VALVE BODY ASSEMBLY

General operation & Instructions

Assembly Instructions
Preventive Maintenance & Lubrication
Troubleshooting & Routine Functional Testing

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WOM

GATE VALVE
GENERAL OPERATION & INSTRUCTIONS

Rev. no.: 0
Date
: 10.9.00

Principle Of Operation:
The valve provides a thru-conduit seal, sealing both upstream & downstream.
This enables the valve to be installed in the line in any direction (bi-directional).
The valve provides a metal-to-metal seal between the gate and seat and a metal-tometal stem backseat.
The valve also incorporates a de-energizing mechanism by which body cavity
pressure continuously tries to equalize the line pressure in the bore. At zero line
pressure the valve holds approximately 150 to 300 psi in the body cavity. Before
opening the bonnet, precaution should be taken to bleed off the retained pressure in
the body cavity by using bleed off plug provided on bonnet or cycling the valve to
bleed the body cavity pressure to the line.
Operating Instructions:
1. Operate the valve as rapidly as possible. This eliminates the gates and seats
exposure to turbulence and excessive wear during the opening and closing
process. Thereby the service life of the valve is increased.
2. Gate valve should never be used to throttle line fluid. Throttling will result in
seat and gate damage.
3. Follow the recommended preventive maintenance and lubrication procedures to
achieve good performance and life.
Valve Testing:
The valve should be shell tested with gate in half open position.

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GATE VALVE

WOM

Rev. no.: 0
Date
: 10.9.00

ASSEMBLY INSTRUCTION
VALVE BODY

Assembly Instructions:
1. Install the Seat retainer backup ring and Seat retainer bottom seal in the Seat
retainer as shown in the figure below.
2. Install the two Seat seals along with the Seat backup ring in the Seat as shown
in the figure below.
3. Insert the Seat assembly into the Seat retainer.
4. Install the Seat retainer top seal in the body seat bore first.
5. Insert the Seat / Seat retainer assembly in the body seat bore as shown in the
figure below.
6. Follow the same procedure for the other side of the body seat bore.
7. Install the gate through the vertical bore of the body between the seat and seat
retainer assembly. Gently tap the gate using a mallet to get it in. Take care not
to damage the gate surfaces in the process.
8. Install the grease fitting in the body port (some of the bodies does not have one).
For Valve Mounted With Actuator:
Fail close: The gate should be assembled such that the solid gate enters the body first
and then the gate bore.
Fail open: The gate should be assembled such that the gate bore enters the body first
and then the solid gate portion.
SEAT SEAL
SEAT BACKUP RING
SEAT RETAINER BACKUP RING
SEAT RETAINER TOP SEAL
SEAT
RETAINER

GATE
SEAT RETAINER BOTTOM SEAL

SEAT

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GATE VALVE

WOM

Rev. no.: 0
Date
: 10.9.00

BODY ASSEMBLY

SEAL ASSEMBLY

GATE

GREASE FITTING
(OPTIONAL)

BODY

ASSEMBLY
VALVE BODY

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WOM

GATE VALVE
PREVENTIVE MAINTANANCE
& LUBRICATION
VALVE BODY

Rev. no.: 0
Date
: 10.9.00

General Instructions:
1. Preventive Maintenance and Lubrication is mainly a function of the following
factors:

Type of fluid and "relative" cleanliness of fluid being handled

"Relative" corrosion/erosion properties of line fluid

Frequency of valve operation

Line pressure during operation of the valve relative to its rating

Recommended Lubricant:
"Magnaseal" is the result of extensive testing and will maximize service life. Only
in emergencies, if Magnaseal is not available, a high viscosity all-purpose grease
can be used. In that case the lubrication frequency should be shortened to
compensate the limited characteristics of all-purpose grease. Magnaseal will
increase service life substantially. The lubricant in the magnum is only subjected to
washing and contamination during opening and closing cycles. In the full open or
full closed positions, body cavity lubricant is isolated from the flow stream.
Least hostile condition - an example situation:
If the valve were used in the run of a christmas tree on a well producing clean,
sweet, low-solids natural gas and the valve were operated once a day, lubrication
and flush-out schedules could be least frequent.
Most hostile condition - an example situation:
If, on the other hand, the valve were used in a choke and kill manifold handling
heavy, fine mesh, weighted mud with many additives and cycled several times in
day, lubrication and flush-out schedules could be more frequent.

