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Chapter 1 Page 1
The Valve Care Products referred to in this handbook have been developed to meet the specific needs of
valve maintenance technicians. Similar products from other manufacturers may, or may not, be as effective.
A common set of test standards is currently under development in order to more accurately compare the
many brands of valve lubricants and sealants currently available. Copies of the technical papers presented at
the 1990 and 1991 Offshore Technology Conferences can be obtained by contacting your nearest Sealweld
office.
ALWAYS consult the valve manufacturers owners manual prior to commencing work on any valve.
Keep injection pressures below 4,000 PSI on cast iron and semi-steel valves. NEVER EXCEED the
working pressure of the valve you are servicing when filling the body cavity with grease.
Use EXTREME CAUTION before opening a valve body vent fitting. Know what product is in the
valve. In cases of sour gas, wear emergency breathing apparatus and notify your fellow workers.
ALWAYS turn off your vehicle and work well down wind of all sources of spark or ignition.
When working around pressurized valves and pipelines, use extreme care and DO NOT take chances. Be
prepared for equipment failure and have contingency plans. ALWAYS have a properly sized stabbing valve
available in case of fitting failure. When working around valves containing sour gas, ALWAYS have your
emergency breathing apparatus within arms reach as high-pressure injection may cause a damaged fitting to
leak or break when you least expect it. Hydraulic pressure created inside the valve with a high-pressure
grease gun can stretch bolts on bolted plug valves and cause leakage. Should this occur, simply release the
pressure in the gun and hose assembly; the flange should sit back down and the leaking should stop.
Page 2 Chapter 1
Chapter 2
High-Pressure Gauge
NOTICE how slowly the needle drops when pumping stops. This indicates how quickly sealant is
moving into the valve. When the needle stops dropping or begins to fall more slowly, this usually
indicates the seat sealant system is full.
Gauge readings while injecting valve cleaner are often considerably lower than when injecting the lubricant /
sealants because of its lighter viscosity. If the injection gauge climbs and does not drop off, this may indicate
a plugged or restricted passage. Watch the gauge closely to see if the needle is moving at all. In cases
where the sealant system is plugged, it is usually as a result of the drying and hardening of old sealant. Inject
valve cleaner and leave it to soak from a few hours, to overnight in severe cases. Leave the gun attached to
the valve and note the gauge pressure. Check the gauge periodically; a passage is cleared when the gauge
begins to drop off. Cycle the valve to ensure complete coverage of the cleaner; continued injection will wash
the residue downstream.
Chapter 2 Page 3
ALWAYS wear eye protection when working around high-pressure equipment. A spray of grease
which could not pierce skin can do severe damage to soft eye tissue.
Page 4 Chapter 2
Chapter 3
Chapter 3 Page 5
Sealweld ACTIV-8
The Sealweld ACTIV-8 sealant injection pump is
one of the most effective tools for servicing large
diameter pipeline ball, gate and plug valves. It offers
a very simple field repairable design. It is powered
by compressed air, bottled breathing air or natural
gas which is utilized to generate up to 10,000 PSI
injection pressure instantly.
One of the more common problems with the old style
Air Ram Bucket Gun was that because it has so
many wearable parts, it is very difficult to repair and
keep running in the field. The Air Ram Bucket Guns
slower pumping speed usually meant the valve
technician would start the pump and then go on to
other tasks while the lubricant / sealant was being
injected. In many cases the valve would be overlubricated because the pump was left running too
long or the valve was under-lubricated because there
was a pocket of air in the can of lubricant / sealant
and the pump air locked.
The ACTIV-8 has proven to be extremely effective
on large diameter plug valves where hydraulic force
is required to physically jack the tapered plug from its
seat. A short quick shot of lubricant / sealant can
often pop the plug from its seat. The high speed
action can also wash contaminants from critical seal
faces and will cut hours from the time spent when
completely cleaning and re-lubricating large diameter
valves.
Uni-Seal Pump
The Uni-Seal Pump is a high speed hand-held
pump that uses the same air / hydraulic motor as
the Sealweld ACTIV-8. It is extremely effective
for quickly servicing valves in hard to reach areas
such as on towers or in tunnels. Its light weight
makes it ideal for heli-portable work. Many
operators power the pump with 125 PSI
(maximum) natural gas.
ALWAYS use a filter and lubricator when utilizing
natural gas as your power source.
The Uni-Seal will discharge sealant at up to 10,000
PSI and can empty a (1) one pound cartridge of
sealant in less than (2) two minutes. In
comparison, a hydraulic hand gun would require
over 800 strokes and would need to be refilled
once to discharge the same pound of sealant. A
Sealweld SuperGun would require over 300
strokes to discharge a pound of sealant. It is easy
to see why valves seldom receive sufficient
quantities of lubricant / sealant.
Page 6 Chapter 3
Chapter 3 Page 7
Operating Instructions
1. Open ram pull down valve # 1. This will allow
compressed air to escape the upper
assembly.
9.
11. Once the pail has settled onto the base and
follower plate has settled into the pail of sealant,
open the throttle valve # 6 slightly and allow
motor to run slowly. Sealant will begin to
escape out vent valve # 4. Catch the escaping
sealant on the pail lid or similar object.
12. Close both vent valve # 4 and valve screw # 5.
Pressure should begin to move. Close release
valve # 7, pressure should again begin to climb.
13. Open throttle valve # 6. Pump pressure should
continue building to 100 times the inlet pressure.
The motor will stall at this point. Discharge
pressure will remain steady until release valve #
7 is opened.
14. To remove empty pail, elevate the pump
assembly as in steps 1, 2 & 3 and tip pail until it
breaks free of follower plate. If pail will not
break free, remove as follows: Open vent valve
# 4 and valve screw # 5. Connect air supply to
the air nipple on vent valve # 4, the compressed
air will blow the pail off the follower plate.
For repairs to this and any make of hand or power-operated lubricating equipment, contact:
Sealweld Corporation in Calgary or Houston
Page 8 Chapter 3
Chapter 3 Page 9
Page 10 Chapter 3
Chapter 3 Page 11
Description
Part #
KIT #
Qty Reqd
R-RG-01
Retainer
R-RG-02
Throttle Valve
R-RG-03
Relief Valve
R-RG-04
Air Tube
R-RG-05
Male Connector
R-RG-06
Air Nipple
R-A8-15A
R-RG-08
K-4
O-RING
R-RG-09
K-4
10
Gasket
R-RG-10
K-4
11
O-RING
R-RG-11
K-4
12
Yoke
R-RG-12
13
R-RG-13
14
R-RG-14
15
Lock Washer
R-RG-15
16
R-RG-16
17
Air Coupler
R-A8-14H
18
Base
R-RG-18
19
Cylinder
R-RG-19
20
Cylinder Head
R-RG-20
21
Cylinder Gasket
R-RG-21
22
Piston Rod
R-RG-22
K-4
23
R-RG-23
24
O-RING
R-RG-24
25
R-RG-25
26
Piston Packing
R-RG-26
