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MOGAS Watson Series, Installation, Operation And Maintenance Manual

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MOGAS Watson Series Installation, Operation And Maintenance Manual Download Page 3

© Copyright 03/31/2021 MOGAS Industries, Inc.   

www.mogas.com

3

VALVE ITEM REFERENCE NUMBER

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TRANSPORT AND STORAGE

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PRE-INSTALLATION

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INSTALLATION

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OPERATION

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MAINTENANCE

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REPLACE BALL & SEAT

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REPLACE STEM PACKING

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DISASSEMBLY

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RE-ASSEMBLY

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LOCATE VALVE INFORMATION

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RETURN MERCHANDISE AUTHORIZATIONS (RMA)

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SERVICE CONTACT

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Contents

Summary of Contents for Watson Series

Page 1: ...nstallation Operation and Maintenance Manual PREPARE THE VALVE FOR INSTALLATION INSTALL THE VALVE PROPERLY MAINTAIN THE VALVE FOR OPTIMAL OPERATION AND PERFORMANCE for the MOGAS Watson Series Ball Valve ...

Page 2: ...he valve CLOSE OPEN Sequential procedure required to perform operation Bold numbers correspond with items shown in the Valve Item Reference Number sections Warning statement to prevent unwanted consequence Note s to support procedure All information within this manual is relevant to the safe and proper care of your MOGAS ball valve Please understand the following examples of instructional informat...

Page 3: ...FERENCE NUMBER 4 TRANSPORT AND STORAGE 6 PRE INSTALLATION 7 INSTALLATION 8 OPERATION 10 MAINTENANCE 11 REPLACE BALL SEAT 12 REPLACE STEM PACKING 13 DISASSEMBLY 17 RE ASSEMBLY 23 LOCATE VALVE INFORMATION 31 RETURN MERCHANDISE AUTHORIZATIONS RMA 32 SERVICE CONTACT 32 Contents ...

Page 4: ...ing 04 Body 05 End Connect 06 Body Gasket Spiral Wound 07 Stem 08 Stem Seal 09 Thruster Gland Flange 10 Gland Flange 11 Ring Stem Packing 1 12 Stud Body 13 Nut Body 14 Stud Gland 15 Nut Gland 1 Quantity varies with valve size 08 12 01 02 07 03 02 03 06 05 13 04 11 09 10 14 15 Valve Item Reference Number Manual Adaption Handlever ...

Page 5: ... Copyright 03 31 2021 MOGAS Industries Inc www mogas com 5 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 6: ...e REMOVING VALVE FROM SERVICE Before the valve is removed from the line it should be placed in the partially open position to relieve trapped pressure and prevent further internal damage to valve components Do not place the valve in the fully open position until it has been cleaned of service debris in the next step The valve should be placed in a vertical position or raised at an angle The bore o...

Page 7: ...sembly drawing with the bill of materials and the actuator manual if supplied shipped with the valve REMOVE PROTECTIVE COVERS Remove protective covers from the valve ends Inspect internally for shipping debris or damage INSTALL OPERATOR The valve comes configured with a handlever from MOGAS It should arrive pre assembled and tested from the factory If already assembled proceed to Installation page...

Page 8: ... Note Larger valves may require the actuator to be in place to rotate the ball Note Valve item numbers shown in bold correspond with items shown in the Valve Item Reference Number section pages 4 5 of this document CAUTION The actuator if supplied must not be re oriented without removal from the valve This prevents 180 rotation of the ball and assures the mate lapped ball and seat surfaces match S...

Page 9: ...t possible damage Note Actuator gear operators and handle stops are pre set at the factory and should not require any further adjustments Should the actuator or gear operator require removal for installation please call the factory or authorized Service Company first POSITION VALVE IN PIPING Verify that the valve and actuator handlever orientation is correct Verify that the valve is in the open po...

Page 10: ...operate turn counter clockwise to open and clockwise to close Note When cycling the valve open or close make sure that the valve is fully opened and fully closed This wipes debris from the ball and ensures optimal performance and long valve life OPEN CLOSE CAUTION Throttling with ball valves is NOT recommended Prolonged exposure of a portion of the ball to flow can compromise the sealing integrity...

