALVEWORKS USA Model FM1 Operation Manual Tighten the packing retainer locknut with an The next step is to insert the studs into the expanding wrench as well bottom of the valve body Coat the threads of the body bonnet stud holes Tighten the studs using a certified impact wrench with anti seize compound and screw in the studs Place the bonnet on the body over the studs and screw a hex nut onto each stud ee Tighten the hex nuts onto the studs using Coat a 5 8 set screw with anti seize coat and screw an impact wrench into 6 gear attachment holes around the bonnet 10 VALVEWORKS USA Model FM1 Operation Manual Tighten each of the set screws with a Coat the outer threads and screw the balance 5 8 Allen wrench stem protector down until tight NOTE PLACE THE LOWER BONNET WHERE THE GREASE FITTING POINTS TOWARDS ONE OF THE NON CONNECTED SIDES OF THE VALVE BALL SCREW PREPARATION tuam Screw the operating stem into the travel The shoulder of the stem should make contact with the screw of the ball screw assembly bottom of the travel screw similar to the sample above CAUTION Do not allow the trave
21. nsert ring joint into the Align the service flange holes with the body flange valve flange holes Push a stud thru each aligned hole until there is a stud thru each hole Screw a hex nut on both sides of each stud by hand Torque the service flange hex nuts with a A finished flange should appear as certified torque gun until they are tight shown Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 30
22. r line scale sediment and other foreign matter which tend to accumulate in the valve body A regular draining program will increase the life of a valve against damage caused by e Water freezing in the body cavity causing damage to the body e An accumulation of foreign matter in the lower part of the body which could prevent the valve from fully closing resulting in a throttling action which may cause inefficient sealing e Foreign matter trapped in the body may become lodged between the sealing surfaces of the gate and seats resulting in scored or damaged sealed e Venting a Model FM1 valve is a positive method of checking the sealing ability of the gate and seats If the body vents down to zero pressure with the valve in fully closed position this is definite indication that sealing surfaces are in good condition PROCEDURE TO VENT OR DRAIN e Place the valve gate in a fully opened or fully closed position Remove the safety cap from either Attach the pressure release tool body grease fitting CAUTION Remove the safety cap slowly to allow the ball check to sufficiently seal and avoid uncontrolled venting Should the ball check fail to seal properly pressure will continue to blow through the safety cap orifices You should then retighten the safety cap screw and vent through the other body grease fitting Once the body pressure is bled to zero you should then attempt to repair the leaking ball check e Screw the stem of the rele
23. r to prevent corrosion and excessive wear a normal amount of lubrication is recommended to extend the life and serviceability of the valve Maintenance Tools To perform normal maintenance and lubrication the following tools are recommended B Grease pump with adapter and coupling Safety pressure releasing tool Valveworks USA API Gate Valves at 15 000 PSI W P are supplied with 9 16 17 4SS autoclave fitting connections BALL SCREW BEARING LUBRICATION Valveworks USA FM1 valves are equipped with alemite hydraulic type 1 8 NPT bonnet grease fittings Ball Screw bearing lubrication is accomplished through this fitting using a standard type grease gun Any good grade No 3 grease is recommended for this lubrication Ball screw bearings normally do not require great amounts of grease If too much lubrication should occur excess grease will flow around the stem to the atmosphere Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 21 VALVEWORKS USA Model FM1 Operation Manual CAUTION If bearings should need to be changed the valve must be removed from service During pressurized valve body lubrication pressure applied to the valve body with the grease gun must not exceed the maximum working pressure of the valve being lubricated VENTING OR DRAINING A VALVE Most products contain a certain amount of wate
24. screw nut as shown above Then apply anti seize compound to the threads of the ball screw nut as shown above Wipe any excess anti seize compound from Weld the stem adapter to the underneath the stem adapter and cover the upper ball screw nut as shown bearing spacer and bearing race set Place a bearing race set onto the stem Grease the lower bearing race set that is adapter as shown above between the upper and lower bearing spacers VALVEWORKS USA Model FM1 Operation Manual Grease the upper bearing race set that is The greased ball screw assembly should appear resting on the stem adapter very similar to the one shown above CAUTION Do not allow the travel screw to unscrew from the ball screw nut in either direction This can cause the ball screw to de ball FINAL ASSEMBLY Unscrew the ball screw assembly until there is Coat the outer threads of the upper approximately a 4 25 space between the bottom of bonnet with anti seize compound the lower bearing spacer and the top of the upper bonnet Use a jack bolt to secure the space Insert and tighten 3 Alemite grease fittings into the 3 The top of the ball screw housing holes along the outside of the ball screw housing should appear as shown Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 17 VALVEWORKS USA Model FM1 Operation Manual
25. ssses 21 VENTING DRAINING A VALVE cccssscecccssececccsssceccasscceccasesecccuesecccuucsceccueseeceuseseeccueeseceutesesenaners 22 TROUBLESHOOTING 6svesssestesccd2zscssccdscsensesoiaacscesssd2sotssccsescosedusedecsonstesssesstaesecbsats susuleoasscdasseshsvesvassesseesdesstessasensetease 23 MAINTAINANCE INTERVAL S cccccccscsssscsscssscssscsscsesssssesecssssesecsessesscsessesecsessesessessssessesecsessesecsersesscsesseseeserseseeees 24 FES T PROGEDUR E veasisassceasoasssgessaennces sucasdasnceasensansasscosuanssacnueasdasacenesaeaueassovoasaveasavcavansavenveceasecbousaavaveasabvevavangevensanes 24 HYDROSTATIC BODY TEST ccccceicciscaddgesswatuuetaticectesetscecaneeteeceewsedsaseteersenceaeedesduceasevcouSiecsancassasducguceses 25 HYDROSTATIC SEAT TEST veiin E E E E A A E ET 26 STUDDED OUTLET INSTALLATION TESTING cccccccscsscsccsscsesssssscesssssssessssscsssssesssssesessessessssssesessessesenseses 27 VISUAL INSPECTION sssisscssasectuscdsnsonsoasusvesevssasadensutessvecessusestustesevoeavedsadesusssesuosssvenessiesesecsusenstescosesesdestestesessosvesesvens 29 FIELD HOOK UP INSTRUCTIONS c cccccccsccsscsssccssccsscessccsscessscccsessececsessesecsessesecsessesecsessesecsessesecsasscsessesecsessesess 30 Proprietary Booklet of Valveworks USA Do not reproduce without explicit permission Address 1650 Swan Lake Road Bossier City LA 71111 Ph 888 425 0266 Fax 318 425 0934 2 VALVEWORKS USA APPLICATIONS Model FM1 Operation Manu
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