K-4
27
Retaining Ring
R-RG-27
K-4
28
O-RING
R-RG-28
K-4
29
O-RING
R-RG-29
K-4
30
R-RG-30
33
Pump Body
R-RG-33
34
Follower Plate
R-RG-34
35
Follower O-ring
R-RG-35
36
R-RG-36
37
Roll Pin
R-RG-37
38
Piston Rod
R-RG-38
39
R-RG-39
42
Tube Extension
R-RG-42
43
Stop Washer
45
46
2
K-4
2
2
K-4
1
1
K-5
3
1
K-5
R-RG-43
K-5
Steel Ball
R-RG-45
K-5
Hex Nut
R-RG-46
K-5
Page 12 Chapter 3
Item #
Description
Part #
KIT #
Qty Reqd
47
R-RG-47
K-5
48
Cotter Pin
R-RG-48
K-5
49
Steel Washer
R-RG-49
K-5
50
Valve Seat
R-RG-50
K-5
51
Gasket
R-RG-51
K-5
52
Lock Washer
R-RG-52
K-5
53
Extension
R-RG-53
K-5
54
Primer Body
R-RG-54
55
R-RG-55
56
Coupling
R-RG-56
57
Spring
R-RG-57
58
Coupling
R-RG-58
59
Piston Plug
R-RG-59
60
Nipple
R-A8-15A
61
Gasket
R-RG-61
62
Gasket
R-RG-62
K-5
63
R-RG-63
K-5
64
R-RG-64
65
R-RG-65
66
Valve Screw
R-RG-66
67
Vent Valve
R-RG-67
68
Pressure Gauge
R-RG-68
69
High-Pressure Hose
S-120XHP
70
"L" Swivel
H-SV-L1
71
Straight Swivel
H-SV-ST1
1
1
K-5
K-5
1
1
K-5
2
2
1
K-5
2
1
K-4
1
1
72
H-CPSG-2
75
Handle
R-RG-75
76
Can Shield
R-RG-76
78
Kick Stand
R-RG-78
79
Axle
R-RG-79
K-1
81
Spring
R-RG-81
K-2
82
Retaining Ring
R-RG-82
K-1
83
Release Valve
H-RVAB
K-2
84
Wheel
R-RG-84
85
R-RG-85
K-2
86
R-RG-86
K-2
87
5/16" Washer
R-RG-87
K-2
88
R-RG-88
K-1
89
R-RG-89
K-1
90
3/8" - 16 Nut
R-RG-90
K-1
92
R-RG-92
K-1
94
5/16" - 18 Screw
R-RG-94
K-1
100
R-RG-100
Chapter 3 Page 13
Item #
Description
Part #
KIT #
101
R-RG-101
102
Flat Washer
R-RG-102
103
Cap Tube
R-RG-103
K-1
K-3
Qty Reqd
1
104
R-RG-104
105
Air Cylinder
R-RG-105
106
Piston Nut
R-RG-106
107
Back-Up Washer
R-RG-107
108
Doughnut Packing
R-RG-108
109
Aluminum Washer
R-RG-109
110
Packing Spacer
R-RG-110
111
Motor Nut
R-RG-111
112
Gasket
R-RG-112
113
Cylinder O-RING
R-RG-113
K-3
114
Toggle Cap
R-RG-114
K-3
115
R-RG-115
K-3
116
Toggle Spring
R-RG-116
117
Plunger
R-RG-117
K-3
118
Toggle
R-RG-118
K-3
119
Shuttle
R-RG-119
120
R-RG-120
121
Lock Washers
R-RG-121
122
R-RG-122
123
Valve Retainer
R-RG-123
K-3
124
R-RG-124
K-3
125
Elbow
R-RG-125
1
K-3
1
K-3
2
K-3
126
Compression Nut
R-RG-126
127
Compression Sleeve
R-RG-127
K-3
128
Cover
R-RG-128
129
Cover Screw
R-RG-129
130
Piston Rod
R-RG-130
131
Nylon Washers
R-RG-131
132
Lower Packing
R-RG-132
133
Spacer
R-RG-133
K-3
134
Brass Washer
R-RG-134
K-3
K-1
R-RG-K1
K-2
R-RG-K2
K-3
R-RG-K3
K-4
R-RG-K4
K-6
K-5
R-RG-K5
K-6
K-6
R-RG-K6
K-6
Page 14 Chapter 3
Chapter 4
The added replaceable sleeve over the pump piston cuts repair costs by over 75% compared to similar
equipment. The sealant barrel was enlarged 33% so that less refills would be required and so that it would
hold the contents of a regular (16 oz.) sixteen ounce grease gun cartridge. Several other enhancements were
added to make the gun more durable, easy to carry and pump faster. The SuperGun will discharge (1 oz.)
one ounce of lubricant / sealant with every (25) twenty-five strokes of the handle, making it the valve
technicians favorite gun for routine topping-up procedures when only small quantities of lubricant / sealant are
required.
Chapter 4 Page 15
There exists the risk for a dangerous problem with corrosion occurring on some hydraulic guns internal
hydraulic relief valves. Some of the older styles of hydraulic hand guns utilized an internal relief valve which
was not zinc plated. Over time, as air and water got into the hydraulic system, these un-plated relief valves
would begin to corrode and then not relieve properly. This resulted in some guns building up to 20,000 PSI
before thread failure would occur and the gun barrel blew out. Several valve technicians were injured before
the problem was identified. All Sealweld hydraulic hand guns have a zinc plated relief valve. If you suspect
some of your existing hydraulic guns may have the old un-plated relief valve, Sealweld can inspect or repair
them and / or teach your personnel how to do their own gun repairs.
Another improvement included the introduction of a nylon sealant piston cup seal instead of the old hardened
leather type. The nylon has superior wear resistance and sealing ability which prevents the hydraulic fluid in
the gun from being contaminated by the lubricant / sealant.
Page 16 Chapter 4
Open by-pass valve # 4, check gauge to make sure all internal pressure has been relieved from the system.
2.
Remove grease cap # 1 with hose assembly from gun. Unscrew the handle # 10 and use it as a lever if the cap # 1 is
difficult to remove.
3.
Push the barrel piston # 2 to the bottom of barrel # 3 with handle # 10. Be careful not to scratch the inside of the
barrel with the handle.
4.
Turn the gun over so that the grease barrel # 3 points down (towards ground). Secure in a vise if possible.
5.
Close by-pass valve # 4 and replace pump handle # 10. Pump handle (50) fifty strokes.
6.
7.
Remove end cap # 1 from fluid bag barrel. Some older versions have the end cap secured by small set screws.
Remove the set screws before unscrewing end cap.
8.
Remove Allen screw from the end of the fluid bag # 12. The hole in the fluid bag should be pointing straight up.
9.
To top-up fluid bag # 12 with hydraulic fluid, use a squeeze bottle and add fluid slowly. Work your fingers around the
top of the fluid bag in an attempt to dislodge air bubbles which may be trapped inside. Leave the Allen screw out
while trapped air continues to escape; overnight is ideal.
10. Top-up the fluid bag and leave open until bubbles are no longer seen escaping.
11. Replace Allen screw and tighten. Replace end cap # 14 and tighten.
12. Reload the barrel with valve cleaner or lubricant / sealant. Replace end cap # 1 and tighten in place.
13. Close by-pass valve # 4. Attach gun coupler to valve fitting and begin pumping handle to build pressure. Read the
high-pressure gauge to determine what is happening inside the valve.
Body Profile
Body Cross
Section
Handle Latch
Assembly
Chapter 4 Page 17
Description
Part #
KIT #
Qty Reqd
R-HG07
Piston Assembly
R-HG08
2A
Cap Screw
R-HG08A
2B
Washer
R-HG08BA
2C
O-Ring
R-HG08B
2D
R-HG08C
2E
R-A8-20C
2F
Piston Body
R-HG08E
2G
Piston O-Ring
R-HG08F
2H
R-HG08H
XX
2I
R-HG08I
Sealant Barrel
R-HG09
3A
Barrel Gasket
R-HG10A
3B
R-HG10
Body Assembly
R-HG11
Body (Bare)
R-HG11A
R-HG11B
XXX
5A
R-HG11C
5B
R-HG11D
5C
Pump Piston
R-HG11E
XXX
XX
4
4A
5
1
XX
1
1
XX
1
1
1
R-HG11F
6A
Copper Washer
R-HG11FA
6B
Ball
R-HG11FB
6C
Spring
R-HG11FC
6D
R-HG11FD
6E
R-HG11FE
R-HG11G
7A
By-Pass Stop
R-HG11H
7B
Cap Screw
R-HG11I
7C
O-Ring
R-HG31
R-HG11J
R-HG11K
8
8A
1
XX
1
1
Fulcrum Assembly
R-HG12
10
Handle
R-HG13
11
Linkage Assembly
R-HG14
11A
Link
R-HG14A
11B
Bolts
R-HG14B
11C
Washers
R-HG14D
11D
Lock Nuts
R-HG14C
Hydraulic Fluid
R-HOPINT
XX
Fluid Bag
R-HG15
XX
R-HG15A
12
12A
Page 18 Chapter 4
Item #
Description
Part #
13
R-HG16
14
R-HG17
R-HG33
15 *
16
KIT #
Qty Reqd
R-HG30
16A
R-HG30A
16B
Latch Screw
R-HG30B
16C
Spring
R-HG30C
16D
Retainer
R-HG30D
16E
Latch Arm
R-HG30E
16F
Spring
R-HG30F
16G
Latch Sleeve
R-HG30G
16H
Cap Screw
R-HG30H
R-HGOREP
XX
R-HGMIN
XXX
R-HGMAJ
Latch Conversion
R-HG-LC
Chapter 4 Page 19
Page 20 Chapter 4
Chapter 5
Chapter 5 Page 21
Page 22 Chapter 5
Chapter 6
Chapter 6 Page 23
Be very careful of grease escaping through the vent hose on release valve # 6. DO NOT have your thumb or
fingers over the hole when closing the valve and beware of spraying grease.
