1
User’s Manual
Disk Type Mud Valve 7.5K Family (2” 3” 4” 5”)
This document contains proprietary and confidential information which belongs to National Oilwell Varco. Reproduction, in whole or part; or use of this design or distribution of this information to others is not permitted without the express written consent of National Oilwell Varco. This document is to be returned to National Oilwell Varco upon request and in any event upon completion of the use for which it was loaned.
National Oilwell Varco 7th Avenue Team Valley Trading Estate Gateshead Tyne and Wear NE11 0JW Phone +44191 4820022 Fax +44191 4878835
Document Number M127
Rev. 3
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2
Issue Sheet
3
15.06.2012
5” service parts added
JDW
TW
NK
2
24.05.2012
Rev sheet attached, formatting amended
JDW
TW
NK
1
01.02.2012
First Issue
Rev
Date (dd.mm.yyyy)
Reason for issue
CHANGE DESCRIPTION
Revision 01 02 03
Change description First Issue Rev sheet attached, formatting of diagrams corrected 5” extraction tool and replacement kits added
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NK
Prepared
Checked
Approved
3
Table of Contents
General Information Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personal Training .......................... Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . General System Safety Practices . . . . . . . . . . . . . . . . . Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . .
Page 4 Page 4 Page 4 Page 4 Page 4 Page 4 Page 4
Parts Location
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Page 5
Dismantling
................................
Page 6-10
Inspection
................................
Page 11-14
Assembly
................................
Page 15-20
Maintenance
................................
Page 21
Operating
................................
Page 22
Spares, Special Tools and Lubricants . . . . . . . .
Page 24-25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 22-23
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General Information Illustrations Illustrations (figures) provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale. For component information specific to your assembly, see the technical drawings included with your NOV Mission Products documentation.
Personal Training –
To avoid injury to personnel or equipment damage, carefully observe requirements outlined
in this section.
All personnel performing installation, operations, repair or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation and maintenance to ensure their safety. Personnel should wear protective gear during installation, maintenance and certain operations. Contact NOV Mission Products if you require for more information about equipment operation and maintenance training.
Recommended Tools Service operations may require the use of tools designed specifically for the purpose described. NOV Mission recommends that only these tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when following service procedures or using tools not specifically recommended by NOV Mission Products.
General System Safety Practices –
Read and follow the guidelines below before installing equipment
or performing maintenance to avoid endangering exposed persons or damaging equipment.
Isolate energy sources before beginning work. Avoid performing maintenance or repairs while equipment is in operation. Wear proper protective equipment during equipment installation, maintenance or repair.
Replacing Components Verify that all components (such as cables, hoses, etc.) are tagged and labelled during
assembly and disassembly of equipment to ensure correct instalment. Replace failed or damaged components with NOV Mission Products certified parts. Failure to do so could result in equipment damage or injury to personnel.
Routine Maintenance –
Failure to conduct routine maintenance could result in equipment damage or injury to
personnel.
Equipment must be maintained on a routine basis. See the service manual for maintenance recommendations.
Proper Use of Equipment NOV Mission Products equipment is designed for specific functions and applications, and should be used only for its intended purpose. www.nov.com/mission
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Parts Location
1. Body 2. Boot Support Ring 3. Boot 4. Stem 5. Gate 6. Bonnet 7. Retaining Plate 8. Stem Screw
9. Bearing Housing 10. Handle 11. Thrust Bearing Assy 12. 12 Point Screw 13. Stem Cap 14. ‘O’ Ring (Support Ring) 15. ‘O’ Ring (Bonnet) 16. Body Stud
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17. Body Nut 18. Stem Seal 19. ‘O’ Ring (Retainer Plate) 20. ‘O’ Ring (Brg. Housing) 21. Woodruff Key 22. Grease Fitting 23. Stem Guide Ring 24. Bonnet Bleed Fitting 25. Tube
6
• •
•
NOV Mission Disc Type Mud Valves are in-line repairable and all routine maintenance such as packing change out, seat replacement and minor refurbishment may be performed in situ. All maintenance activities contained within this procedure should be performed by a suitably trained operator with experience of this product range or similar. If in doubt please consult your nearest NOV representative for assistance. Valves with butt weld ends need to be fully disassembled so that only the body is exposed to the heat from fabrication onto the connecting pipework. On completion of fabrication and subsequent post weld heat treatment, the re-assembled valve should be pressure tested to 1.5 x maximum rated (working) pressure with the valve in the half open position.