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WOM

GATE VALVE
PREVENTIVE MAINTANANCE
& LUBRICATION
VALVE BODY

Rev. no.: 0
Date
: 10.9.00

A general guide:
Many applications will fall somewhere between these two extremes. Only on-site
seasoned personnel and some trial and observation can determine the optimum
lubrication and flush-out schedules. Therefore, this document deals mainly with
the procedures recommended; frequency is a policy and practice decision of the
operations and maintenance personnel.
Body Cavity Lubrication:
1. The body can be lubricated with the valve in either the full open or full closed
position; fully open position is preferred. In the closed position the stem may
not be lubricated; when thoroughly lubricated the valve can be cycled to the
open position.
2. The valve can be in service during lubrication, shut down is not required.
Caution! There will be some trapped pressure in the body cavity (from the last
open/close cycling), which must be bled off. If the valve is handling H2S or
similar toxic materials, appropriate safety precautions and protective
equipment should be used. Consult your safety coordinator if unsure.
3. Follow this sequence:
A. Bleed off fitting may be an Autoclave plug or Allen head fitting. Loosen
bleed off fitting on OD of bonnet flange by turning counter-clockwise 2-3
full turns to vent trapped body pressure to zero. Do not remove this plug,
only loosen.
B. When body cavity is completely vented, remove the cap (only) of the body
greasing fitting. Do not remove the grease fitting body (a check valve inside
prevents pressure loss, but will accept grease input).
C. Connect grease gun to grease fitting in the body of the valve.
D.
Pump lubricant into the valve body and allow old lubricant to vent
through the bonnet fitting.

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WOM

GATE VALVE
PREVENTIVE MAINTANANCE
& LUBRICATION
VALVE BODY

Rev. no.: 0
Date
: 10.9.00

4. If valve is used in service where much line contamination is present, it is

recommended that new grease replace old grease each time the body is
lubricated. Consult 'general lubrication policy and procedures' for your
particular application and installation.
5. Remove grease gun.
6. Replace cap on body grease fitting and tighten.

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WOM

GATE VALVE
TROUBLE SHOOTING
& ROUTINE FUNCTIONAL TESTING
VALVE BODY

Rev. no.: 0
Date
: 10.9.00

Routine functional test of Gate/Seat Assembly:

This functional test is to be done only in shop. Maximum pressure at which this
test is performed is working pressure of the valve.
1. If undamaged, the valve will seal both upstream and downstream. The
condition of the gate/seats assembly can be checked by the following steps.
Caution: If the valve has been in H2S or similar toxic service, personal
hazard protection prevention measures should be observed.
2. With the valve in either the full open or full closed position, vent the body
cavity by loosening the bleed off fitting on the OD of the bonnet. Make sure
that body pressure is completely vented.
3. Completely remove the bleed off fitting on the OD of the bonnet.
4. Make up a test unit to check pressure in bleed off port. All components must
have a minimum rating equal to the valve working pressure.
5. Install the test unit in the bleed off fitting port on the bonnet.
6. Leave the valve in the open position. Apply working pressure in the bore.
7. If the pressure builds up in the test unit, as determined by the test unit gage,
damage has occurred to the seats and/or gate. See Trouble Shooting Procedure
for repair instructions.
9. If no pressure builds up within 5 minutes, you can be assured that your gate
and seat assembly is still in functional condition.
In the event of gate/seat leakage:
Excessive wear to the seats and/or gate may occur from rigorous usage and/or
improper preventive maintenance. The seats and gate for the gate valve can often
be repaired without removal of the valve from the line.
To repair in line, see following steps. Shop repairs follow the same procedure as
below, beginning at step 1B.