Adapters
Couplers
Low-Pressure Couplers
High-Pressure Gauges
Page 24 Chapter 6
Item #
Description
Part #
Sealweld SuperGun
H-S-HOSE
H-H-HOSE
Uni-Seal Pump
H-U-HOSE
H-R-HOSE
H-A-HOSE
1A
H-AD-2F2F
1B
H-AD-2F4F
1C
H-AD-2F7F
1D
H-AD-2M2M
1E
H-AD-2M4F
1F
H-AD-2M4M
1G
H-AD-2M7F
1H
H-AD-2M7M
1I
H-AD-4F4F
1J
H-AD-4F4M-L90
1K
H-AD-4F7F
1L
H-AD-4M7M
1M
H-AD-4M4M
1O
H-AD-4M2F
1P
H-AD-4M6F
1Q
H-AD-4M6F-L90
1R
H-AD-7M2F
1S
H-AD-9M2F
1T
H-AD-9M4F
2A
H-CPSG-2
2B
H-CPSGR
2C
H-CPSO
2E
H-CPRG
2F
H-CPRGR
2G
H-CPAG
2H
H-CPAGR
2I
H-CPAS
2J
H- CPASR
2K
H-CPAS-B
2L
H-CPLS
2M
H-CPLS-B
3A
H-GD-01
3B
H-GD-01C
3C
H-GG-2.5
Category
Item #
Description
Part #
4A
H-HS-18"XHP
4B
H-HS-28"XHP
Call Sealweld
4C
H-HS-120XHP
for pricing
4D
H-HS-60XHP
and
4E
H-HS-180XHP
availability
4F
H-HS-240XHP
of these items
4G
H-HS-360XHP
4H
H-HS-18"LP
Hoses
Swivels
4I
H-HS-120HP
5A
H-SV-Z1
5B
H-SV-ST1
5C
H-SV-L1
5D
H-SV-ST2
5E
H-SV-ST3
Release Valve
1/4M X 1/4F
H-RVAB
Tee
H-T-444
Chapter 6 Page 25
Page 26 Chapter 6
Chapter 7
Chapter 7 Page 27
The illustration on the left, is the other type of two-piece buttonhead fitting. The manufacturer's catalogue
describes the fitting as being designed for heavy duty use, on industrial construction and earth moving
machinery. Notice the single lip which secures the hardened buttonhead.
We encountered a failure of this style of buttonhead fitting several years ago. The top section separated at
only 3,000 PSI while injecting sealant at approximately eighty 80 degrees Fahrenheit. This was on a twenty
20" inch ball valve manufactured in Scotland. The fitting had been provided as original equipment from the
manufacturer. Upon further discussion with the manufacturer, they advised that they quit installing the twopiece buttonhead fitting in 1988 and now only utilize the one-piece design. Fortunately no one was injured
when the fitting came apart because the buried inner check valve held back the 1000 PSI gas pressure.
Page 28 Chapter 7
double ball check system. These types require an even larger internal passage which further reduces the
wall thickness in the threaded area. This lowers the burst rating of the fitting and offers little if any safety
margin.
Unfortunately most valve manufacturers have cut only a 1/4" NPT thread into the body of the valve for sealant
fittings. We strongly recommend that you urge the valve manufacturers to use a 3/8" NPT or 1/2" NPT thread
to reduce the risk of this type of fitting failure on all new valves. For valves that must use a 1/4 NPT fitting,
standardize with a .316 stainless steel material for increased mechanical strength.
Chapter 7 Page 29
Suggested Actions
There are such a wide variety of designs and styles of sealant fittings it is difficult to recommend that any
particular fitting be withdrawn from a pipeline system without close examination. The best way to judge if it is
one-piece or two-piece construction is to examine the bottom of the fitting. If the fitting is installed into a
pressurized valve, it would be extremely dangerous to remove it to examine the bottom in an attempt to
determine whether or not it is of one-piece construction. DO NOT rely on the buried inner check valve to hold
back line pressure. ALWAYS blow down the pipeline both upstream and downstream before removing any
sealant injection fittings on ball and gate valves. As this is impractical in most situations our best advice
would be to NOT service the valve if the technician has any doubts if the fitting is safe or not.
Call Sealweld for on-site valve maintenance training seminars, available worldwide.
When examining sealant fittings; if a crimp is obvious then you can be almost certain that it is of one-piece
construction. If the bottom is flat and no crimp is present, then it is probably a two-piece fitting and should be
discarded. The FLOW WOLF design is obvious by its threaded cage (with Allen head) screwed into the
bottom of the fitting and FLOW WOLF stencil on the wrench flats. Sealweld valve maintenance technicians
tour the many miles of pipeline on a regular basis. We would be glad to stop in at any location and examine
any fittings in question to make a determination. By spending a little time with your valve technicians, we can
show them some of our many failed fitting samples and teach them how to make their own determinations
regarding the integrity of fittings.
Page 30 Chapter 7
Chapter 7 Page 31
Page 32 Chapter 7
Chapter 7 Page 33
Page 34 Chapter 7
Chapter 7 Page 35
Page 36 Chapter 7
Chapter 8
DO NOT tighten the fitting into the valve by the bolt or cap.
Screw the fitting into the valve tightly, being careful not to cross thread the fitting. Should the threads begin
tightening prematurely, back the fitting out and inspect for thread damage. Re-tape the threads and repeat as
necessary.
Once tightly installed, service fittings as described below.
Place wrench on bolt and turn counterclockwise, making sure to use a back up wrench
on the fitting body. DO NOT unscrew the bolt
from the body. Once the valve is pressurized,
beware of escaping product from the valve.
Follow company safety regulations for venting
pressurized valves.
Chapter 8 Page 37
Packing Injectors
Back the bolt all the way out of the body then lubricate
threads with penetrating oil or similar light oil. Insert
screw bolt back into body and tighten. Be sure to use
a back up wrench on the body when tightening and
removing.
Packing Injector
Page 38 Chapter 8
Chapter 9
Chapter 9 Page 39
Page 40 Chapter 9
Chapter 10
Gate Valve Body Filler Grease in (10) ten pound pail - Part Number S-GV-10
Valve Cleaners, Lubricants & Sealants
Chapter 10 Page 41
Valve Cleaner Plus in (10) ten pound pail - Part Number S-VC-10
Valve Lubricants
Are made from materials which are insoluble in whatever gas, or liquid is inside the valve. Modified vegetable
oils are often blended with synthetic oils, special corrosion inhibiting agents and other additives to give the
lubricant its sticky texture. These viscous and sticky lubricants will provide some sealing ability and are
generally recommended for new valves or valves with very little wear. It is very important that a good quality
valve lubricant be resistant to breakdown or shearing of the gel structure under high-pressure injection and
the enormous load forces commonly seen across seal faces. It must also be stable over a broad temperature
range and not break down or harden when pumped at freezing temperatures and in higher temperature
service such as may be seen in compressor discharge applications.
Sealweld Equa-Lube Eighty in (10) ten pound pail - Part Number S-EQ-10
Sealweld Total-Lube # 911 Lubricant / Sealant in (10) ten pound pail - Part Number S-TL-10
Sealweld # 5050 Sealant in (10) ten pound pail - Part Number S-VS-10
Page 42 Chapter 10
Emergency Sealants
Sealweld XH # 5050 Sealant in (10) ten pound pail - Part Number S-XS-10
Sealweld XXH # 5050 Sealant in (10) ten pound pail - Part Number S-XXS-10
When using the heavier emergency sealants, ALWAYS open the valves body vent fitting (if possible) in order
to draw the sealant over the damaged seal face.
Remember to wait (10 - 20) ten or twenty minutes with the body vent open to ensure the seal is
holding.
DO NOT be fooled by the viscosity of the sealant. Heavy and / or cold sealants will take time to extrude
through the tiny leak paths before the valve starts to leak again. Watch the injection gauge very closely to
see if the sealant is pushing into the valve or if the seal is holding.
Once a reliable seal is achieved, leave the gun hooked up and under pressure. Remember to check the
gauge periodically. Leave the valve alone; DO NOT cycle the valve or the seal will be lost. Leave the body
vent fitting open, otherwise pressure will build-up in the valve's body cavity and there is a risk that the gas or
liquid will escape downstream. By watching and / or listening to the leakage through the body vent fitting you
are able to judge how the seal is holding.
Chapter 10 Page 43
We draw your attention to the graph illustrated above and on the last page of Offshore Technology
Conference Paper # 6697. Notice that sealants "B" and "E" demonstrated some initial sealing ability then
failed abruptly after approximately (6) six minutes. This would indicate that the valve technician should
always wait some time before assuming it is safe to work downstream of any valve in which sealant has been
injected.
Page 44 Chapter 10
Mineral Oil
Color:
Black
Temperature Range:
Texture:
Thin Paste
Pressure:
10,000 PSI
ASTM Penetration:
270 - 320
Dropping Point:
None
Solvent Resistance:
N/A
Special Additive:
Graphite
Compatibility:
Dispersant
Particle Size:
Micronized
Composition:
Semi-liquid
Application:
Used as an internal valve cleaning compound for use in ball, gate and plug valves
as well as orifice fittings. Use in wellhead valves, at pump and compressor stations
and distribution systems.