Dismantling Caution - If the valve is to be dismantled in the flowline ensure all pressure has been released from the flowline immediately upstream and downstream of the valve location. Isolate the valve by fully closing and locking the valves upstream and downstream of the subject valve and label them ‘Caution do not use’ chaining them closed to prevent inadvertent operation during in line maintenance. 1. Run the valve to the half open position. Ensure any remaining pressure has been evacuated from the valve by opening the bleed valve (24).
24
Fig d1. Bleed fitting location
2. Body to bonnet interface - remove nuts (17) from studs (16). Lift the bonnet assembly from the body (1).
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7 17
6
Fig d2. Bonnet removal
16
3. Remove the bonnet seal (14), slide the gate (5) from the stem (4).
14 4
Fig d3. Remove bonnet seal and gate
5
4. Insert a flat tipped screw driver either side of the seat between the boot (3) and the two boot support rings (2). Prise the two upper edges of the boot together to release the boot locking rings out from the boot support rings (2). Hold the two upper edges together as you lift the boot (4) up out of the body (1).
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3 PRESS TOGETHER TO REMOVE BOOT
Fig d4. Boot removal
5. Withdraw the boot support rings (2) from the body (1). A screw driver may be used to extract the rings using any gap created between the boot ring (2) and the body (1) and also the groove in the bore of the seat ring. NOTE do not tilt the seat ring too far out of alignment with the valve bore causing possible damage to the seal bore. A special tool is available to aid disassembly of the boot support rings from the valve body. Refer to Special Tool Parts List at the end of this document for details. 6. Remove the ‘O’ rings (19) from the boot support rings (2).
3
19
2 19
2
Fig d6. Boot support rings removal
7. NOTE at this point the gate (5), boot (3) and boot support rings (2) may be replaced with no further dismantling of the valve. Refer to the Inspection Section for evaluation of these components and potential replacement. If these are the only parts that need to be replaced, proceed from assembly step (13). Otherwise continue by dismantling the valve top works as follows. www.nov.com/mission
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8. To disassemble valve top works, start by unscrewing the stem cap (13), removing tube (25), handwheel (10) and key (21).
13
Fig d8. Topworks disassembly first stage
25 10
21
9. Remove 12 point flanged screws (12), bearing housing (9) and bearing housing ‘O’ ring (15).
15 12
Fig d9. Topworks disassembly second stage
9
10. Remove the upper thrust bearing assembly (11). 11. Unscrew the stem screw (8) from the stem (4). Remove the lower thrust bearing assembly (11).
11 8
Fig d11. Topworks disassembly third stage
11 4
12. Remove retaining plate (7) complete with ‘O’ring (20) then withdraw the stem (4) down through the bonnet (8). www.nov.com/mission
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10 20 7
Fig d12. Topworks disassembly fourth stage
4
13. Remove the ‘O’ring (20) from the retaining plate (7). 14. Remove stem guide ring (23) and stem seal set (18) from the bonnet (6). 18
Fig d14. Topworks disassembly fifth stage
6
23
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Inspection The following relates to ensuring the disc type mud valve performance on re-assembly but does not replace common engineering practice on standard components (eg. condition of studs, nuts, keys, bearings etc). Thoroughly degrease all parts to allow close inspection of the sealing surfaces. Particular close attention should be paid to the following areas •
Gate (5), boot (3) and boot support ring (2) sealing surfaces for signs of wear or damage from service. o Replace where signs of wear or damage are apparent SEAL FACE
SEAL FACE
EDGE
FACE
‘O’ RING GROOVE
SEAL FACE
•
Boot support ring sealing location (a) in body (1) o Rework any light damage by hand using fine (1200) grit paper where practical to do so. If damage is irreparable by hand and cannot be reworked consult nearest NOV representative.
•
API ring groove or hub end sealing faces (b) on body (1) flange / hub ends (if applicable)
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o
Rework any light damage by hand using fine (1200) grit paper where practical to do so. If damage is irreparable by hand and cannot be reworked consult nearest NOV representative.
