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MOGAS ASME Class 600, Installation, Operation And Maintenance Manual, Page: 1 / 28

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ESI-6136

© Copyright 09/2018 MOGAS Industries, Inc.  

 www.mogas.com

Installation, Operation  

and Maintenance Manual 

for the

Coker Switching Valve

ASME Class 600 / 900

PREPARE THE VALVE  

FOR INSTALLATION

INSTALL THE VALVE 

PROPERLY

OPERATE THE VALVE 

PROPERLY

PURGE AND MAINTAIN 

THE VALVE FOR  

OPTIMAL OPERATION 

AND PERFORMANCE

Summary of Contents for ASME Class 600

Page 1: ...as com Installation Operation and Maintenance Manual for the Coker Switching Valve ASME Class 600 900 PREPARE THE VALVE FOR INSTALLATION INSTALL THE VALVE PROPERLY OPERATE THE VALVE PROPERLY PURGE AND MAINTAIN THE VALVE FOR OPTIMAL OPERATION AND PERFORMANCE ...

Page 2: ...AD THIS MANUAL All information within this manual is relevant to the safe and proper care of your MOGAS switching valve The following are examples of instructional information used throughout this manual SAFETY INFORMATION It is important to read and follow these safety instructions REMOVE STEM PACKING Using a small pick or scribe carefully remove packing rings 09A and anti extrusion rings 09B fro...

Page 3: ...om 3 Contents IMPORTANT VALVE INFORMATION 4 RECEIVING AND INSPECTION 5 VALVE ITEM NUMBERS 6 INSTALLATION 8 OPERATION 10 PURGING AND DRAINING 12 MAINTENANCE 13 DISASSEMBLY 14 EVALUATION AND REWORK 19 RE ASSEMBLY 20 STORAGE 26 RETURN MERCHANDISE AUTHORIZATIONS 27 ...

Page 4: ...ve design extending the highest degree of safety first approach Please review this document in its entirety to understand the MOGAS switching valve functionality VALVE CONFIGURATION The MOGAS switching valve requires an operator electric actuator with worm gear to perform switching functions Each switching valve configuration may be slightly different due to customer specifications Note Review any...

Page 5: ...lied shipped with the valve INSPECT VALVE INTERNALLY Remove protective covers from valve ends Inspect valve internally for shipping debris or damage Replace protective covers until ready for installation 1 2 3 4 VERIFY OPERATOR If the valve was ordered with an operator from MOGAS it should arrive pre assembled and tested from the factory If already assembled continue with the valve installation If...

Page 6: ...1 03C 21 04 10 08A 01C 01G 01B 01G 01G 01G 01G 01B 01C 01B 01G 01C 01A 08E 09D 08C 07F 02B 06A 55 Valve Item Numbers BONNET AND PACKING BODY BALL STEM AND SEATS Note Contact MOGAS or a MOGAS Authorized Repair Center to determine the spare parts and quantities required for your specific circumstance ...

Page 7: ...AD SPRINGS VARIES 7F BALL SLEEVE SPRING 1 08 STEM THRUST BEARING 1 8A STEM BEARING 1 8C BALL SLEEVE 1 8E BALL SLEEVE BEARING 1 9A STEM PACKING 3 9B ANTI EXTRUSION RING 2 9C LANTERN RING 1 9D BALL SLEEVE OD SEAL RING 1 10 BODY STUD VARIES 11 BODY NUT VARIES 12 GLAND STUD 3 14 MOUNTING FLANGE SPOOL 1 15 GLAND NUT 3 16 MOUNTING FLANGE BUSHING 1 16A STEM BUSHING 1 21 GRAPHITE SEAL 1 22 ALIGNMENT STUD ...

Page 8: ...gled position make sure the drain ports are positioned at an angle that will allow the coke to be drained off the during switching process PIPING Allow for sufficient flexibility in piping system for thermal growth and mechanical strains on pipe work Install purge drain piping in accordance to customer s normal work practices Orientation and purge port drain connection sizes and types shall be ava...

