BONGKOT FIELD DEVELOPMENT PROJECT

PHASE 4A
CENTRAL FACILITIES
PPS, BRIDGES, FLARE TOWER
CAMERON B4D INSTRUCTION MANUAL
FOR
PNEUMATIC ON/OFF BALL VALVES, CLASS E
Grove Facility
(CAM Ref.: 1487592)
Return Status by HHI
The Document is :
Reviewed without Comments and
Proceed with Fabrication. Submit one
revision up and next status document
within 2 weeks unless further
modification are made
Code A
Reviewed with Comments and Proceed
with Fabrication. Submit one revision
up and next status document within 2
weeks after Incorporation of comment.
Code B
Reviewed with Comments and Proceed
with Fabrication. Resubmit in next
revision and same status document
within 2 weeks after incorporation of
comment.
Code C
Reviewed with Comments and Hold
Fabrication. Resubmit in next revision
and same status document within 2
weeks after incorporation of comment.
Code D
Signed by HHI :
Date :


1 Jun 08, 2010 LS Approved for Construction SAB AD
0 Apr 09, 2010 LS Issued for Comments SAB AD
REV DATE BY DESCRIPTION
CHECK APPR. SPEC. RESP.

ENGINEER APROVAL COMPANY APPROVAL
STATUS CODE : A = Issued for comments - B = Issued for approval - C = Approved for Construction
TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN
WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER
PTT Exploration and Production
BONGKOT FIELD DEVELOPMENT PROJECT - Phase 4A
THAI-4A-GEN-P02A-15-01-0011
REVISION
1
STATUS
C
CLASS
1
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2
11 JUN 2010
SIC
PTT Exploration and Production
CAMERON B4D INSTRUCTION MANUAL
Document Number
THAI-4A-GEN-P02A-15-01-0011
Revision : 1 Status : C
Ext. Interface : MWS WPS1 QPS PTT EXP. LlNE Others
Rev. Date : Jun 08, 2010
Vendor document number: 201003/172 REV.01
Page : 2 / 18
BONGKOT Field Development Project - Phase 4A
Revision History
Revision Date Description Remarks
0 Apr 09, 2010 Issued for Comments
1 Jun 08, 2010 Approved for Construction


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PTT Exploration and Production
CAMERON B4D INSTRUCTION MANUAL
Document Number
THAI-4A-GEN-P02A-15-01-0011
Revision : 1 Status : C
Ext. Interface : MWS WPS1 QPS PTT EXP. LlNE Others
Rev. Date : Jun 08, 2010
Vendor document number: 201003/172 REV.01
Page : 3 / 18
BONGKOT Field Development Project - Phase 4A
TABLE OF CONTENT
Page No.
CAMERON B4D INSTRUCTION MANUAL 4~18
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B4D
BALL VALVES
FIRE SAFE DESIGN
INSTRUCTION
& MAINTENANCE
MANUAL
doc. no. 201003/172
CUSTOMER: HYUNDAI HEAVY INDUSTRIES CO LTD
P. ORDER: QE518A2EDV
OUR FILE: 1487592
ITEM: 1-2-3-4-15-16-20-21-22-24-28
REVISIONS
NO. DATE PREP. APPR. DESCRIPTION
01 30/03/2010
F.D.
E.B.
FIRST ISSUE
This document and its content are property of Cameron - Grove Facility Neither this document nor its contents may be reproduced,
transferred or used in any other way without preliminary written permission
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SCOPE
The scope of this manual is to supply the users with instructions about installation,
operating, maintenance and repair operations, that may be carried out on the CAMERON
Grove Facility side entry ball valves.
Any servicing not covered by these instructions must be made in an authorised service
station, after preliminary approval has been given by CAMERON Grove Facility
SAFETY INFORMATION
Valves shall be operated and maintained strictly in accordance with these
procedures. Operation or maintenance outside these procedures constitutes abuse
of the product and voids all warranty and claims.