(a)FACE
Fig. i1 Body wear areas (Note: Applicable to both sides of valve, one only shown for clarity)
(a)DIAMETER (b)
•
Bonnet (6) – ‘O’ ring seal groove (a), stem seal pocket (b) and bleed port (c) o For ‘O’ ring groove and stem seal pocket - rework any light damage by hand using fine (1200) grit paper where practical to do so. If damage is irreparable by hand and cannot be reworked consult nearest NOV representative. o Bleed port – ensure the bleed hole is clear and unobstructed and the ½” NPT thread is undamaged. Rework ½” NPT thread within ASME B1.20.1 specification where practical or replace bonnet (6) where necessary.
(b)
Fig i2. Bonnet wear areas
(a)
(c)
•
Stem (4) – sealing surface (a) and threads (b) for wear or damage o Check main sealing diameter for marks and scratches. Replace as necessary. o Check thread integrity and coating condition. Replace as necessary.
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Fig i3. Stem wear areas
(b) (a)
•
Stem Screw (8) – bearing surfaces (a) and threads (b) for wear or damage o Check thrust bearing mating surfaces for damage. Rework light damage by hand using fine (1200) grit paper or replace as necessary. o Check thread integrity and coating condition. Replace as necessary.
(b)
Fig i4. Stem screw wear areas (a)
(a)
• •
Thrust Bearings (11) – check condition. Replace where necessary. Bearing Housing (9) – check ‘O’ ring groove (a) and thrust bearing mating surface (b) o Check ‘O’ ring groove for signs of corrosion. Rework light damage by hand using fine (1200) grit paper or replace as necessary. o Check thrust bearing mating surface for damage. Rework light damage by hand using fine (1200) grit paper or replace as necessary.
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(a)
Fig i5. Bearing Housing wear areas
(b)
•
Retaining plate (7) – check ‘O’ ring groove (a), bleed hole (b) and thrust bearing mating surface (c) o Check ‘O’ ring groove (a) for signs of corrosion. Rework light damage by hand using fine (1200) grit paper or replace as necessary. o Ensure bleed holes (b) are clear and unobstructed. o Check thrust bearing mating surface (c) for damage. Rework light damage by hand using fine (1200) grit paper or replace as necessary. (c)
Fig i6. Retaining plate wear areas (a) (b)
Note - Soft seal replacement is recommended regardless of condition (referenced items 14, 15, 18, 19, 20, 23).
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Assembly 1. Before commencing the assembly ensure every part is clean and free from foreign matter. Pay particular attention to the stem thread surface that passes through the stem packing. Polish if required with a fine (1200) grit paper. 2. Apply a coating of recommended assembly lubricant to seals, seat and stem screw (see Section on Recommended Lubricants). 3. Install the stem guide strip (23) into the locating groove at the bottom end of the bonnet (6).
(6)
Fig a3. Bonnet – stem guide ring assembly
(23)
4. NOTE. Care must be taken not to damage the seal sections as they are passed over the stem thread. See Figure a4 for correct orientation. The gland ring (18A) has a flat upper surface with a ‘V’ cut in its lower face to accept the ‘V’ of the first secondary seal ring (chevron element 18B). Section (18C) acts as the primary radial seal, assembled with the open end containing the springs, supported by the T-Ring (18D) at the base of the seal stack.
18A
Fig a4. Typical Stem seal stack arrangement
18B 18C 18D
5. Pass the threaded section of the stem (4) up through the bonnet (6) 6. Pass the stem seal set (18) over the stem (4) and into the seal pocket in the bonnet (6). www.nov.com/mission
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(4)
(18)
Fig a4. Topworks assembly first stage (6)
7. Place ‘O’ring (20) into the retaining plate (7), place the retainer over the stem (4) and down onto Bonnet (6).
(4)
Fig a7. Topworks assembly second stage (7)
(6)
8. Place the lower thrust bearing assembly (11) over the stem (4) and onto the retaining plate (7). 9. Screw the stem screw (8) down over the stem (4) and into the lower bearing assembly (11) until no further rotation is possible i.e. the stem back seats in the bonnet. The top bearing race in the lower thrust bearing should come hard up against the lower shoulder of the stem screw when the stem screw is threaded down hard onto the stem. 10. Lower the upper bearing assembly (11) over the stem screw (8).
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17 (11)
(8)
Fig a10. Topworks assembly third stage (11)
11. Insert the bearing housing ‘O’ ring (15) into the bearing housing (9). Lower the bearing housing over the stem screw (8) and fully secure to the bonnet with 6 off 12 point flanged head screws (12) to a maximum torque of 30 foot pounds.