Ideal for use on valves with plugged sealant fittings, seat leakage problems or
valves which are hard to turn. Leave in valve for at least (30) thirty minutes. Purge
from system with regular lubricant / sealant after use.
Synthetic
Color:
Natural / Opaque
Temperature Range:
Texture:
Tacky
Pressure:
<10,000 PSI
ASTM Penetration:
220 - 250
Dropping Point:
None
Solvent Resistance:
Excellent
Special Additive:
No TFE Fluorocarbon
Compatibility:
Excellent
Particle Size:
N/A
Composition:
Semi-Liquid
Application:
Used as an all purpose synthetic valve seat lubricating compound. Ideal for use in
new ball, gate and plug valves for reducing torque, preventing galling of mated
seating surfaces and keeping contaminants from entering the valve sealant system.
Insoluble in oil, natural gas and water related services. Use in wellhead valves,
pump and compressor stations and distribution systems.
Chapter 10 Page 45
Synthetic
Color:
White
Temperature Range:
Texture:
Tacky
Pressure:
10,000 PSI
ASTM Penetration:
165 - 195
Dropping Point:
None
Solvent Resistance:
Excellent
Special Additive:
PTFE Fluorocarbon
Compatibility:
Excellent
Particle Size:
Micronized
Composition:
Semi-Liquid
Application:
Used as a premium grade synthetic lubricant / sealant for ball, gate and plug valves
as well as orifice fittings. Insoluble in oil, natural gas and water. Use in wellhead
valves, at pump and compressor stations and distribution systems. Proven to
reliably seal a leak path of up to 0.10. Ideal for sealing damage to O-rings, chevron
seals and U-Cups.
Designed specifically as a premium grade synthetic valve lubricant / sealant to
provide the longest service life for valves that cannot be serviced frequently. Valves
serviced with Total-Lube # 911, require less frequent maintenance than valves
serviced with conventional lubricants.
Synthetic
Color:
White
Temperature Range:
Texture:
Tacky
Pressure:
10,000 PSI
ASTM Penetration:
200 - 225
Dropping Point:
None
Solvent Resistance:
Excellent
Special Additive:
PTFE Fluorocarbon
Compatibility:
Excellent
Particle Size:
Micronized
Composition:
Semi-Liquid
Application:
A slightly less viscous formulation than regular # 911 ideal for outdoor applications,
block valves and automatic lubricators on suction and discharge valves.
Page 46 Chapter 10
Synthetic
Color:
Green
Temperature Range:
Texture:
Tacky
Pressure:
10,000 PSI
ASTM Penetration:
165 - 195
Dropping Point:
None
Solvent Resistance:
Excellent
Special Additive:
PTFE Fluorocarbon
Compatibility:
Excellent
Particle Size:
Micronized
Composition:
Semi-Liquid
Application:
Used as a synthetic sealant for ball, gate and plug valves. Insoluble in oil, natural
gas and water related services. Use in wellhead valves, at pump and compressor
stations and distribution systems. Proven to reliably seal a leak path of up to 0.30.
Ideal for scratches, scarring or pitting on critical seal faces. Use for sealing stem
and seat seal damage when Total-Lube # 911 fails to hold a reliable seal.
Synthetic
Color:
Green
Temperature Range:
Texture:
Tacky
Pressure:
10,000 PSI
ASTM Penetration:
200 - 220
Dropping Point:
None
Solvent Resistance:
Excellent
Special Additive:
PTFE Fluorocarbon
Compatibility:
Excellent
Particle Size:
Micronized
Composition:
Semi-Liquid
Application:
Used as an emergency sealant for ball and gate valves Insoluble in oil, natural gas
and water related services. Use in wellhead valves, at pump and compressor
stations and distribution systems.
Not recommended for use in plug valves except in an emergency. The excellent
sealing ability of this compound may restrict internal sealant passages and / or plug
them completely. Purge from system after use.
Hydrocarbon - Natural Gas, Oil, Related By-Products Use in ball and gate valves with
EXTREME leakage problems.
Chapter 10 Page 47
Texture:
Moldable
Dropping Point:
None
Solvent Resistance:
Excellent
Special Additive:
PTFE Fluorocarbon
Composition:
Putty
Application:
Injectable valve stem packing for gate valves and plug valves in hydrocarbon service.
Synthetic
Color:
Gray
Temperature Range:
Texture:
Tacky
Pressure:
10,000 PSI
ASTM Penetration:
310 - 340
Dropping Point:
None
Solvent Resistance:
Excellent
Special Additive:
PTFE Fluorocarbon
Compatibility:
Excellent
Particle Size:
Micronized
Composition:
Semi-Liquid
Application:
Lubricant / sealant - Use in all sizes of ball and gate valves with minor seat leakage.
Use in plug valves larger than 6, as well as in orifice fittings.
Designed for use in LPG / NGL, low temperature service.
Page 48 Chapter 10
Emergency Sealant - Use in ball and gate valves with SEVERE leakage problems.
Call Sealweld for assistance. Do not use in small diameter plug valves.
Synthetic
Color:
Silver
Temperature Range:
Texture:
Tacky
NLGI:
ASTM Penetration:
295 - 320
Dropping Point:
None
Solvent Resistance:
N/A
Special Additive:
Proprietary blend
Compatibility:
Excellent
Particle Size:
< 4 microns
Composition:
Semi-Liquid
Application:
Use in valve stems and gearboxes to prevent corrosion, extend bearing life and
reduce torque. Use in ball, gate and plug valves in high-temperature service.
Synthetic
Color:
Blue
Texture:
Buttery
Dropping Point:
None
Application:
Used as a lubricant for gate valve bodies. Fill the body with this inexpensive
lubricating grease. Contains corrosion inhibitors and antioxidizing ingredients.
Chapter 10 Page 49
Page 50 Chapter 10
Chapter 11
You can build a safe, cost and time effective, Valve Maintenance Program with the Sealweld
ValvePro series of software solutions.
Perform an audit on every valve and build a data base describing each valve, its performance and
preventative maintenance history.
ALWAYS read the valve manufacturers owners manual before commencing any maintenance
procedure.
Chapter 11 Page 51
Valves have different types of internal sealing mechanisms. Some key points to remember are:
Gate valves are typically downstream seating. API or wellhead-type gate valves typically DO NOT have
any provision for internal seat pressure relief. Always use extreme caution when injecting grease or
sealant into these types of gate valves. DO NOT over-fill the valve with grease or the valve body may
rupture. Some of the larger pipeline type gate valves may have a self relieving upstream seat ring and
may be equipped with a seat sealant system similar to ball valves.
Floating Ball Valves (without internal trunnion) are typically downstream seating. These valves typically
DO NOT have a provision for de-pressurizing the body cavity.
Trunnion Mounted Ball Valves come in a variety of seat sealing configurations. The term Double Block
and Bleed has been misinterpreted by valve manufacturers and pipeline operators alike. Most trunnion
mounted ball valves feature bi-directional sealing, meaning the valve will isolate line pressure in either
direction. Some valves have the capability to test the seat seals by depressuring the body cavity in either
the full open or full closed positions. Other valves such as the Grove B-5 can only de-pressurize the body
cavity in the full closed position. Trunnion mounted ball valves are typically upstream seating. The two
most common seat sealing designs are those that have a self-relieving downstream seat ring, and those
that have a bi-directional or independent sealing (not self relieving) downstream seat ring, like the Grove
B-5. These differences can become important when sealing a valve in an emergency.
The addition of the body vent fitting feature in pipeline ball and gate valves has enabled the valve technician
to determine the effectiveness of his maintenance techniques. By evacuating the body cavity between the
two valve seats, the technician can determine if the valve seats are holding a seal. If leakage persists, the
technician can usually judge which seat is passing by listening or waiting for the leak to diminish as sealant is
injected into each seat ring.
For valves in gas service, Sealweld has recently developed and is field testing a turbine gas meter which
connects to the valves body vent fitting. This new tool enables the valve technician to take an accurate
metered reading of gas volumes out through the valves cavity. The test can be performed both before and
after servicing each valve and is used to determine the effectiveness of your current maintenance program. A
hard copy printout is provided which can be collected over a period of months or years for long term
maintenance analysis.