When special operation is required, a formal written request to the company must
be made for approval to operate in this manner if warranty and product liability is to
be maintained.
The personnel working on the installation shall always use all safety precautions set forth
by the law and any regulations required by the employer.
The maintenance personnel doing the repairs should be well trained, and familiar with all
of the information contained in this manual.
The valves shall be appropriately used for the purpose they are built for.
Transport, unpacking, lifting, connections to the different types of systems (electric,
pneumatic, hydraulic systems, etc.) shall be made by expert and qualified personnel.
Should any difficulties or abnormalities arise which cannot be solved by the technician, it is
necessary to contact CAMERON Grove Facility.
WARNING
CAMERON Grove Facility DOES NOT ASSUME ANY RESPONSIBILITIES FOR ANY
DAMAGES DERIVING FROM ANY INEXPERT OR IMPRUDENT OPERATIONS OR
FOR OPERATIONS CARRIED OUT BY AN INEXPERT PERSONNEL, OR WHICH DO
NO COMPLY WITH THIS MANUAL.
Actions not to be carried out
CAMERON Grove Facility valves comply with all safety regulations and requirements,
but imprudence and inexperience always cause:
danger for human safety
danger for the users valuables
danger for the work quality and efficiency
Do not carry out any actions when the results are uncertain. This includes lifting, repairing,
or removing and reapplying pressure.
Do not remove or tamper with protections or safety devices of any types.
Do not use the valve before the efficiency of all safety devices has been restored.
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INSTALLATION INSTRUCTIONS
The Ball valves are packed in wooden cases in accordance with CAMERON Grove
Facility specification.
Note: Sometimes the valves are shipped loose on pallets.
In this case, clearly identify the valve through its data plate, check its weight with the
packing list or relevant documents and just put it on a plane horizontal surface, using
suitable handling equipment.
Before handling the case, read the packing list carefully to clearly identify the valve
and check its weight. The packing list is included with the shipping documents and a
further copy is contained in a metal plate fixed outside the case.
Handling equipment must be provided which is appropriate for total weight of
package.
Unload the case and put it on a plane horizontal surface. The lifting points and
methods are clearly indicated on the case itself.
Take away the bonnet of the case, the polyethylene sheet (provided for seaworthy
packing only) and the joists nailed to the side walls.
It is now possible to take out the valve from the case.
On valves of large dimensions and heavy weights, lifting lugs or eyes are provided for
sling .
In case of small size, light valves, use the line flange holes if the valve has flanged
ends.
Roll a rope around the ends to avoid over turning if the valve has butt welding ends.
Do not use eventual lifting lugs or eyes provided on the gear or actuator.
Pay particular attention that slings do not damage an eventual gear or actuator.
Lift the valve and put it on a plane, horizontal surface.
In case the valve is not provided with supports, take care to avoid damaging drain
valve/drain connection by using wooden saddles or other suitable equipment.
Take away the protective plastic or wooden cups and remove the anti moisture bags
of Silicagel from inside the valve conduit.
During installation the valve must be fully open.
Should the valve be closed, the exposed face of the ball must be protected with
grease or other anti-adhesive product.
The CAMERON Grove Facility ball valves are bi-directional and may be installed
with either end facing up stream.
The valve should be installed in such a way as to facilitate maintenance and
actuating operations.
When the valve has butt welding ends, welding on the line must be performed using
the proper welding procedure. After welding, clean and check the weld bead and
repair as required.
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When installing allow for possible deformations caused by the expansion of the line.
The valve must not support the line.
Avoid any strain in the valve body.
OPERATING INSTRUCTIONS
To open the valve, turn the stem 90 anticlockwise until it stops.
To close the valve turn the stem 90 clockwise until it stops.
The turning can be carried out by means of a lever, a manual operator or motor
operator.
The lever is fixed on the valve stem in such a way that it is parallel to the ball conduit,
so it is possible to have a clear indication of the valves position.
When the lever is parallel to the pipeline the valve is fully open.
When the lever is perpendicular to the pipeline the valve is fully closed.