Page 11: ...bolting at these same locations periodically 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 OPEN CLOSE VALVE REGULARLY Valves remaining open or closed for a long period of time should be cycled open closed at least once a year Valves should always be...

Page 12: ...e metal seats and ball are fitted together as a matched set and must be fitted to the valve as a set Note This operation must be performed by authorized service organization or a factory trained technician CLEAN THE VALVE Remove all remaining media from the valve 2 MOVE VALVE TO AUTHORIZED REPAIR ORGANIZATION Remove all remaining media from the valve 3 The service organization will refurbish the v...

Page 13: ...ESS PACKING Remove the handle or actuator and any other obstruction and expose the top of the stem 1 Relieve all pressure from the valve and the valve s body cavity by cycling a removed valve to the 45 position or half open REMOVE GLAND FLANGE THRUSTER Loosen gland nuts 15 slowly in case there is trapped pressure in the stem area Remove gland flange 10 followed by gland flange thruster 09 Use plye...

Page 14: ...e Always wear a face shield or mono goggles to protect eyes from flying debris 11 CAUTION Care should be taken at all times in removing the packing in case the media is hazardous and harmful Safety glasses gloves or other personal protective equipment should be worn PACKING RING SET Prepare the packing set by removing them from their protective packing container Care should be taken when handling ...

Page 15: ...all the set of packing rings 11 one ring at a time in the order as illustrated Ensure all rings are snugly fitted all the way down against the previous ring 4 RE INSTALL GLAND FLANGE THRUSTER AND FLANGE Slide gland fland thruster 09 over stem 07 and push snugly against stem packing 11 followed by gland flange 10 5 09 10 11 Replace Stem Packing ...

Page 16: ...and flange to ensure that it remains perpendicular to the stem and the gap around the stem remains concentric during the tightening process 15 The valve should be cycled several times and gland nuts 15 re tightened The nuts should only be snugged and not over tightened Once the valve is placed into operation torque all nuts evenly per the specifications included with the test certificate for each ...

Page 17: ... of the valve body Mark any matching components with a marker prior to disassembly for ease of reassembly and to identify orientation CAUTION If you disassemble rework and re assemble this ball valve YOU WILL VOID YOUR WARRANTY SECURE VALVE Turn valve on body end 04 and secure valve with clamps or bolts to allow for stable disassembly 1 REMOVE NUTS Loosen body nuts 13 from body bolts 12 and then r...

Page 18: ...RK END CONNECTION Mark centerline on end connection 05 05 REMOVE END CONNECTION AND BODY STUDS Pull end connection 05 off valve body 04 It may be necessary to use a tool such as a rubber mallet to loosen the end connection Remove body studs 12 4 05 04 Disassembly 12 ...

Page 19: ...ion two dots on ball 01 facing end connection Remove and inspect ball for damage It may be necessary to loosen the ball with a screw driver or similar leverage tool Mark ball 01 one dot facing body Inspect ball for damage Mark centerline on seat face 02 inside body cavity 02 05 01 01 02 CAUTION Do not scratch the ball or internal components Scratches could cause a leak THIS WILL AFFECT THE VALVE W...

Page 20: ...10 REMOVE SEAT Use a thin flathead screwdriver and mallet to pry the seat 02 away from end connection 05 6 02 LOOSENING THE THRUSTER It may be necessary to push most of the stem 07 through the packing bore and into the valve body 04 before the gland flange thruster 09 can be worked off the stem Do this by using a rubber mallet to tap the stem further into the the valve body cavity Use plyers to wo...

Page 21: ... s shoulder remove it 08 07 07 REMOVE STEM PACKING Using a small pick scribe or screwdriver carefully remove the packing material 11 Make sure that all of the packing is removed 10 CAUTION Do not scratch the packing bore in the body Scratches could cause a leak THIS WILL AFFECT THE VALVE WARRANTY Note Always wear a face shield or mono goggles to protect eyes from flying debris 11 REMOVE STEM SEAL ...