Page 52 Chapter 11
Chapter 11 Page 53
Page 54 Chapter 11
The quantity of cleaner required is detailed on the above sealant capacity chart. Ball valves generally require
one (1 oz.) ounce per inch of valve size into each seat ring. Riser pipe quantities are extra, generally (2 ozs.)
two ounces per foot or (16 ozs.) sixteen ounces per eight foot riser. In other words, a thirty six 36" inch ball
valve would require (36 ozs.) thirty-six ounces (= 2.25 pounds) into each seat ring plus an additional (16 ozs.=
1 pound) sixteen ounces into each of (4) four riser pipes. This quantity can be reduced by the quantity
required to fill the riser pipes. Injecting (36 ozs.) thirty-six ounces of cleaner would fill the sealant riser lines,
the seat ring passage and the sealant channel. Switch the pump back over to the lubricant / sealant and
continue injecting (16 ozs.) sixteen ounces of lubricant / sealant. Stop the pump and allow the cleaner to
soak in the seal face passages for up to (1) one hour. When you are satisfied that the cleaning action is
complete, continue injecting (20 ozs.) twenty ounces of lubricant / sealant to displace all the cleaner. By
opening the valves body vent fitting during the cleaning operation the cleaner is drawn over the seat insert
and allowed to clean the important seal faces.
Chapter 11 Page 55
Notice on the illustration, that the seal face passage and sealant channel are exposed directly to line
pressure. This is the most vulnerable portion of the seat sealant system. The lubricant / sealant can be
scraped off by the seat insert as the valve is cycled washed away by high-pressure jetting action of the line
pressure flowing through the valve and also contaminated by foreign materials flowing along the pipeline
(scale, rust and internal plastic coatings).
By injecting sufficient quantities to replace the lubricant / sealant in the seal face passage you have probably
displaced the foreign materials and refilled the area up to the seat insert. The quantity can vary depending on
the exact seat ring design, generally 1/4 to 1/3 of the sealant system capacity. In other words, if a 36" ball
valve holds (36 ozs.) thirty-six ounces into each seat ring then 1/4 would be (9 ozs.) nine ounces or 1/3 would
be (12 ozs.) twelve ounces. By injecting these top-up quantities at least once a year most valves will operate
and seal properly. Valves which cycle frequently or are closer to the compressor (because of increased
temperature) should be topped-up more frequently.
Another good indication of the seat sealant system becoming full is to watch the injection gauge while
topping-up. One of the best ways to practice getting the feel for when the seat sealant system is full, is to fill
valves for the first time from a dry condition. As the passages become full, the lubricant / sealant will have
more difficulty escaping, the injection gauge will begin to climb rapidly and will fall more slowly when pumping
is stopped. This is not always a reliable method in cold climates where the increased lubricant / sealant
viscosity can send confusing signals.
Page 56 Chapter 11
Chapter 12
Lack of sealant
Improper adjustment
Rusted stem threads underneath the stop collar at the outboard end of the stem
In order to determine which of these problems are the likely source of the difficulty, the following steps must
be taken.
Locate the sealant injection fitting on the top of the valve (see illustration). Inject Sealweld Valve Cleaner
Plus using a high-pressure sealant injection pump in sufficient quantities to completely displace the old
sealant.
ALWAYS watch and read the injection pressure gauge to judge what is happening inside the valve.
In most cases, as the cleaner is injected, the pressure will increase until a rapid de-pressurization or blow will
occur as the old sealant is pushed out of the valve. The cleaner will then run in smoothly with very little
increase in pressure. The plug valve should be cleaned in the fully open or fully closed position in order to get
all the old sealant out from under and around the plug. Cycle the valve several times to ensure complete
coverage of the cleaner.
Once the cleaning is complete, inject Sealweld Total-Lube # 911 plug valve lubricant / sealant in equal
quantities as the valve cleaner. The plug should be in the fully opened or fully closed position. As the sealant
is injected, the pressure gauge will increase and slowly decline as the sealant enters the sealant grooves.
When pumping stops, the gauge will begin to drop. The more slowly the gauge drops, the tighter the fit
between the plug and valve body. The tighter the fit, the better chance you have of achieving a seal. Too
tight a fit and the valve may be difficult to cycle.
Chapter 12 Page 57
The plug can be adjusted in order to improve the valve sealing and turning ability. Look on the bottom of the
valve and you will notice a cap tack welded to the body of the valve. The plug position is set at the factory
and the cap is tack welded to prevent unnecessary tinkering. If the cap weld is intact then the setting should
be correct. If the weld has been broken some adjustment may be necessary. Consult the proper valve
manufacturer's service manual for proper setting adjustment advice.
Page 58 Chapter 12
Equipment Requirements:
Sealweld Valve Cleaner Plus, Sealweld Total-Lube # 911 and Sealweld Slick Sticks Stem Packing
Penetrating oil
The objective is to safely remove the old stem packing and replace it with Slick Sticks valve stem packing.
This packing is a special preparation for pipeline valves and includes special inhibited grease and a variety of
PTFE particles which bridge to form a durable, rebuildable seal. The stem seal can then be rebuilt by simply
injecting additional Slick Sticks or Super Stem Packing compounds through the packing injection fitting.
Chapter 12 Page 59
Read this handbook and the corresponding valve manufacturer's manuals completely before starting
any maintenance routine.
Hard Hat
Safety Glasses
Steel-Toed Boots
Hearing Protection
A full port stabbing valve of the same thread and internal dimensions as the plug opposite the packing
injector. An XH Nipple (schedule 80) should be thread taped and tightened into the valve. The other end
of the nipple should also be thread taped. Keep the stabbing valve in the open position and within arms
reach in case of kick through the stem packing gland while the plug is removed. The stabbing valve must
be full port.
ALWAYS notify your supervisor or the control room before attempting this procedure.
In the worst case, if the valve is under pressure the following procedure could expose the Valve Maintenance
Technician to full line pressure escaping through the stem or packing injector or packing plug (once removed).
Depending on the product in the line, the location of the valve and wind direction, this can present serious
consequences. Additionally, when removing the packing plug opposite the packing injector - if pressure has
entered the stem packing area, the plug will blow out at great velocity once the last engaged thread is
unscrewed. Due to the excellent sealing ability of most packing compounds and valve sealants, the threads
may not leak until the last engaged thread is unscrewed. This is why a stabbing valve must be ready before
the procedure begins. The check valve devices installed in most sealant fittings and packing injectors are
unreliable and prone to leakage and / or failure.
Always use EXTREME CAUTION when working with valves under pressure.
Use liberal amounts of foaming type leak detector when unscrewing any fitting on pressurized gas valves. If
at any time line pressure is suspected to be entering the stem packing area, stop this procedure and proceed
only after you are sure all sources of pressure have been eliminated.
Have an evacuation plan discussed and ready for implementation in case of emergency.
Page 60 Chapter 12
Assuming the plug has been cleaned with valve cleaner as previously discussed, inject valve lubricant /
sealant such as Total-Lube # 911 through the sealant fitting on the top of the valve. Keep pressure on the
fitting in excess of line pressure. If the lower threads on the stem have failed it is possible to have a kick once
the plug is removed. By having the valve charged these threads should seal themselves with the sealant.
Also, by watching the pressure gauge you can better judge if the lower threads have failed by a
corresponding drop in gauge pressure as the plug is unscrewed.
Carefully back the Allen screw out of the packing injector body and replace it with the proper sized buttonhead
fitting from the stem servicing kit. It may be necessary to wrap the threads with thread tape. Always check
for leakage before completely unscrewing.
Carefully begin to unscrew the plug opposite the packing injector. Being a tapered thread you should be able
to unscrew it by hand after (1 - 2) one or two turns. If the plug still requires a wrench, it may be a sign that
line pressure is evident in the stem area. The packing will be in compression and will expand once the plug is
unscrewed. This can send confusing signals to the technician.
Quickly install the stabbing valve and tighten in place. Working through the open stabbing valve, remove as
much of the old packing as possible with a packing puller or screw driver. As the packing is normally in
compression, a certain amount of expansion is going to occur once the plug is removed. This is normal.
Watch the gauge on the sealant gun for signs of sealant entering the stem area. Should a leak or kick occur quickly remove the packing puller or screw driver from the stabbing valve and close the stabbing valve to
contain the leak.
Inject Sealweld Valve Cleaner Plus through the buttonhead adapter on the packing injector fitting. As the
cleaner is injected, the old packing should begin to extrude through the open stabbing valve. At this point you
will be most vulnerable to a kick as most of the packing has been removed. Watch the gauge pressure on the
sealant gun for any sign of pressure drop. Should the packing begin to blow, simply close the stabbing valve
to contain the leakage.
Close the stabbing valve and pressure up the stem area with valve cleaner. This will force the cleaner into
the stem threads and moisten the old packing. By repeatedly pressuring up the stem area and quickly
opening the stabbing valve, the old packing can be carried out with the cleaner. If possible, cycle the valve
partially or fully to distribute the valve cleaner up and down the threaded stem.
You may now begin to replace the packing. Remove the buttonhead adapter in the packing injector and
insert Sealweld Slick Sticks. The Slick Sticks are injected by screwing in with the original Allen screw.
When the Allen screw bottoms out, back it out and repeat the procedure. Leave the stabbing valve in the
open position while additional Slick Sticks are added. The Slick Sticks will push out the old packing and valve
cleaner as it enters the packing gland. When Slick Sticks are evident in the stabbing valve, the stabbing valve
can be removed and the plug replaced.