(15)
(12)
(9)
Fig a11. Topworks assembly fourth stage
(8)
12. Place key (21) into the stem screw (8). Lower the handwheel (10) over the stem (4) and onto the screw housing (8) aligning the key (21) with the slot in the handwheel (10). Place the clear tube (25) over the stem (4) locating on the spigot on the top of the stem screw (8) then screw the stem cap (13) hard down to secure the handwheel (10) into position.
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(13)
Fig a12. Topworks assembly fifth stage
(25)
(10)
(21)
13. Install the bonnet ‘O’ ring seal (14) into the ‘O’ ring groove in the bonnet (6). Apply assembly lubricant to the seal and adjacent diameter to aid assembly. 14. Place an ‘O’ ring (19) into each of the boot support rings (2). Using the recommended assembly lubricant, grease the boot support ring sealing bore inside the body (see Section on Recommended Lubricants) and install the boot support rings (2). Ensure the support rings are pushed fully home into position, use only wood or plastic implements to push the rings home, to avoid potential damage to sealing surfaces.
(19)
(19) (2) (2)
Fig a14. Boot support rings assembly
15. Squeeze the top two edges of the boot (3) together. Insert the boot down into the body (1) locating the obround boss at the base of the boot into the profiled hole in the bottom of the internal valve body cavity. Allow the two edges of the boot (3) to spring apart so that the locating rings on the outer faces of the boot enter the boot support rings (2) and snap into place.
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19 (3)
PRESS TOGETHER TO ASSEMBLE BOOT INTO BOOT SUPPORT RINGS
Fig a15. Boot assembly
16. Operate the handwheel (10) on the bonnet assembly such that the T slot on the stem (4) is lower than the bottom face of the bonnet (6). 17. Place the gate ‘T’ slot (5) over the end of the stem (4). Retract the stem and gate to the fully open position by turning the handwheel (10) anti clockwise (when viewed from above). 18. Install the bonnet assembly over the studs (16) and onto the body (1). Ensure the gate aligns with the opening in the boot (3), secure with nuts (17) to a torque of approximately 200 foot pounds. (17)
Fig a17. Bonnet Assembly
(16) (1)
19. Assemble bleed fitting (24) to ½” NPT port on bonnet (6). Important – do not use PTFE tape on the NPT threads – use liquid o ring. 20. Install one of the grease fittings (22) into the bearing housing (9) if they have been removed. Important – do not use PTFE tape on the NPT threads – use liquid o ring. www.nov.com/mission
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21. If not removed, then remove one of the grease fittings (22) from the bearing housing (9). Fully lubricate the bearings, stem thread and stem screw through the opposite grease fitting at the same time as operating the valve from the closed to open position to offer even distribution of the grease. Once clear returns of grease are visible through the open grease port, lubrication is complete.
Fig a21. Lubrication points
22. Refit the remaining grease fitting (22) to the bearing housing (9). Important – do not use PTFE tape on the NPT threads – use liquid o ring. 23. Valve assembly is now complete and ready for installation into mud system.
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Maintenance • • • • •
Lubrication intervals will depend very much upon the service conditions and frequency of operation. As a minimum the valve bearings, stem thread and stem screw should be greased every 1-2 months but is dependent on the frequency of operation. The valve sealing mechanism does not require any periodic lubrication for operation. Lubrication is performed via bearing housing (9) located grease fittings (22) using a suitable grease pump and the recommended bearing grease (or nearest suitable alternative) rated for the operating temperature range of the valve. The grease fitting connection is a DIN71412A nipple. Any grease pump hose selected for use on this valve should have the mating DIN71412A fitting. Remove one of the two grease nipples, connecting the grease hose to the remaining fitting. Pump grease until clear returns of grease are apparent from the open grease port.
Fig L1. Lubrication points
• • • • •
Every 1 month, check for free operation of the valve by operating the valve from fully open to fully closed 3 times under ambient conditions. Every 2 months, re-grease the bearings, stem threads and stem screw as shown above to ensure the integrity of these parts. Every 6 months, re-apply wax oil to all visible bare metal parts (including stainless steels) to maintain their corrosion resistance in adverse conditions. Repair any damaged paintwork at the earliest opportunity. During storage, at every periodic check ensure the valve end connection protection caps are fully in place to prevent moisture ingress into the bore which would allow entrapment of fluid inside the valve.
