MODCO FIGURE 500 User manual

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 1of 16
CLOSURE SPECIALISTS SINCE 1981
MODCOTM FIGURE 500 CLOSURE
INSTALLATION INSTRUCTIONS
(!) THE INFORMATION PROVIDED IN THIS DOCUMENT IS VERY IMPORTANT (!)
&
(!) needs to be shared with everyone involved in installing the closure. (!)
(!) Modco appreciates the support of all SUPERVISORS. (!)
This document and under a separate cover “Operations & Maintenance Instructions”
comes with every shipment.
If you are unsure about the provided information or can’t identify parts of this
6 pages long document, please contact immediately (!) customer service:
1-(800)-378-8893 or 1-(936)-539-9222
[e-mail]

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 2of 16
PART 1: Disassembly of not installed closure
1.1 Disassembly of Horizontal Hinge Closure
1. If a Pressure Alert Valve (PAV) is present, remove the
stem and screw it into the retainer on the cap.
2. On closures 14” and under, unscrew the cap from the
hub and lift the attached hinge components from
hinge base.
3. On closures 16” and larger, remove the outer set
collar from the cap pin and remove the hanger arm
from the cap pin. Leave the inner set collar in place,
this will retain the parallel balance set by the
manufacturer.
NOTE: A burr may be left behind by the set screw
in the collar. Using a file or emery cloth, remove the
burr to ease removal of the hanger arm and/or
related components.
16” to 24” ANSI 300 class closures are equipped with
a single roller trolley. Slide the hanger arm from the
cap pin and lift the hinge components from the jib
arm.
24” ANSI 600 and larger closures are equipped with a
dual wheel trolley. Measure the distance from the
bottom of the jib arm to the top of the hanger arm, or
put a reference mark on the adjustment bolt above
the hanger arm. Remove the nut, block and hanger
arm from the closure. Do not remove the trolley from
the jib arm.
NOTE: 36” ANSI 600 closures and larger have roller
bearings inside the cap pin bushing. Make sure the
cap pin is free of all burrs to ease removal of the inner
bearing race. Store bearings with care and keep them
protected from dust, grit and other contaminants.
4. Remove the jib arm from the hinge base. The jib
assembly of 24” ANSI 600 and larger closures are
equipped with a brass bushing and tapered roller
bearing inside the hinge base. Take care not to
damage these components. Remove the tapered
bearing race from the bottom of the hinge base.
5. Attach a hook sling to at least three cap ribs. Use the
supplied opening tool to break the seal and loosen
the cap if necessary. Using a crane, continue to
unscrew the cap using just enough lift to keep the cap
floating between threads. Keep lifting and turning till
the cap clears the hub. Place the cap face down on a
clean, flat surface. Plywood or a wooden pallet is
preferred.
Horizontal 6”-14” drawing
Horizontal 16-24 300” drawing
Horizontal 24 600”- 48” drawing

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 3of 16
1.2 Disassembly of Vertical Hinge Closure
1. Locate the Pressure Alert Valve (PAV), remove the
stem and screw it into the retainer on the cap. The
PAV is standard on all closures 6” and larger,
optional on sizes 2”, 3”, and 4”.
2. On closures 14” and under, unscrew the cap from
the hub and cap with lift the attached hinge
components out of the davit base.
IMPORTANT: Keep the cap centered over the
hub at this time. Swinging the cap to the side will
cause a weight imbalance and the closure may fall
over causing injuries and equipment damage.
On 16” and larger closures, use the supplied
ratchet tool to break the seal, than unscrew the
cap.
IMPORTANT: Keep the cap centered over the
hub at this time. Swinging the cap to the side will
cause a weight imbalance and the closure may fall
over causing injuries and equipment damage.
3. Using a hook sling on at least 3 cap rips and lift the
cap with its hinge components out of the davit
base. Support the davit arm also if needed. Please
be aware the davit arm of 24” ANSI 600 and larger
closures are equipped with a bronze bushing and
tapered roller bearing inside the hinge base. Take
care not to damage these components. Remove
the tapered bearing race from the bottom of the
davit base. Place cap face down on a clean flat
surface allowing the arm to hang freely. Stacked
wooden pallets are preferred.
Vertical 6”-14” drawing
Vertical 16-24 300” drawing
Vertical 24 600”- 48” drawing

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 4of 16
PART 2: Attachment of the Closure
Important:
Recommended Pass:
All welding should be performed by qualified
welders in accordance with qualified
procedures. To avoid hub warpage, complete
all nozzle and attachment welds prior to the
closure installation!
2.1 For Closure Hub in the Field (Manual Welding)
1. Remove the PAV, O-ring, and cap from the closure hub. Remove the hinge components as shown in
“PART I”.
2. Fit the hub to the vessel. The use of internal or “spider” bracing is recommended, especially with thinner
wall thicknesses.
2a. No hinge closures shall be fit with the PAV in the 12 o’clock position on horizontal applications.
2b. Hinged closures shall be fit with the hinge base level vertically.
3. Weld root and hot passes. The amount of heat should be minimized to avoid possible hub sealing
warpage. Using two welders on opposite sides of the closure to reduce the amount of residual stress
induced is highly recommended on sizes 16” and larger. A recommended pass sequence is illustrated
on the top of the page.
4. Replace the PAV and reassemble the closure. Make any necessary adjustments. Reference the
horizontal or vertical adjustment section of the Operations & Maintenance Manual for proper
adjustment procedures.
2.2 For Closure Hub in the Fabrication Shops (Automatic Welding)
1. Remove the PAV, O-ring, and cap from the closure hub. Remove the hinge components as shown in
“PART 1”.
2. Fit the hub to the vessel. The use of internal or “spider” bracing is recommended, especially with thinner
wall thicknesses.
2a. No hinge closures shall be fit with the PAV in the 12 o’clock position on horizontal applications.
2b. Hinged closures shall be fit with the hinge base level vertically.
3. Weld the root pass. Using two welders on opposite sides of the closure to reduce the amount of residual
stress is highly recommended on sizes 16” and larger. A recommended pass sequence is illustrated on
the top of the page.
4. Complete the hub to vessel weld using care to minimize heat build up to avoid possible warpage of the
hub seal face.
5. Before post weld heat treatment, remove all grease from the hub threads. A coating of an anti-splatter
product used for welding will protect against scale build up during the post weld heat treatment. DO
NOT PERFORM POST WELD HEAT TREATMENT ON HINGE COMPONENTS OR THE CAP!
6. Replace the PAV and reassemble the closure. Make any necessary adjustments. Reference the vertical
or horizontal adjustment section of the Operation & Maintenance Manual for proper adjustment
procedures.