Page 22: ...EAT Use a thin flathead screwdriver and mallet to pry away the seat 02 from inside body 04 12 REMOVE SEAT RING Remove seat ring 03 from body seat landing The seat ring may be afixed to the bottom of the seat 02 13 REMOVE BODY GASKET Remove body gasket 06 from body 04 14 06 02 03 02 ...

Page 23: ... body flange Apply Krytox or equivalent lube inside packing box Note Each Watson Series stem packing set will contain three to five rings total They are all made from the same graphite material but sets are different diameters thicknesses and shapes depending on bore size Install the set of packing rings 11 one ring at a time in the order as illustrated Ensure all rings are snugly fitted all the w...

Page 24: ...ALL GLAND STUDS Apply anti seize compound before inserting the gland studs 16 Turn the threads finger tight until they reach the bottom 3 16 07 07 Re Assembly 08 07 04 INSERT STEM Insert the stem 07 from inside the body 04 and out through the top stem bore If there is a letter stamped on the stem orientate stem 07 so the letter which is etched on stem end faces the valve s bottom ...

Page 25: ...02 onto the seat ring 03 with curved sealing face facing upward towards the ball side The newly installed seat should spin with ease 6 CAUTION Entrapped debris between the seat and seat ring will affect a tight seal Notes IMPORTANT The seats are uniquely identified to fit only a body or end connection Seats identified with a odd number fit the body only seats identified with an even number fit the...

Page 26: ... hand tighten studs into body holes until they bottom out 8 INSERT BALL Lubricate the ball 01 with silicon or another light lubricant Match number inside ball slot to newly installed seat 02 Lower ball 01 in the closed position into body ensuring matching numbers on ball and seat 7 CAUTION Do not use WD 40 as lubricant 01 14 01 ...

Page 27: ...ce facing downward Lay the second seat ring seal 03 onto the back of the second seat 02 9 Notes IMPORTANT The seats are uniquely identified to fit only a body or end connection Seats identified with a smaller number fit the body only seats identified with a larger number fit the end connection only Seat identification is also provided inside the stem slot of the ball to ensure correct assembly of ...

Page 28: ...y studs 14 and onto body 11 FINGER TIGHTEN BODY NUTS Install body nuts 15 onto body studs 14 Only finger tighten the nuts 12 INSTALL GLAND FLANGE AND THRUSTER Slide gland fland thruster 09 over stem 07 and push snugly against stem packing 11 followed by gland flange 10 13 05 04 15 09 10 14 CAUTION Visually inspect that seat 02 and seat ring seal 03 are centered on ball 01 and body seal 06 is still...

Page 29: ...ilizing a star pattern followed by one last check applying the specified torque to each fastener sequentially in a clockwise pattern 16 CAUTION Torque the valve body bolting per the specifications included with the test certificate for each individual valve serial number 15 FINGER TIGHTEN GLAND NUTS Install gland nuts 15 onto gland studs 14 Only finger tighten the nuts 14 CAUTION The gland flange ...

Page 30: ...l valve serial number TIGHTEN GLAND FLANGE NUTS Use a proper squence to tighten the gland flange nuts 17 17 PRESSURE TESTS Move valve to test stand Hydrostatic Shell Test This test is performed at MOGAS while the ball is partially open This test is not possible at the field If partially opening the ball is not possible due to high initial torque pressure the valve from one side to about 1000 psi w...

Page 31: ...ditional information may also be provided on identification tags per customer request 1 3 2 Locate Valve Information Stroke the ball to ensure proper rotation 01 INSTALL HANDLEVER AND VERIFY OPERATION Align length of handlever inline on stem 07 Handlever should slide into place Note The MOGAS valve operates counter clockwise to open clockwise to close Using the handlever stroke the ball 01 to ensu...

Page 32: ...hat goes through the valve Total estimated cycles from last installation Operating temperature max F Operating pressure max PSI Actuator specifics Contact the MOGAS Service department to obtain authorization and to receive shipping instructions The RMA request may also be submitted online by accessing the Service page of our website www mogas com MOGAS Service may be reached 24 hours per day 7 day...

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