Cycle the valve several times to ensure it has returned to its normal condition and that it turns easily with the
original wrench provided. Inject additional Slick Sticks until the Allen screw becomes harder to turn. Check
the valves torque requirements to ensure the packing material is not over-compressed.
Return the valve to its original position (fully opened or fully closed).
Return to the valve site and inject additional Slick Sticks if necessary over a period of (2 3) two or three
days. For this period additional Slick Sticks may be required as the valve cleaner and lubricating oil in the
Slick Sticks is displaced. Be careful not to apply excessive force to the Allen screw as a great deal of
pressure can be generated with even a short wrench.
Additional Slick Sticks can be added if necessary as part of a maintenance routine on an annual or semiannual basis. If stem leakage is still a problem, a heavier grade of Super Stem Packing is also available.
Chapter 12 Page 61
it is beneficial to introduce a lubricant such as Sealweld Valve Cleaner Plus into the stem area to reduce the
valve operating torque and moisten the old dried packing.
Remove the Allen screw from the packing injector, dig out as much of the old hard packing as possible.
Install the proper sized stem servicing buttonhead adapter.
Attach the sealant gun, filled with valve cleaner, to the buttonhead adapter on the packing injector.
Apply pressure by means of the sealant gun until the gauge reads 4000 PSI. Stop pumping and observe
whether there is a drop in the gauge reading. Maintain a 4,000 PSI pressure for (10) ten minutes. Check
the valve turning torque. Turning the valve, even a small amount, will help to distribute the valve cleaner
around the stem threads.
Remove the stem servicing adapter and insert Slick Sticks stem packing before re-installing the Allen
screw in the packing injector. Inject a sufficient quantity of Slick Sticks to sufficiently seal the stem and
still provide minimal torque requirements.
Return to the valve site and inject additional Slick Sticks if necessary. Be careful not to apply excessive
force to the Allen screw as a great deal of pressure can be generated with even a short wrench.
Additional Slick Sticks can be added as part of a maintenance routine if necessary. If stem leakage is still a
problem a heavier grade of Super Stem Packing is also available.
Summary
If these procedures are not successful at reducing torque and eliminating stem leakage, the valve has more
serious mechanical damage and should be repaired or replaced at your earliest opportunity.
This document has been prepared in order to provide valve maintenance personnel with a better
understanding of some of the procedures which can be utilized in order to make plug valves easier to turn or
seal. If you do not clearly understand the procedures being described, contact Sealweld Services for an
explanation or on-site demonstration.
Page 62 Chapter 12
Chapter 13
Welded body construction (as compared to a bolted body design) is more compact.
The body draining feature allows the valve maintenance technician to test each seat rings sealing ability
with the ball in either the full open or full closed positions. This is accomplished by opening the body vent
fitting which de-pressurizes the valve body cavity (inside each seat ring). By learning how to properly use
the valve body vent fitting the technician can judge how effective the present maintenance program is and
whether or not additional maintenance is necessary.
Sealant injection fittings access directly to each seat ring. This enables the technician to top-up the
quantity of lubricant inside the valves sealant injection system on a periodic basis. Valve cleaner can also
be injected into these fittings to flush out the old grease in the valve and to clean critical seal faces on the
ball. Heavier sealants are also injected through the sealant injection fittings during an emergency when a
critical seal is required.
Ratcheting seats are unique to the Cameron welded body ball valve. A cog attached to the valve stem
reacts with teeth cut on each seat ring which rotates both seat rings each time the valve is cycled to the
closed position. After (24) twenty-four closings each seat ring has rotated 360 degrees. This feature is
an advantage to the technician. If an acceptable seal can not be achieved after cleaning and
relubricating the valve, rotate the valve a few times. This ensures the seat ring and ball face seal at new
positions. If a wire draw is present across the seal face, the cut on the seat ring and ball face would not
realign for (24) twenty-four more cycles. The ability to achieve a seal through the use of heavier sealants
is significantly increased if the technician can reduce the size of the leak path by 50% by simply cycling
the valve.
Fitting Identification
Chapter 13 Page 63
Cameron has a reputation for manufacturing a high quality valve. The welded body design means the valve
must be cut open in order to replace damaged seat rings and balls. This type of repair is very expensive and
the valve must be returned to the factory for repair. Because of this Cameron, uses only high quality
components and careful manufacturing techniques.
Page 64 Chapter 13
Be patient; the valve cleaner often takes time to clean seal faces thoroughly.
If the sealant fitting or buried inner check valve is plugged from old dried sealant, it may take some time for
the valve cleaner to soften the old material. If plugged, the gauge will climb quickly and will not drop off. If
this occurs, keep the gauge pressure under 8,000 PSI and come back every few hours and try to push a little
more cleaner into the sealant injection fitting. Many hand-held injection guns are capable of injection
pressures of up to 15,000 PSI. If too much pressure is applied, the high pressure may blow the slug of
sealant and the ball check out of the fitting and into the valve body. If this has occurred, as you attempt to
remove the grease gun from the fitting you may be exposed to full line pressure. To reduce the risk of this
occurring, install a Leak-Lock on the plugged sealant fitting so that if the ball check in the sealant fitting is lost,
you can stop line pressure from escaping with the ball check in the Leak-Lock. Leak-Locks are available for
both small (Part number D-LL#2) and giant buttonhead fittings (Part number D-LL#1) A special Cameron
adapter (Part number D-CAM-SO) is available which screws onto the Cameron small buttonhead with cap
fitting and adapts it to a giant buttonhead so you can use your regular grease gun coupler. This will keep line
pressure from escaping.
NEVER attempt to remove a sealant injection fitting from a valve which is under pressure.
The sealant channel accesses the seat ring area upstream of the seat insert. This means that the sealant
fitting accesses the pipeline upstream of the ball / seat sealing interface. Even if the valve is closed and the
valve body vented to atmosphere, there is still pressure under the sealant fitting if there is pressure in the
pipeline. Make sure there is no pressure in the pipeline upstream and downstream of the valve before
attempting to remove the sealant injection fitting.
DO NOT rely on the inner check valve located under the sealant fitting to hold back line pressure.
These small check valves become damaged easily and are seldom reliable.
Chapter 13 Page 65
REMEMBER to close the body vent fitting BEFORE cycling the valve.
If cleaning, re-lubricating and cycling the valve have not stopped the leakage, check that the valve stops are
clean of dirt, rust, paint or other foreign materials and that the valve is truly open or closed. It should not be
necessary to adjust the valve stop adjustment screws found on many gearboxes after the initial setup or when
the valve is first installed. When the technician is sure the valve has been cleaned, re-lubricated and the
valve stops clean, if leakage is still a problem it is then time to inject a heavier sealant.
Maintaining a Seal
Achieving and maintaining a reliable seal is often a question of confidence which is only acquired through
experience. When a problem leaking valve is found in the system, use this valve to practice your sealing
techniques.
A typical situation is one in which the downstream side of the valve is de-pressurized and full line pressure is
being held upstream of the closed valve. The valve has been cleaned and re-lubricated, still some leakage is
still being realized through the open body vent fitting. At this point a heavier sealant can be injected.
Page 66 Chapter 13
Cameron valves are trunnion-mounted or in other words the ball is in a fixed position and the spring loaded
seat rings are allowed to float. In this application, the upstream seat ring is being pushed hard against the
ball by line pressure. With the body vent open, the downstream seat ring is being pushed against the ball by
the force of the seat ring springs.
The lubricant / sealant must be displaced before the heavier sealant fills the sealant system. The same
calculations used for injecting valve cleaner are applicable (one (1 oz.) ounce per inch of valve size into each
seat ring plus riser pipe quantities). Concentrate sealing efforts on the upstream seat ring at first. Inject
sufficient quantities of sealant slowly so that the PTFE particles are distributed evenly. When the sealant
reaches the seat ring, open the body vent fitting so that the PTFE particles are drawn over the damaged seat
ring insert. Listen, as the leak diminishes stop pumping. The leak should decrease until it is a mere whisper.
ALWAYS notify fellow workers of the leak and flag the area where the product is being vented.
Where possible, a blind flange should be installed downstream of the valve to ensure no product escapes into
the section of pipeline being serviced.
More severely worn valves can be successfully sealed by using even heavier sealing compounds. These
compounds often contain increased quantities of PTFE in various sized particles. The object being to build a
small dam of PTFE particles which will stop the leakage. One of the consequences of using the extra heavy
and double extra heavy sealants is the risk of plugging the sealant injection fitting or buried inner check valve
with PTFE particles. The patented FLOW WOLF sealant injection fitting and in-line check valve have been
designed so they will not plug, even with these heavier sealing compounds. These fittings have to be
installed before the valves are pressurized. Heavier sealants should be displaced with a lighter sealant or
lubricant / sealant after the critical seal is no longer required to avoid plugging problems associated with the
old style fittings.