Page 9: ...E VALVE IN PLACE Install flange gaskets and bolting per customer requirements Note MOGAS valve flanges are supplied in the customary straddle centerline hole orientation unless otherwise specified VERIFY OPERATION To verify operation after installation Disengage all position stop pins 1 2 and BP Ensure the actuator keys are engaged Cycle valve from port A to B to BP and then from BP to B to A Repe...

Page 10: ...sition If position indicators are not visible the scribe line on gland flange 07 can be used to determine the position of the ball bore When viewed through the mounting adaptor opening 14 the stem scribe line and gland flange scribe line should align Operation LOCATE POSITIONAL STOP PINS The installed operator performs all switching functions between drums A B and BP Positional stop pins are used ...

Page 11: ...ing position Drum A or B Insert BP Lock Stop Pin fully into position to prevent accidental switching to Bypass Port For Drum A operation insert Lockout Pin 1 and keep BP Lock Stop Pin in locked position For Drum B operation insert Lockout Pin 2 and keep BP Lock Stop Pin in locked position Note Once starting position is set and lockout pins are engaged use lock in pins to secure positions SWITCHING...

Page 12: ...DRAINING MOGAS coker switching valves are typically equipped with drain ports which will allow any coke and water from the steam buildup in the body cavity area to be flushed out at the end of each switching cycle The drains are to be opened and remain open for 15 minutes after each cycle Note Review any job specific or general arrangement drawings provided for drain locations and procedures CAUTI...

Page 13: ...important to follow these steps to ensure maximum valve performance THIS WILL AFFECT THE VALVE WARRANTY CAUTION If bolting torque is lower than specified values on the test certificate provided for each individual valve serial number re torque bolting as necessary THIS WILL AFFECT THE VALVE WARRANTY FIELD MAINTENANCE If a packing leak develops verify that the packing gland nuts 15 are properly tor...

Page 14: ...tion of the ball bore When viewed through the mounting adptor opening 14 the stem scribe line and gland flange scribe line should align Note To replace valve internal parts the valve may be repaired inline or removed from the line MARK COMPONENTS Prior to disassembly mark any matching components with a marker tape etc for ease of re assembly ALIGN BALL BORE Before removing bonnet 03C ensure the ba...

Page 15: ...or rod 05D using socket head screw Remove operator keys by lifting straight up Remove mounting adaptor hex nuts 37 Lift operator and mounting adaptor assembly 14 straight up and off the valve Note Use nylon straps around sturdy section of operator or adaptor Remove mounting adaptor studs 31 to provide clear access to packing area Remove hex nut 52 indicator rod 05D and wedge lock washer 60 3 ...

Page 16: ...e sure all packing material is removed New packing material must be used for re assembly Remove lantern ring 09C CAUTION Do not scratch the stem or the packing bore in the body Scratches could cause a leak 4 5 REMOVE BONNET Loosen and remove body hex nuts 11 Attach chain to lifting eyes of bonnet 03C Lift bonnet straight up to remove Place aside with internal surfaces protected Remove graphite sea...

Page 17: ...ing and seat removal only be performed by authorized MOGAS service personnel Contact MOGAS to learn more Secure an S hook rod behind the spring 01C Attach to crane and lift spring straight up and out of body With spring removed grab the seat ring 01B by hand or use the S hook rod if needed and lift seat ring straight up and out of body Repeat the spring and seat ring removal steps on remaining por...

Page 18: ...r or damage and replace if needed If part is reusable clean for later reuse REMOVE BALL SLEEVE AND SPRING Wash out any remaining coke around ball sleeve and sleeve spring Remove graphite seal ring 09D and discard Graphite seal ring must be replaced at re assembly Remove ball sleeve 08C from body Inspect top of ball sleeve for any excessive wear or damage and replace if needed If part is reusable c...