On the top of the manual operator there is a position indicator firmly secured to the
valve stem with the indication of the fully open and fully closed position.
If the valve is motor actuated, read carefully the specific actuator instructions before
operating the valve.
In any event - whether lever, manual operator or motor operator, - the end stops have
been shop set-up to assure the correct 90 rotation from fully open to fully closed
position, so do not change their adjustment.
WARNING
Standard CAMERON Grove Facility ball valves are of the on/off type and
consequently the ball must always be either in the fully open or fully closed
position.
Standard CAMERON Grove Facility ball valves must not be used as flow rate
control system.
Valves, during their service, may accumulate water, scale, deposits and other foreign
matters.
These materials may damage the valve in the following ways:
Ice may form at low-temperature inside the valve and hinder its normal
operation.
Foreign matters may prevent the valve from fully closing up and the ensuing
throttling may damage the ball or the seal o-rings.
Foreign matters may get caught between the ball and the seat and damage
their surfaces.
A drainage schedule is the best way to prevent damages caused by foreign matters.
Should it be impossible to implement a regular drainage schedule, it is recommended
that drainage would be carried out in the following cases:
Whenever the valve does not close
Before the arrival of the cold season
After washing the line
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After a hydraulic test
For drainage procedure see the relevant paragraphs in the " Maintenance
Instructions " section.
The CAMERON Grove Facility ball valves have been designed and tested in such a
way that they do not require the use of sealants during their normal service operation.
Anyway the implementation of a regular lubrication program extends the service life
of the valve before carrying out maintenance operations and improves its
performances.
It is recommended to schedule a regular lubrication program based on the frequency
of operations and the severity of the service .
Should it be impossible to implement a regular lubrication schedule, it is
recommended that lubrication would be carried out in the following cases:
- Before operating the valve if the valve has been left in its position, either fully open
or closed, for long periods without moving it.
- As soon as an increase of stem torque is noticed.
For lubricant grease injection procedure, if present, see the relevant paragraphs
LUBRICATION in the final note section.
MAINTENANCE INSTRUCTIONS
These instructions cover the maintenance and repair operations that may be carried
out on the CAMERON Grove Facility ball valves.
Valves referenced to are those with the operator mounted directly on the adapter
plate without stem extension.
Any servicing not covered by these instructions must be made in an authorised
service station after preliminary approval has been given by CAMERON Grove
Facility.
These instructions are applicable to valves covered by CAMERON Grove Facility
general drawings and herewith attached.
Drainage procedure
Close the valve completely.
Open the bleed valve if present or slowly unscrew the grease fitting (189) whichever
are provided.
Slowly open the drain connection (39).
WARNING
Open the drain valve slowly until the pressure in the body cavity has been
discharged.
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Remove the drain connection (39) paying attention not to damage its o-rings (94
and 94b).
Mount again the drain connection (39) with its o-rings (94 and 94b).
GENERAL MAINTENANCE WITH PRESSURE ON THE LINE
These instructions cover the maintenance operations that can be carried out on the valve
with line under pressure. These maintenance operations are very useful in an emergency,
for repairs without stopping the line. Furthermore these partial maintenance operations
allow the general maintenance to be postponed until the planned time.
Replacement of the upper stem sealing
In case of leakage through the stem, it is possible to substitute the upper stem sealing as
per the following instructions:
With the valve in the fully closed position, drain the valve as per the paragraph
Drain procedure
By opening the bleed valve if present or slowly unscrewing the grease fitting (189),
whichever is provided, vent the eventual residual pressure in the stem area.
WARNING
Check carefully that seats are perfectly sealing, it means that after some times the
flow through the drain valve stops completely. Otherwise it is not possible to carry
out the following operations.
WRENCH OR OPERATOR DISASSEMBLY
If the valve is wrench operated
1) By untightening the screw in the side, unlock the wrench unit and remove it.
2) Remove the retaining ring on the stem and slip the stop collar out.
