Gate Valve

 Work Order: AGV 150031

 Item Code: AAEGVA 00004

 Description:
 2.16”-5m, flange end, TC model, GVA 6A
 Material: EE-0.5 API6A PR1&2
 Temperature: U PLS3 Material: AA-HH
 Assembly drawing:000008
 Assembly Procedure: 000009
 Test Procedure: 000003

 The GATE VALVE ASSEMBLY: ‘as per procedure 000009 part 3.0’

1.1 Gather the BOM components, which consist of:

 Body
 Bonnet
 Stem
 Seat A&B
 Gate

2.1 Assure all of the components are free of damages:

 Seat pockets
 Seats A&B
 Inside of body
 Gasket area
 The Grooves
 Bottom of Bonnet
 Stem
 Gate
 Stem Packing area
 Stud & Nut
 Stem packing
 Lube fitting
 Hex bolt
 Packing nut
 Roller thrust bearing & Split collar
 Bonnet cap
 Zerk fitting & Hex head screw

3.1 Eliminate the Body, Bonnet, Seats, Gate & Stem of soils, chips, excess grease, etc.

4.1 Clear the rest of the components:

 Mentioned above

5.1 Slightly grease the mating items:

 Gate
 Seats
 Grooves
 Mating part of Body and Bonnet

6. Begin assembly of Gate Valve

6.1 Lapping using the 60-emery cloth until removing the roughness and smoothens the seat pockets.
6.1.1 Lapping for seats to clear it of excess grease and make it a flat surface.
6.1.2 Lapping for seats back side on 60-emery cloth.
6.1 Seal the Seats grooves with the backup ring, O-ring & Teflon. Grease around the Seals. Insert in body with serial number
facing up.
6.2 Using the drifting tool and a rubber hammer, carefully use to push the seats further in.
6.3 Slightly grease the gate, insert the T-nut and slowly lower it in Body.
6.4 Slightly grease the gasket area, carefully place the gasket and grease the top also.
6.5 Slightly grease the inside of stem packing area
6.5.1 Insert the stem packing in order after proper greasing,
6.5.2 Finish it with packing nut after applying Copper slip on its threads. Seal tightly.
6.6 Apply grease on stem where necessary and insert inside bonnet. Lock properly.
6.7 Begin lowering down the Roller thrust bearing and Split Collar along with the appropriate greasing.
6.8 Using the molipold grease, apply it on the stems threads.
6.9 Apply copper slip on the studs and tightening them.
6.10 Using the hand-wheel and shear pin carefully lift and lower it on the body.
6.11 Apply copper slip on the tips of the studs. Close with the Nuts.
6.12 After the torqueing is finished. Apply copper slip at the bonnet caps threads and tightening it.
6.13 Insert the Hex bolt, Zerk fitting & lube fitting.

7. Torqueing
7.1 For size of nuts 3/4 = 40psi on the impact torqueing.
7.2 Start tightening the opposites, then a full round.

8. Hand wheel operation:

8.1 Turn the gate to fully open and fully close condition to check for smooth operation.

9. Drifting
9.1 Operate the hand wheel anti-clock wise till its fully open then operate it clock-wise by ¼ turn and drift.
10. Name plate
10.1 Fix nameplates in the body by means of 4 drive screws and mark as per the details provided.

 Gate Valve Testing:

4.1 Valve Body Test

4.1.1 Drift test for all valves

The drift bar confirms to API6A should completely pass through the bore after the valve has been assembled.

4.1.2 Hydrostatic Body Test:

a) Connect the flanges 2 1/16mm - 5m, 3m.
b) Connect bleeder, hose and chart recorder.
c) Release all entrapped air.
d) Close bleeder.
e) Begin pumping, Hold pressure at specified level and time. Record
f) Release and being test again.

4.1.3 Hydrostatic Seat Test

a) Continue to have gate at half open.
b) Fill coolant to bleed off entrapped air. Close Bleeder
c) Pressurize the valve according to chart along with addition pressure for pressure drop when bleeding off downstream.
d) Close the valve with ¼ open.
e) Bleed off downstream side to zero.
f) Pressure must be minimum at 5000.
g) When the pressure stabilizes, begin recording on chart according to PSL mentioned in the chart.
h) Release pressure between tests.
i) Once rest is finished. Begin testing the other side ‘B’

Note: PLS 1&2 only requires switching the place of the bleeder and pressure gage, whereas PLS 3 requires to place the gate
valve at the opposite flange.
 Sub Clause
Parameter
PSL-1 PSL-2 PLS-3
Drift Test Required Required Required
1) Hold 3 min. @7500 1) Hold 3 min. @7500 psi 1) Hold 3 min. @7500 PSI
PSI 2) Drop to zero 2) Drop to zero
Hydrostatic
2) Drop to zero 3) Hold 3 min. @7500 psi 3) Hold 15 min. @7500 psi
Body Test
3) Hold 3 min. @7500
PSI
1) Hold 3 min. @5000 1) Hold 3 min. @5000 psi 1) Hold 3 min. @5000 psi
psi 2) Open the Valve at diff. pres. 2) Open the Valve at diff.
2) Drop to zero 3) Hold 3 min. @5000 psi pres.
3) Hold 3 min. @5000 4) Open the Valve at diff. pres. 3) Hold 3 min. @5000 psi
Hydrostatic
psi 5) Hold 3 min. @5000 psi 4) Open the Valve at diff.
Seat Test
4) Open the Valve at diff. 6) Open the Valve at diff. pres. pres.
pres. 5) Hold 3 min. @5000 psi
6) Open the Valve at diff.
pres.
Chart Recording Not Required Not Required Required

 Tools Needed:
 Spanners
 Impact
 Torque Range
 Forklift

 Spanner To Use:
 Zerk: 11mm
 Hex: 13mm
 Lube fitting: 1”
 Nuts: 32 bonnet
 Nuts: 7/8 flange
 Flange: 36 mm