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VALVE RECLAMATION
PROCEDURE

WORK SHOP SOP


Manual
EFERT MANUFACTURING DIVISION

UNIT / SECTION : WORK SHOP

Maintenance Department

PREPARED BY:

MP-37

REV. NO.
ISSUE NO.
EFFECTIVE DATE
PAGE NO.
ORIG. PREPARED BY
REVISED BY

: 01
: 00
: JULY 01,1999
: 1 OF 5
: MIA
: UE

AREAS : ALL

___________________________________________________
FSE (UE)

REVIEWED BY:

DATE

_____________________________________________________
(AMn)

APPROVED BY:

DATE

___________________________________________________
MM (AAKn)

DATE

CHANGE RECORD

S. NO

REV. NO.
01

01

DATE

PAGE NO.
July
30,
02

DISTRIBUTION
DAHARKI LAN
DISTRIBUTION AS PER LIST (MP-01)

SECTIO
N
8

DESCRIPTION OF CHANGE
Added new section on
chemical cleaning work peices

DOC. NO

WORK SHOP SOP


Manual
EFERT MANUFACTURING DIVISION
Maintenance Department

VALVE RECLAMATION
PROCEDURE

UNIT / SECTION : WORK SHOP

MP-37

REV. NO.
ISSUE NO.
EFFECTIVE DATE
PAGE NO.
ORIG. PREPARED BY
REVISED BY

: 01
: 00
: JULY 01, 1999
: 2 OF 5
: MIA
: UE

AREAS : ALL

PURPOSE & SCOPE


The purpose of this procedure to document and implement repair procedures,
responsibilities and process of repairing any type of valves available in the plant site.

TYPES OF VALVES:
Warehouse Material Catalogue, Volume.1, and Class 022 gives a complete list of valves
and their spares available in the plant as stock. Also valve packings, gaskets, and ORings are available in the same catalogue under Class 023 and 024 items. Apart from
this valves for Reciprocating Compressors are available under Class 030 and 130. Control
valve spares are grouped under Class 082 and 182. Pressure Safety Valves (PSV) are
listed under Class 009 and 109. Any spare not stocked under the classification can be
locally manufactured at Shop Facility with a review from Shop Facility Section Head or Incharge as per the Shops Standard Operating Procedures.

TYPES OF PROBLEMS / REPAIRS


Gland leaks, Flange leaks, Bonnet flange leak, Leak through, body cracks/ failure, Short
bolting, control failure of control valves, are common types of problems faced in valves.
For PSV, the common problems are Simmering, Chattering, Hang-up, and Leak through.
3.1
Gland packing leaking is handled by tightening packing by its gland for initial leak
arresting followed by reinforcement or replacement of packing with valve in closed
position and isolated, if possible, depending upon the valve application and Work
permit procedure regulations.
3.2
Flange and Bonnet leaks are due to improper sealing surfaces, an improper gasket
application or installation or continuous deterioration due to wire- drawing. If the
leak can not be arrested from either gland or flange during service, then a suitable
Box-up arrangement will have to arranged as per Temporary repair Maintenance
procedure.
3.3
Leak through the seating surfaces occur due to erosion of seating surfaces, or
foreign material entrapment, or incorrect seating material specification or
preparation, or due to bent spindle or over operating pressure and temperature.
3.4
Cracks in body or body failure may be due to improper material specification for
application, thermal stresses, improper handling and storage.
3.5
HARD TO OPERATE:
Opening and closing is very hard for hand operation.
This could be due to bent spindle, defective threads of spindle, out dated or poor
quality of gland packing or corrosion or insufficient lubrication of packing or foreign
material entrapment.
QUALITY AND SAFETY REQUIREMENTS
4.1
Before working on a valve in service, work permit procedure requirement shall be
followed by Field Maintenance.

4.2

Any change in specification of valve as a whole or in spares shall be with the


conformance to SMP Control of change; all Field Maintenance and Valve Shop
shall follow the control of change procedure applicable in their area.