3) Undo the capscrews (132) and slip the bearing housing (165) out of the stem (5).
4) Remove the gland bushing from the stem (5). Now the fire safe seal (186) is free.
Remove and substitute it with a new one.
If the valve is gear or actuator operated
1) Following the relevant instructions, remove the manual or motor actuator unit by
lifting it up vertically.
2) Remove the stem extension and the key if present.
3) If present, remove the retaining ring on the stem and the stop collar.
4) Undo the capscrews (132) and remove the adapter plate (160), being careful not to
damage the relevant pins.
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5) Remove the gland bushing (10) from the stem (5). Now fire safe seal (186) is free.
Remove and substitute it with a new one.
WARNING
OPERATOR IS KEYED TO STEM (5) AND HAS TO BE LIFTED STRAIGHT UP UNTIL STEM IS
CLEAR . BE CAREFUL NOT TO DAMAGE OR LOSE KEY.
GENERAL MAINTENANCE WITHOUT PRESSURE ON THE LINE
These instructions cover the maintenance and repair operations that may be carried out on
the valve, after depressurizing the line. Therefore, these maintenance operations should
be included on a general maintenance plan, that foresees the shutdown of the line.
At this stage, the valve will be completely disassembled to proceed with the clearing of all
parts, the lubrication where required and the eventual minor repairs of the damaged parts.
The valve will then be reassembled.
Prior to starting any overhaul of the valves it is essential that spares are available: as a
minimum one set of seals and bearings per valve.
WARNING
Before removing parts, paint or stamp witness marks for correct reassembly
procedure.
DISASSEMBLY PROCEDURE
1) Release the line pressure both upstream and downstream.
2) Operate the valve to the half position of the ball and check if a residual pressure is
still remaining by opening the drain connection (39). Then the same valve can be
removed for cleaning paying attention not to damage its o-rings (94 and 94b).
3) Operate the valve to the fully open position, then open and remove the bleed valve or
the grease fitting (189),whichever is provided, and the relief connection if present.
4) Remove the valve from the line.
WARNING
BEFORE REMOVING PARTS PAINT OR STAMP WITNESS MARKS FOR THE
CORRECT REASSEMBLY PROCEDURE.
WRENCH OR OPERATOR DISASSEMBLY
If the valve is wrench operated:
a) By untightening the screw in the side, unlock the wrench unit and remove it.
b) Remove the retaining ring on the stem and slip the stop collar out.
c) Undo the capscrews (132) and slip the bearing housing (165) out of the stem (5).
If the valve is actuated or gear operated:
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a) Remove the connections which secure the operator to the valve adapter plate and
lift vertically the operator (for major information, please refer to the actuator
manual).
CAUTION
The actuator is coupled to the valve by means of the stem key.
Be careful not to damage it when performing the operation.
b) Remove the stem key if present.
c) If present, remove the retaining ring on the stem and slip the stop collar out.
d) Undo the capscrews (132) and remove the adapter plate (160), being careful not to
damage the relevant pins.
5) Undo the top cover capscrews (131) and pull the top cover (9) out from the stem
paying attention not to damage the soft seals.
6) Remove the gland bushing (10) and the stem f.s. seal (186).
7) Remove the stem o.ring (134) with its back up rings (164) if present, and the top
cover O-ring (136) with its back up rings (136a) if present, from the respective
grooves on the top cover.
8) Remove the top cover fire safe seal (122) from its housing on the body.
9) Remove the upper thrust washer (150), the stem thrust ring (416) and stem lock ring
(65). Push with care the stem (5) paying attention not to damage the drive pin (153)
remove the stem bearing (168) from he stem (5).
10) Stand the valve on one end and be careful not to damage the sealing surface of the
flange.
11) Undo the lower trunnion capscrews (180) and pull the lower trunnion (169) out of the
valve body, paying attention not to damage the soft seals.
12) Remove the trunnion O-ring (170) with its back up rings (170a) if present, from the
trunnion groove and the lower trunnion fire safe seal (80a) from its housing on the
body.