When piping is used to vent the body vent fitting or to equalize body pressure, it is important to be sure that
pressure can not enter the valve body through these sources if workers downstream are depending on this
Chapter 13 Page 67
valve to hold. It is important to be sure that all the small valves on the piping system DO NOT leak or
pressure could enter the valve body. On many designs the downstream seat is self relieving. This is a builtin safety feature so that the valve body will not rupture if over-pressurized (usually caused by the thermal
expansion of liquids trapped in the valve body). This can also present dangerous problems for workers
downstream of the leaking valve. If pressure is introduced into the body cavity, the springs holding the
downstream seat will lift off at approximately 200 PSI in excess of line pressure, sending the leakage
downstream. As long as the open body vent fitting can vent all the leakage into the body cavity, the
downstream seat should remain intact.
Valves which require sealant in order to achieve an acceptable seal must be topped-up each time a seal is
required. Once the valve has been cycled, the seal will be lost until sealant is re-injected and the seat testing
procedure is repeated.
Stem Lubrication
The stem seals on a Cameron valve are designed for many years of service with little or no maintenance.
The stem area is sealed top and bottom with rigid graphite / PTFE type seal rings. Only small quantities of
lubricant / sealant or sealant, if any, are required on a periodic basis.
Attach the gun onto the stem seal fitting and watch the injection gauge very closely. DO NOT EXCEED 2,000
or 3,000 PSI in the stem area. Usually (1 2) one or two strokes of a manual gun is all that is required. Stop
pumping and watch how slowly the gauge falls. If both upper and lower seals are holding, the gauge should
not drop at all. If the gauge drops slowly, give it another stroke of sealant and watch the results. If the gauge
continues to fall, look at the top of the stem to see if sealant is present. If sealant is escaping from the top of
the stem, tighten the cap screws that hold the top seal ring in place. If sealant continues to escape, the top
stem seal ring should be replaced during the next shut-down. If sealant is not present and the gauge
continues to fall, you may suspect the lower seal is damaged. If this is the case, slowly inject a heavier
sealing compound until the leak reaches acceptable limits.
ALWAYS consult the proper Cameron maintenance manual before attempting any mechanical
repairs.
Gearbox Maintenance
Many Cameron valves come equipped with manual gearboxes. Keep the gearbox filled with a high quality
waterproof lubricant such as Sealweld Eterna-Lube 1000. Replace damaged seals and O-rings as soon as
they are discovered to prevent water from entering the gearbox and causing corrosion.
Keep the gearbox lubricant topped-up by injecting through the Zerk nipples located on the top, side or back of
the gearbox. Be careful not to over-fill the gearbox or the weather seals can be blown out.
If high torque is twisting the gearbox and seals are failing to hold the gearbox oil or lubricant, Sealweld D1014 lubricant / sealant has been used successfully as a year-round gearbox lubricant / sealant.
Manual Gearbox
Page 68 Chapter 13
Bettis Gas / Hydraulic Operator, Two Way Manual, Shown In Power Gas Mode
Switch To Manual position to lock out remote switching signal before proceeding with local
manual operation
With Power Gas:
Press upper left relay handle and hold to close line valve
Press upper right relay handle and hold to open line valve
Turn lower left valve handle and operate hand-pump to close line valve. Return valve
handle to vertical
Turn lower right valve handle and operate hand-pump to close line valve. Return valve
handle to vertical
Chapter 13 Page 69
To Disarm Operator:
Switch to Auto position and ensure lower valves handles vertical and gas supply valve
open to resume unattended automatic operation
In Summary
Whenever servicing valves, rock the valve off its full open or full closed position (only when safe to do so) to
keep the valve from being seized in one position. Rotate the valve fully closed at least once a year to move
the seat rings to a new position.
The pressure MUST BE equalized on both sides of large diameter valves before they can be cycled.
NEVER remove a sealant injection fitting or stem seal fitting from a pressurized system. The sealant injection
fittings enter upstream of the seat rings. With the valve closed and the valve body de-pressurized, there is
still full line pressure immediately under the check valve in the sealant injection fitting. DO NOT rely on the
buried inner check valve to hold if the sealant injection fitting becomes damaged. Wait for the pipeline system
to become de-pressurized before attempting to replace fittings. Beware of trapped pressure inside valve
bodies, valve stems and sealant systems especially riser pipe assemblies. Remember, threads do not always
weep or leak like they should in the presence of sealants.
Page 70 Chapter 13
If valve leakage continues to be a problem, check the valve stops to ensure that the valve is fully open or
closed. Occasionally dirt, grime and rust can build-up on valve stops and keep them from closing or opening
fully. Cameron normally provides plugs on the riser assembly which can be removed to visually examine
the stops for build-up. If the riser is filled with oil or anti-freeze, this will need to be caught as the plug is
removed.
Learn the capacities for topping-up and completely replacing the lubricant / sealant in the valves sealant
system, including riser assemblies. DO NOT OVER-LUBRICATE. If topping-up does not accomplish the
desired results, it may be time to clean the valve or switch to heavier sealant.
Cameron uses a unique sealant injection fitting which is uncommon to industry standards. These small
capped fittings should be replaced with Sealweld fitting (Part number F-SC1/4BH) capped sealant injection
fitting with giant buttonhead or a FLOW WOLF (Part number F-FW1/2BH) with a reducing adapter to 1/4"
NPT the next time the system is down and all pressure removed. When ordering new valves from
Cameron, insist on Sealweld FLOW WOLF fitting (Part number F-FW1/2BH) and in-line check valve be
installed at the factory.
Older Cameron valves have 1/4" NPT plugs screwed into the valve body where the sealant fittings should
be. There is usually a buried inner check valve located under the plug. DO NOT remove the plug if there is
pressure inner check or product in the pipeline. Wait until the pressure can be taken off the pipeline and
remove the plug carefully. Install a new fitting instead of the 1/4" plug (Part number F-FW1/4BH-SS). Begin
by injecting valve cleaner very slowly. Quite often the inner check is plugged and it may take some time to
open a passage to the seat ring.
ALWAYS consult the appropriate Cameron manual for advice on repair or parts information.
Copies of most manuals are available from Sealweld Services ValvePro Reference Library at no
charge.
Chapter 13 Page 71
Neglect is the principal cause of valve leakage. Once a valve is put into service a maintenance program
should be started. Remember to keep topping-up the valves at regular intervals and inject valve cleaner
whenever the valve will not seal or becomes hard to turn. A small amount of routine maintenance can keep
ball valves operating reliably for years and even decades.
Page 72 Chapter 13
Chapter 14
NOTICE that there are no springs associated with the seat rings. In this design the seat rings are in
a fixed position, and the ball is allowed to float.
Chapter 14 Page 73
Line Pressure Pushes The Ball Onto The Downstream Seat Ring
Page 74 Chapter 14
It is possible to lock-up the valve after venting the body cavity. This is caused by the line pressure pushing
both seat rings hard against the ball. This is a more common problem on high-pressure or large diameter
valves. To unlock the seat rings, equalize the pressure in the body cavity by introducing line pressure into the
body cavity through an auxiliary inlet. It is possible to jack the seats off the ball by injecting grease into the
body cavity. It will take a substantial quantity because the hole in the ball must be filled as well.
NOTE: Be very careful not to over-pressure the body cavity as it could rupture the body casting.
Chapter 14 Page 75
ii)
Pressure relief valve - at or near the top (stem end) of the valve. In natural gas service the relief
valve may be replaced with a threaded pipe plug. Replace only with written authorization from your
Engineering Department and only if safe to do so.
Page 76 Chapter 14
Inject a small quantity of synthetic valve lubricant sealant such as Sealweld Total-Lube # 911 or Sealweld
Equa-Lube Eighty into the seat sealant injection fittings with a high-pressure sealant injection pump.
Chapter 14 Page 77
Notify your fellow workers that venting is about to begin. Wait for all workers get to a safe area
with appropriate safety equipment and to indicate proceed by showing the thumbs up hand sign.
Page 78 Chapter 14
The valve stops may be out of alignment. Inspect the valve stops and make sure the valve is fully closed.
Misalignment by more than two or three (2 3) degrees may expose the bore hole through the ball to the
pipeline pressure resulting in continuous leakage.
Old sealant and other pipeline debris may have built-up contaminants in the seal face area.
This build-up could prevent proper contact of the seal face between the ball and seat ring, resulting in
seat leakage.
The ball, seat ring or seal O-ring (elastomer) may be scratched, scared or otherwise physically damaged.