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Operating •
• •
• •
The disc type mud gate valve is an isolation valve and should not be used in any position other than fully opened or fully closed. Using the valve in any intermediate position will result in washout of the valve pressure controlling parts and body causing premature failure in service. Never subject the valve to pressures above the rated working pressure of the valve or operating system, whichever is lowest. The valve should be operated using the supplied handwheel mechanism only. No additional aids should be required for operation of this relatively low torque valve. Any excessive force required to operate the valve could be an indication of worn parts needing replacement at the earliest opportunity. Any excessive force applied could result in damage to valve components affecting adequate operation of the valve mechanism. When operating the valve from the opened to the fully closed position, back the handwheel off ¼ turn from the fully closed position to allow the gate to float and seal effectively. It is not necessary to back the valve off ¼ turn from the fully open position.
Troubleshooting Possible leak paths A. Valve leaking from stem seal B. Leaking between Boot Support Ring and Body C. Leak between Gate and Boot D. Bonnet seal leak E. Bleed fitting
A E D
B C
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Fault A. Valve leaking from stem seal
Causes a) Worn Stem Seal b) Contamination in Stem Seal Pocket c) New seal damaged on assembly or incorrectly installed
B. Leak between Boot support ring and Body
a) Damaged or worn boot support ring, or contamination between support ring and body b) Wash out in Body cavity a) Damaged Gate
C. Leak between Gate and Boot
b) Valve not fully closed
D. Valve leaking from Bonnet
E. Leaking bleed fitting
a) Damaged Bonnet Seal
a) Damaged thread or sealing mechanism
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Remedy a) Strip and replace b) Strip, clean and reassembly with new seal c) Strip and replace refer to maintenance assembly instructions a) Strip, clean and reassemble with new boot support rings b) Repair Body
a) Strip, clean and reassemble with new Gate b) Ensure valve is shut completely off, back off Âź turn after closing a) Strip and replace Bonnet Seal NOTE: The bonnet has a radial seal to the body, applying extreme torque to bonnet nuts will not affect the seal once a leak occurs. The valve must be dismantled and the seal replaced a) Strip and Replace
24
Spares, Special Tools and Lubricants
Bearing Grease
Anti- Seize Compound
Part No. 20441 – (6.6lb Tin) – Aeroshell Grease 16 Part No. 45368 – (4.4lb Tin) - Autolube MPM (or nearest suitable equivalent) Part No. 15471 (1lb Tin)
Boot Support Ring Extraction Tool
2” A77749
Mud Valve Parts as assembled. See next page for part replacement order list.
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Valve Size 3” 4” A77750 A77751
5” A39126
25
Generic Valve Assembly Requirement ITEM ** ** * ** ** * * *
* *
**
**
** ** * **
25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 *
Commissioning / 2 Years Operation / 5 Years Operation
ORIGINAL DESCRIPTION QTY. 1 TUBE 1 BODY BLEED FITTING 1 STEM GUIDE RING 2 GREASE FITTING 1 WOODRUFF KEY 1 O-RING (BEARING HOUSING) 1 O-RING (RETAINING PLATE) 1 STEM SEAL SET 8 BODY NUT 8 BODY STUD 1 O-RING (BONNET) 2 O-RING (BOOT SUPPORT RING) 1 STEM CAP 6 12 POINT SCREW 2 THRUST BEARING 1 HANDLE 1 BEARING HOUSING 1 STEM SCREW 1 RETAINING PLATE 1 BONNET 1 GATE 1 STEM 1 BOOT 2 BOOT SUPPORT RING 1 BODY Denotes Seal kit part
QUANTITY
**
UNIT PRICE
EXT. PRICE
DELIVERY
Denotes Redress kit part (includes all seal kit parts)
Part Replacement Kits
Seal Kit Redress Kit
2” A77743 A77744
Valve Size 3” 4” A77745 A77747 A77746 A77748
5” A79004 A79005
National Oilwell Varco offers a world-wide back-up service for all its products. In the first instance contact your local National Oilwell Varco Stockist or Agent. If you are in any doubt whatsoever, do not hesitate to contact one of our main offices world-wide. We are only a fax, email or a phone call away and we would be pleased to give any assistance we can.
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Contact numbers and addresses for National Oilwell Varco can be found below. When ordering spare parts it is important that the component is correctly described, use the description given in the parts list as well as the part number from the relevant general arrangement and quote this maintenance leaflet number (M127 issue 1)
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