WARNING
The antistatic device (197), if provided, remains in its housing and shall not be
removed
13) Remove the body studs nuts (32) and loosen the body stud (31).
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14) Lift the upper closure (2) off the body (1), paying attention not to damage the soft
sealing.
15) Remove the closure O-ring (8 or 8a) with its back up rings (103) if present, from the
groove on the closure and the closure fire safe seal (121) from its recess.
16) Pull the integral seat (6e) out of the closure, paying attention not to damage the soft
sealing.
17) Slip the seat gasket O-ring (135) with its back up rings (190) if present, out of the
seat ring, and remove the seat gasket (305) from its recess.
18) Remove the spring washer (142) from its housing on the closure.
19) Remove the ball (4) from the body cavity.
20) Pull the trunnion bearing (20) from the bottom of the ball.
21) Turn the valve and repeat the operation for the other closure.
WARNING
Before proceeding with valve reassembly, please refer to para CLEANING &
INSPECTION final note section.
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RE-ASSEMBLY PROCEDURE
Assuming that all components have been visually inspected and accepted by a competent
person, the reassembly of the valve may proceed.
To ensure that the valve performs satisfactorily in service, it is essential it is assembled
with care and attention to details. Particular care must be paid that all reference marks are
properly lined up during the reassembly.
During the reassembly of the valve, take care when rigging the heavy weights involved in
some components.
Use wire slings only when lifting via an eyebolt and hook, otherwise use nylon slings.
1) Place one closure (2) on a clean, solid surface so it will hold weight of assembled
valve securely on port face. Attention should be given to the sealing surface.
2) Replace the body O-ring (8 or 8a) with its back up rings (103) if present, on its groove
of the closure.
3) Replace the closure fire safe seals (121) over shoulders of both parts of the body.
4) Replace the seat springs (142) in both the closure.
5) Replace the seat gasket O-ring (135) with its back up rings (190) if present, on its
groove and the seat gasket (305) into its recess of both integral seats (6e).
6) Press the integral seats (6e) assembled into the closure recess.
7) Lift the body (1) into position over the closure and carefully lower it over the closure,
paying attention not to damage the soft seals. Replace and tighten two far from each
other body stud (31) and body stud nuts (32).
8) Place the trunnion (20) bearing into the lower ball bearing.
9) Position the ball (4) over the body cavity in fully closed position and carefully lower it
into body.
10) Reassemble the second closure as the first one.
11) Lift the second closure (2) over the body and lower it on its proper site. Replace and
tighten two far from each other body stud nuts (32).
12) Replace the lower trunnion fire safe seal (80a) on its housing of the body and the
trunnion O-ring (170) with its back up rings (170a) if present, on its groove of the
trunnion (169).
13) Replace the trunnion (169) into the body fitting the lower ball bearing and secure it by
the lower trunnion capscrews (180).
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14) Replace the drain connection (39) with its o-rings (94 and 94b) on the lower
trunnion.
15) Turn the valve assembly upright so that the stem is in vertical position.
16) Replace the thrust washer over shoulder of the stem with Teflon surface against
stem shoulder.
17) Fit the stem bearing (168) into the stem head.
18) Replace the two drive pins (153) in their holes on the top of the ball.
19) Position the stem (5) over the body recess and carefully lower it into the body, so the
drive pins (153) on the top of the ball fit on the stem holes. Replace the stem lock
ring (65) and the stem thrust ring (416) and the upper thrust washer (150).
20) Replace the top cover O-ring (136) with its back up ring (136a) if present, and the top
cover fire safe seal (122) in the top cover (9) recesses.
21) Replace the stem O-ring (134) with its back up rings (164) if present, on the internal
grooves of the top cover (9).
22) Replace the top cover over the body recess with their holes aligned with the
threaded holes in the body.
23) Insert the top cover capscrews (131) into their threaded holes of the body and tighten
them evenly.
24) Replace the stem fire safe seal (186) on its recess of the top cover (9).