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WOM

GATE VALVE
TROUBLE SHOOTING
& ROUTINE FUNCTIONAL TESTING
VALVE BODY

Rev. no.: 0
Date
: 10.9.00

1. To repair the valve while in the line, follow these steps:

A. Isolate the valve in the system by blocking with valves upstream and
downstream.
Caution: If the valve has been in H2S or similar toxic service, personal hazard
protection prevention measures should be observed.
Special Note: You can bleed down the line from some vent other than the valve
or with the valve itself. To bleed the line through the valve, keep the valve in
the half-open position. Loosen the bleed off fitting on the OD of the bonnet to
vent.
B. If the line is not bled off through the valve, the body cavity must be bled off
separately. Bleed off is accomplished by loosening the bleed off fitting on
the OD of the bonnet.
2. Loosen and remove all bonnet bolts or nuts as applicable.
In case of Manual / Gear / Electric Operated valve:
a. Operate the valve until the gate bottoms out in the bottom of the body. Further
operation should lift the bonnet away from the body of the valve. If the valve
has been in service for some time, it may be necessary to hit the bonnet flange
with a hammer to help break the bonnet seal.
Caution: Be careful not to damage studs or grease fittings.
b. When the bonnet stops moving up, lift entire bonnet assembly straight up off
the body until the gate comes out of the body. A lifting device is recommended.
In case of Pneumatic / Hydraulic operated valve:
a. Two threaded holes are provided on actuator housing for lifting purpose.

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WOM

GATE VALVE
TROUBLE SHOOTING
& ROUTINE FUNCTIONAL TESTING
VALVE BODY

Rev. no.: 0
Date
: 10.9.00

b. Lift the actuator along with the bonnet and gate until the gate comes out of the
body.
3. Remove each seal assembly one at a time from the valve body with a
screwdriver. Seat retainers are a close-tolerance slip fit, but should slide out
easily.
4. Cleanout seat retainer recesses thoroughly.
5. Replace seals if necessary.
6. Refer assembly-body section for seat and seat retainer assembly.
7. Lightly lubricate the new gate. Replace the gate by hand such that the gate Tslot is out of the body. Do not attempt to assemble the gate along with the
bonnet assembly. To start the leading edge of the gate between the seal
assemblies, a slight rocking motion may be needed. Light bumping with a
wood mallet is okay, but care should be taken not to damage gate.
8. Replace the bonnet gasket with a new one. Do not attempt to reuse an old
bonnet gasket.
In case of Manual / Gear / Electric Operated valve:
a.
b.

c.

Assemble the T-nut on to the gate.

To remount the bonnet assembly, position the stem on top of the T-Nut and
rotate the stem(handwheel or switch as applicable) counter clockwise until
bonnet contacts the bonnet gasket. Further rotation will simply begin raising
the gate toward the open position.
Complete the assembly by installing the bonnet nuts. Tighten the nuts that are
diagonally opposite and go in circle in the same manner to complete all the
nuts. Torque to values provided in the table.

In case of Pneumatic / Hydraulic operated valve:

a. Connect Pneumatic / Hydraulic line to the inlet port and pressurize the
cylinder, so that the operating stem moves down.
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GATE VALVE
TROUBLE SHOOTING
& ROUTINE FUNCTIONAL TESTING
VALVE BODY

Rev. no.: 0
Date
: 10.9.00

b. Two tapped holes are provided on actuator housing for lifting purpose. Lift the
actuator/bonnet assembly and slide the stem into the T-slot in the gate.
c. Complete the assembly by installing the bonnet nuts. Tighten the nuts that are
diagonally opposite and go in circle in the same manner to complete all the
nuts. Torque to values provided in the table.
d. Reduce the Pneumatic / Hydraulic pressure to zero. The valve should close
fully.

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