Page 19: ...arings rings gaskets seals and packing required If you do not have a spare parts kit refer to Valve Item Reference Number pages 6 7 for a recommended spare parts list Note Contact MOGAS or a MOGAS Authorized Repair Center to determine the spare parts and quantities required for your specific circumstance EVALUATION Contact MOGAS for inspection and evaluation to determine if rework of components ma...

Page 20: ... sleeve bore Apply silicone or nonflammable adhesive to sleeve to grip new graphite seal ring 09D Place ball sleeve with newly installed graphite seal ring on top of spring INSTALL BALL AND STEM ASSEMBLY Attach lifting eye to ball and stem assembly 01A Insert new ball sleeve bearing 08E into bottom of ball Using lifting eye lower ball and stem assembly into body 02B placing it on top of sleeve 08C...

Page 21: ...peat this process for remaining two seat rings INSTALL SEATS AND SPRINGS Place seat ring 01B with new graphite rings into body seat pocket aligned with ball opening Repeat this process to install remaining two seat rings rotating ball opening to align with each port With all of the seats in place install springs 01C behind seats INSTALL STEM BEARING AND BUSHING Slide stem thrust bearing 08 over th...

Page 22: ...ches bottom then back out one half turn Install new body gasket 04 into groove in body face Attach chains to lifting lugs on bonnet 03C and lift to working height Apply silicone or non flammable adhesive to groove in bonnet to secure new graphite seal 21 in place Insert bonnet alignment pin 06A into body 02B Align bolt holes with studs and ensure bonnet purge openings are aligned with the body pur...

Page 23: ...taggered or alternated during installation This is done to prevent formation of a possible leak path THIS WILL AFFECT THE VALVE WARRANTY 9 10 CLEAN PACKING BOX Before installing the new packing make sure the packing box is clean If needed use an air hose to clean debris from packing box before installing new packing rings PREPARE PACKING RING SET The new packing ring set will contain five rings to...

Page 24: ...s on top of packing Install spring discs live loading 07C over gland studs Note Spring discs must be installed in opposing pairs Apply anti seize compound onto gland studs 12 and gland nuts 15 Install gland nuts 15 and torque all nuts evenly per the specifications included with the test certificate for each individual valve serial number 8 CAUTION The gland flange must be pulled down evenly to pre...

Page 25: ... washer 60 on top of stem Thread indicator rod 05D into the top of stem aligning flat of indicator rod with ball bore Tighten hex nut 52 to secure the position Install flange bushing 16 into mounting flange spool 14 Align key slots of stop plate 58 with key slots of stem then insert stop plate 58 into flange bushing 16 Insert keys 06 into key slots of stop plate 58 and stem With stop plate in plac...

Page 26: ... with any of three ports to prevent internal damage to valve components Once removed the valve should be placed in a vertical position or raised at an angle The bore of the valve should be either steamed cleaned or power washed to remove slurry and debris The valve should be allowed to drain and dry A petroleum based rust inhibitor should be applied through the bore of the valve immediately after ...

Page 27: ... to submitting an RMA request Serial number End user Total estimated hours in service Application specifics where the valve is used Media what goes through the valve Total estimated cycles from last installation Operating temperature max F Operating pressure max PSI Actuator specifics Note Valve information is provided on a nameplate wire fastened to body for easy access Contact the MOGAS Service ...

Page 28: ...re differentials Velocity control Noise control MOGAS INDUSTRIES INC Headquarters 14330 East Hardy Street Houston TX USA 77039 1405 Phone 1 281 449 0291 Fax 1 281 590 3412 E mail mogas mogas com AUSTRALIA Phone 61 0 8 9456 3533 CANADA Phone 1 780 436 4485 CHINA Phone 86 0 10 8454 9478 EUROPE Phone 44 0 1162 793367 MIDDLE EAST Phone 971 0 4 889 5667 To locate a sales and service center in your area...

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