25) Fit the gland bushing (10) into the stem, over the stem fire safe seal (186).
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WRENCH OR OPERATOR REASSEMBLY
If the valve is wrench operated:
a) Replace the bearing housing (165) on the stem and secure it with the capscrews
(132).
b) Screw the remaining body stud nuts (32) and tighten them evenly.
c) Insert the stop collar and lock it replacing the retaining ring on the stem.
d) Replace the wrench unit and tighten its locking screw in the side.
e) Replace the grease fitting (189), whichever is provided.
f) Carry out any complete cycles from fully closed to fully open position in order to
check the manoeuvrability of the valve and then replace it on line.
If the valve is actuated or gear operated:
a) Replace the adapter plate (160) on the stem.
b) Insert the relevant pins and secure the adapter plate (160) with the capscrews (132)
tightening them evenly.
c) Screw the remaining body stud nuts (32) and tighten them evenly.
d) Replace the key and the stem extension if present.
e) Following the relevant instructions, replace the actuator on the valve. Pay attention
not to damage the stem key.
f) Replace the grease fitting (189), whichever is provided.
g) Replace the actuator on the valve. Pay attention not to damage the stem key.
h) Check the alignment of the actuator by cycling from fully closed to fully open position.
If the stem does not turn freely, remove the actuator and check the alignment of the
stem. If the valve operates freely, finish the mounting of the actuator.
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FINAL NOTE
Cleaning & Inspection
After the complete disassembly, all components of the valve should be cleaned, in order to
remove any debris or corrosive products.
For a complete cleaning procedure, carry out the following operations:
Remove any foreign or corrosive products formed within the body. Compressed air
and different grades of sandpaper can be used.
CAUTION
Abrasive cleaning should never be used, especially on sealing area. If water jetting is
used, dry as far as possible with compressed air.
Clean all metallic components with a soft brass wool.
Clean sealing surfaces with a soft cloth saturated with a solvent.
If present, clean the grease channels as far as possible.
If present, clean the grease injection fittings and the relief valve (154) on the body
Clean the sealing rings and the gaskets with a soft cloth, if necessary, wash them
with suds and rinse them with clean water.
After cleaning, all valve components should be inspected for damages.
If any damage is found, proceed with the repair where possible, or with substitution of the
parts.
For a complete inspection procedure, the following operations shall be carried out:
Check the metallic parts for damages (dents, scorings, etc.) along the sealing
surfaces and on moving surfaces. Particular attention should be paid to surface
nicks and corner damage.
Make sure that the sealing rings and gaskets are not slashed, extruded and/or
otherwise damaged.
Check the surfaces of the bearings, the thrust washers, the spacers, the gland
bushing and the seat components.
Inspect all spares that are going to be used to ensure damage has not occurred in
storage or transportation.
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Minor repairs
If any damage is found, the minor repairs should be carried out by competent persons,
otherwise, contact CAMERON Grove Facility.
The minor repairs, that may be carried out at site by maintenance personnel, shall be in
accordance with the following points:
Rectify by normal good engineering practice the damage on metallic surfaces.
Remove by using mild abrasive on surface nicks, specially on ball and stem.
Remove by using mild abrasive or with a bearing scraper all corner damages.
Replace all faulty parts and components.
SPARE PARTS
The type and the quality of spare parts will be defined every time, since they are
contractual matter.
Normally the spare parts will be defined according to the Project and the delivery time,
however, the following list indicates the parts which Grove suggests for the maintenance
operations.
x Integral seat (6e)
x Closure o-ring (8 or 8a)
x Drain valve (39)
x Drain valve o-ring (94 and 94b)
x Lower trunnion f.s. seal (80a)
x Closure f.s. seal (121)
x Top cover f.s, seal (122)
x Stem O-rings (134)
x Seat gasket O-ring (135)
x Top cover O-ring (136)
x Seat spring (142)
x Trunnion O-ring (170)
x Stem f.s. packing (186)
x Trunnion and stem bearings
x Upper thrust washer
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