DOC. NO

WORK SHOP SOP


Manual
EFERT MANUFACTURING DIVISION
Maintenance Department

VALVE RECLAMATION
PROCEDURE

UNIT / SECTION : WORK SHOP

MP-37

REV. NO.
ISSUE NO.
EFFECTIVE DATE
PAGE NO.
ORIG. PREPARED BY
REVISED BY

: 01
: 00
: JULY 01, 1999
: 3 OF 5
: MIA
: UE

AREAS : ALL

4.3

If any welding has to be carried out on the valve, relevant Functional Review or
review with Inspection Section is required on the electrode to be used, in case of
general-purpose electrodes not found suitable.

4.4

Hydro test pressure shall be as per standards; once complete tests are done, Valve
shop shall place a tag specifying hydro test pressure and date. Only Valve Shop is
authorized to perform Valve Hydrotest.

4.5

Valve Shop shall follow their SOPs on valve repairs fully. Also SOPs require
continuous reviews at least once a year by Fabrication Shop supervisor, for
updating.

4.6

All welding procedures and welder are qualified in accordance with ASTM A 488 or
the ASME Boiler and Pressure vessel Code Section IX and certified by Inspection
Section.

RESPONSIBILITIES
5.1
Any repair that can be handled at Field shall be carried out by Field Maintenance
either with or without dismantling valves from the location. For example, gland
packing lubrication or reinforcement or replacement. If it is possible to isolate the
valve from operation, Flange or Bonnet gasket replacement can be carried out by
Field Maintenance. In case where valves are repaired (bonnet gasket, plug, spindle
replacement etc.) in situ pressure test upto operating pressure has to be carried
out. Also Field Maintenance shall install any type of valve including transport, and
rigging at their respective area. Field Maintenance is the owner of the valve under
its location. If any temporary repair has to be carried out, like Box-up, complete
responsibility lies with the respective Field in following Temporary Repair
Maintenance procedure including restoration to permanent status.
5.2

Any machining required on the valve shall be carried out by Shop Facilities at their
Valve repair Shop under their (Shops) Standard Operating Procedure.
Documentation is maintained at Shop Facilities on nature of repair done and
spares used. All spare valves are reclaimed by Shop Facilities including transport
and rigging from and to Salvage yard. Valve Shops arrange spares. Ownership of
the Line valves and their standby in salvage yard lies with the Field Maintenance.

5.3

Control valves are dismantled and installed by Field Maintenance, including


transport and rigging. They are disassembled and assembled by Instrument
Section. Any machining or fabrication is done by Shop Facilities under Instrument
Section work instruction. Any hydro-testing requirement is met by Valve repair
Shop. Instrument Section is the complete owner of the control valve irrespective of
its location.

5.4

All PSV are serviced, overhauled and calibrated by Shop Facilities at their PSV Test
bench under a separate Maintenance procedure. Field Maintenance carries out
transport, rigging, dismantling, and final installation. The Calibration Tag attached
at PSV Shop upon its calibration is filled completely by Field Maintenance once the
PSV is fully installed. Field Maintenance will arrange to send the Tag to Inspection

DOC. NO

WORK SHOP SOP


Manual
EFERT MANUFACTURING DIVISION
Maintenance Department

VALVE RECLAMATION
PROCEDURE

UNIT / SECTION : WORK SHOP

MP-37

REV. NO.
ISSUE NO.
EFFECTIVE DATE
PAGE NO.
ORIG. PREPARED BY
REVISED BY

: 01
: 00
: JULY 01, 1999
: 4 OF 5
: MIA
: UE

AREAS : ALL

Section for their record of stewarding calibrated PSV installation. Spares for PSVs
are arranged by Shops through Warehouse. Ownership of PSV, including its
standby lies with its location area.
5.5

All Orbit, Plug valves and Emergency Governor Valves are maintained by Field
Machinists of respective Field Maintenance. They do greasing or lubrication.
However, if the valve has to be disassembled and repairs to be done, Shop
Facilities support can be taken.

5.6

All Reciprocating Equipment Suction & Discharge Valves are repaired and
reclaimed and serviced at Shop Facilities as per their Standard Operating
Procedure. However, final acceptance, and inspection of these valves lies with
Field Machinists of the Field Maintenance. Spares for these valves are arranged by
Shop Facilities.

5.7

Field Maintenance or Warehouse, in the capacity of customers, can document their


problems on Reciprocating Compressor valves, PSV, other valves and any Shop
service in Customer Complaints Register maintained by Shop Facilities Incharge. This is stewarded periodically through Shops systems.