Chapter 14 Page 79
overnight if possible. Cycle the valve at least three (3x) times to distribute the cleaner around the seal face
area. Top-up repeatedly to push the softened contaminants out of the tiny sealant passages and into the
pipeline.
After soaking with valve cleaner, open the body blow down fitting and observe if the leak as diminished or
increased. If the leak was caused by a build-up of varnish, the leak may be completely eliminated by
cleaning. If the leak was caused by scars to the seating surfaces, the leak rate may increase as a result of
cleaning.
Replace the valve cleaner by injecting fresh lubricant / sealant such as Sealweld Total-Lube # 911. Inject
the same quantity of sealant as valve cleaner (one (1 oz.) ounce per inch of valve size per seat ring plus riser
pipe quantities). Cycle the valve at least (3x) three times to distribute the sealant around the seal face area.
Inject very slowly, do not exceed 6,000 PSI injection pressure. It will take more time for the viscous sealant
to fill the sealant passages.
If the damage is due to very small scars or seal face O-ring damage, Total-Lube # 911 will provide an
effective seal for small scars to .010 and O-ring damage.
If the leak appears to stop, then kicks and becomes a larger leak or sputters, it may be necessary to inject a
heavier sealant such as Sealweld # 5050 Ball Valve Sealant. Inject the same quantity of sealant as you
injected Sealweld Total-Lube # 911 (one ounce per inch (1 oz. / inch) of valve size per seat ring plus riser
pipe quantities). # 5050 Sealant will seal scars up to .030 through the use of specially processed PTFE
flakes.
Sealweld # 5050 is also available in XH (Extra Heavy Grade) and XXH (Double Extra Heavy Grade) for
extreme seat scarring damage.
It is always recommended to start with a light grade sealant and gradually work up to the heavier sealants.
Page 80 Chapter 14
The most common design features (2) two O-ring seals (see illustration). There may be a Grove vent plug or
a vented plug (threaded plug with a slot cut along the threads) located between the (2) two O-rings. The plug
may be unscrewed (1 2) one or two turns, if gas escapes this would indicate that the lower stem seal is
worn or damaged. Tighten the plug back in place to energize the upper O-ring.
Notice if gas is escaping out through the upper O-ring seal and into the gear-set or actuator. This
would indicate that both O-rings are worn and / or damaged.
It may be possible to stop this type of stem leak by removing the vented plug and installing a sealant injection
fitting. To accomplish this safely, the valve should be cycled to the closed position and the body cavity
vented to (0 PSI) zero. It may be possible to remove the vented plug in the stem if a very small leak is
present.
Chapter 14 Page 81
Pick up your hand tools, sealant pump and adapters, secure in tool box.
Test for gas leakage to atmosphere from valves, fittings and flanges.
If the valve or valve yard is normally chained and locked, replace these items to their original position. If
padlocks are used, spray the padlock with penetrating oil and open / close repeatedly to ensure easy
operation.
Store and retrieve all preventative valve maintenance procedures in ValvePro, a Series of
Software Solutions from Sealweld.
Report Writing
Before leaving the valve site prepare your written report including the valve detail, work performed and results
achieved. Refer to the samples for Service Report worksheets. Write down all results clearly so they can be
read by all personnel.
Use the areas of the report marked "Comments" to detail any additional work to be performed. Use extra
pages as required.
Keep copies of the reports in a binder that can be taken to the field by the valve technician during the next
maintenance interval or during a pipeline emergency.
For additional information including spare parts lists and repair procedures consult the Grove Series B-5,
B-4B and B-4C Ball Valve Installation & Maintenance Manual Bulletin No. B-IRM 1/94 (2.5M)
Page 82 Chapter 14
Chapter 15
Chapter 15 Page 83
Should stem leaks develop after the packing gland has been fully compressed it is possible to have
professional leak sealers come in and effect repairs. It is done simply by hot tapping into the packing
chamber and injecting Sealweld Pak-King compounds.
Page 84 Chapter 15
In order to get this style of gate valve to seal properly, it may be necessary to operate the valve several times.
Use of heavy sealing compound is generally NOT recommended due to the large quantities which must be
injected. The seat design does not have provision for seat sealant injection; however, in an emergency, filling
the body cavity with an insoluble seat sealant may achieve the desired results.
Chapter 15 Page 85
The smaller capped fitting located near the bottom of the valve body is used for the injection of a body filler
grease. As with other wellhead gate valves, the body filler grease will lower operating torque, prevent
corrosion and prevent hydrates from collecting in the valve body.
Stem packing consists of a series of chevron packing rings in the bonnet assembly. The packing and stem
bearing can be replaced with the valve under pressure by following the instructions as detailed in the owners
manual. The bleeder plug can be removed to check if the stem back-seating was successful.
The stem bearing should be lubricated periodically with a high quality water proof lubricant such as
Sealweld Eterna-Lube 1000.
As with any valve, the valve should be cycled at least once or twice a year to keeping from seizing in one
position.
Page 86 Chapter 15
ALWAYS consult the owners manual before attempting any repair procedure.
The body cavity should be drained periodically to get rid of contaminants which may have collected in the
bottom of the valve. Many pipeline valves are designed with seat seals that will allow for body draining with
the line under pressure and the valve in the open or closed position. Block and Bleed is described as closing
the valve and draining the body cavity. Double Block and Bleed is described as being able to drain the body
cavity with the valve in the full open or full closed position. If the valve does not operate properly, it may be as
a result of contaminants which have collected in the bottom of the valve.
Seat sealing systems vary from one manufacturer to another. In principle they are very similar to a typical
pipeline ball valve. The sealant does not generally travel the circumference of the seat ring like most ball
valves. Rather, it enters through only (1 2) one or two small holes near the seal face area. It is essential to
operate the valve several times to ensure complete coverage of the valve cleaner or lubricant / sealant being
injected. Quantities of lubricant / sealant required to fill the seat sealant system are 25% to 50% less than
similarly sized ball valves. Use approximately 0.50 ounces to 0.75 ounces per inch of valve size into each
seat ring. A ten (10") inch gate valve will require five to seven (5 7 ozs.) ounces to completely fill the seat
sealant system. Quantities required to top-up the seat sealant system will be considerably less as well.
Valves with double block and bleed provisions should have their seat seals tested as part of maintenance
routines.
Chapter 15 Page 87
ALWAYS cycle the valve several times before switching to heavier sealants.
Page 88 Chapter 15
Chapter 15 Page 89
Page 90 Chapter 15
Chapter 16
In Conclusion
Valves are used to re-direct product flow and for basic on-off service. It is the valve maintenance technicians
responsibility to keep these valves in good operating condition and sealing properly.
The products, techniques and procedures detailed in this program have been developed over many years of
pipeline experience. Always consult the proper manufacturers operating and maintenance manual before
starting any repair procedure. Sealweld has a large library of such manuals, many dating back (20 - 30)
twenty or thirty years. Photocopies are available on request.
Keep copies of all the owners manuals on the many valves at your facility readily available for easy
reference. Make a record of your maintenance activities and keep it up to date. Make notations on any
alterations you have made to the original configuration (changes in stem packings, the removal of inner check
valves, etc.). Be sure to include comments on any special procedures required to get the valve to seal, this
could prove invaluable in an emergency.
We trust you will find the procedures detailed in this program useful when maintaining the valves at your
facility. Should you have any question regarding any of these procedures, or if you know of any successful
procedures you would like to share, please contact us at:
T2C 2B3
TOLL FREE
1-800-661-8465
PHONE
1-403-236-0043
FAX
1-403-236-5487
info@sealweld.com
URL
http://www.sealweld.com
In Conclusion
Chapter 16 Page 91
77041
TOLL FREE
1-800-624-4301
PHONE
1-713-466-7373
FAX
1-713-466-7778
info@sealweld.com
URL
http://www.sealweld.com
1-800-661-8465
PHONE
1-403-236-0043
FAX
1-403-236-5487
support@valvepro.com
URL
http://www.valvepro.com
After Words
The HANDBOOK of Valve Lubrication and Maintenance is written from the maintenance departments point of
view and in the language of service people responsible for safe and efficient operation of lubricated plug, ball
and gate valves.
The information in this handbook is intended as a guide only. Always consult the valve manufacturers
recommended maintenance procedures. No warranty is written or implied.
Use of product and / or company names is for reference only.
Sealweld, ValvePro, ACTIV-8, SuperGun and FLOW WOLF are registered trademarks and / or
patents of Sealweld Corporation.
Glossary of Valve Terms - Copyright Grove Valve & Regulator Company, 1980, 1993.
Cameron, W-K-M, and McEvoy are registered trademarks of the Cooper Cameron Corporation.
Microsoft is a registered trademark and Windows and Word 97 are trademarks of Microsoft Corporation.
Page 92 Chapter 16
In Conclusion