TESTING OF VALVES
Facility for Hydro- testing of valves is available at Valve Shop and is carried out to meet
API 598, which in turn, refers to ASME / ANSI B 16-34: 1996, Section 7. Testing is done
under the supervision by Valve Shops itself unless and otherwise requested. The copy of
the standard shall be available with Valve Shop or Fabrication Shop Engineer. PSVs are
counterchecked by Inspection Section as per the relevant Maintenance Procedure based
on relevant standard or vendor instructions. Machine Shop and Field Maintenance check
compressor valves upon completion of repairs or reclamation as per vendor instructions.

PURCHASED OR RECLAIMED VALVES ACCEPTANCE CRITERIA


A new purchased or reclaimed valve can be accepted for use when it meets the following
criteria as per API- 598 Section 2.3:
7.1
VISUAL INSPECTION: Body, Spindle, hand-wheel, flanges, and other damages.

7.2

Flanges bolt holes conformance to rating.

7.3

Material, and other parameters as per specification to meet the intended use and
as per Purchase Requisition.

7.4

Hydro-test of body and for tightness test of seat.

7.5

New valve shall be sealed at either ends, and their body and other parts new.

7.6

Only Valve Shop is authorized to verify for testing; once tested it is tagged; and
owner is informed.

CHEMICAL CLEANING OF WORK PIECES DURING VALVE RECLAMATION


Valves & valve parts need to be free from rust, scaling, lime etc prior to reclamation.
Following procedure is adopted for chemical cleaning.

DOC. NO

WORK SHOP SOP


Manual
EFERT MANUFACTURING DIVISION
Maintenance Department

8
S.#
1

VALVE RECLAMATION
PROCEDURE

UNIT / SECTION : WORK SHOP

MP-37

REV. NO.
ISSUE NO.
EFFECTIVE DATE
PAGE NO.
ORIG. PREPARED BY
REVISED BY

: 01
: 00
: JULY 01, 1999
: 5 OF 5
: MIA
: UE

AREAS : ALL

HANDLING PROCEDURE CHEMICAL CLEANING OF WORK PIECES DURING


VALVE RECLAMATION
Description
PPE Required
Safety Precautions
Pouring of chemical Rubber
a)
Can must be held firmly to avoid
from storage can
Gloves/Face
slippage
into working drum
Shield/Acid Proof b)
Chemical should be poured
Suit/Gum Shoes
gradually in order to avoid splashing
c)
Person performing this activity
must stand in opposite direction of
wind
d)
In case of chemical contact with
body/skin, affected area should be
immediately washed with water
e)
Drum should not be filled more
than 60% of its capacity
Dipping of work
Rubber
f)
Work piece must be dipped
piece in chemical
Gloves/Face
gradually in the chemical drum to
drum
Shield/Acid Proof
avoid splashing
Suit/Gum Shoes g)
Person performing this activity
must stand in opposite direction of
wind
h)
Work pieces should be dipped in
chemical for 10-15 minutes and
person performing the activity should
stand at least 10 feet away from
chemical drum
i)
Work pieces of relatively large size
and weight should not be dipped in
drum
Removal of work
Rubber
j)
Person performing this activity
piece from
Gloves/Face
must stand in opposite direction of
chemical drum
Shield/Acid Proof
wind
Suit/Gum Shoes k)
Work piece should be secured
firmly at the time of removal
l)
Work piece should be washed
thoroughly with water after removal
Disposal of expired Rubber
m)
Expired chemical must be shifted
chemical
Gloves/Face
to Disposal Can as per precautions
Shield/Acid Proof
corresponding to step no. 1
Suit/Gum Shoes n)
Disposal Can must be covered
from top prior to transportation
o)
Expired chemical must be drained
off in the acid/caustic drain trench
only. (near Uty-1 Chemical Unloading

DOC. NO

WORK SHOP SOP


Manual
EFERT MANUFACTURING DIVISION
Maintenance Department

VALVE RECLAMATION
PROCEDURE

UNIT / SECTION : WORK SHOP

Station)

MP-37

REV. NO.
ISSUE NO.
EFFECTIVE DATE
PAGE NO.
ORIG. PREPARED BY
REVISED BY

: 01
: 00
: JULY 01, 1999
: 6 OF 5
: MIA
: UE

AREAS : ALL

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