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 5of 16
PART 3: Final tune ups
3.1. Sandblasting
Take the following precautions to avoid trapping abrasive media in critical areas. Abrasive media trapped
in threads, seal, and moving parts may lead to operation trouble and severe thread galling.
a. Mask critical areas with a suitable masking material.
b. Thoroughly clean the thread, seal, and moving parts after blasting.
c. Avoid blasting directly towards masked areas as shown below.
3.2 Ready to go Actions
Before delivery to the end user or storage plans, ensure the closure is ready for reliable service in the field.
During final make-ready, grease all grease zerks until grease flows from the joint, then wipe away excess.
The closure should operate with little to no thread drag. Operate the closure, if resistance or thread drag is
felt, see section 5 of the Operations Manual for proper adjustment procedure. Keep the cat tool or lug
wrench with their respective closures.

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 6of 16
CLOSURE SPECIALISTS SINCE 1981
MODCO INDUSTRIES, LLC
10650 FM 1484
Conroe, Texas, U.S.A. 77303
[phone]
[phone]
Fax: [phone]
E-mail: [email protected]

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 7of 16
MODCOTM FIGURE 500 CLOSURE
OPERATION AND MAINTENANCE INSTRUCTIONS
(!) THE INFORMATION PROVIDED IN THIS DOCUMENT IS VERY IMPORTANT (!)
&
(!) needs to be shared with everyone involved in operating and maintenance of the closure.
(!)
(!) Modco appreciates the support of all SUPERVISORS. (!)
This document and under a separate cover “Installation Instructions” comes with
every shipment.
If you are unsure about the provided information or can’t identify parts of this
10 pages long document, please contact immediately (!) customer service:
1-(800)-378-8893 or 1-(936)-539-9222
[e-mail]

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 8of 16
Part 1: Operation Instructions
Opening the Figure 500 Closure
a. Make certain all pressure has been safely bled from the vessel or pipeline. Attempting to open
a closure without doing so could lead to a violent expulsion of pressure resulting in injury or
death.
b. Remove the Pressure Alert Valve (PAV) stem, if so equipped, and screw it into the retainer on
the cap. The PAV is used to alert the operator of residual pressure in the vessel or pipeline.
Unrelieved pressure can cause severe injury or death. If residual pressure is indicated, replace
the PAV stem and ensure the vessel or pipeline is bled of all pressure. Do NOT use the PAV to
bleed pressure from the vessel.
NOTE: The Pressure Alert Valve (PIC #1) is
standard on all 6 inch and larger closures. The
PAV may not be present on two, three, or four-
inch closures as it is an option on these sizes
on non ASME code stamp closure.
PIC #1
c. Check for reference marks indicating the closed position of the cap and hub (PIC#2&3). If none
are present, make a temporary mark across the cap and hub (PIC#4), then follow the instruction
in the “First Time Start Up” section of this manual.
d. Rotate the cap counterclockwise with the lug wrench or ratchet tool provided (PIC#5&#7). Do
not use a hammer to open the cap. Hammering will deform the lugs on the cap and possibly
lead to cracking in the cap or injuries.
e. Rotate the cap until it is free of the hub. Then swing the cap to the side to gain access to the
vessel or pipeline.
IMPORTANT: For the safety of the operator and other crew members, stand to the side of the
closure when opening the cap. Do not stand directly in front of the closure when opening (PIC#6
wrong & PIC#7 correct).
Closing the Figure 500 Closure
a. Align the cap to the hub and rotate clockwise. Tighten the cap with a lug wrench or ratchet tool
until your reference marks line up (PIC#2,3&4). The reference marks indicate a metal to metal
contact of the cap and hub sealing surface.
b. On closures with a PAV, replace and tighten the PAV stem into the PAV body hand tight. Do not
use tools to tighten the PAV, damage to the PAV may result.
IMPORTANT: The cap will tighten sufficiently with the included lug wrench or ratchet
tool. Overtightening the cap will result in damage to the threads and sealing surfaces
of the cap. Do not use a hammer to tighten the closure.

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 9of 16
PIC #2
PIC #3
PIC #4
PIC #5
PIC #6
PIC #7

Modco Standard (6.17.2019 - Q.C.) (Revision 1) Page 10 of 16
First Time –Start up
a. Open the closure as shown in the section “Opening a Figure 500 closure”.
b. With the closure open, remove the O-ring and clean the sealing surfaces of the cap and hub
removing all grease and debris.
c. Apply a thin film of clean grease or Prussian Blue non-drying dye to the sealing surface of the
cap. Carefully close the cap until it makes solid contact with the hub. Use caution to avoid over
tightening or unnecessary force when mating the cap to the hub. The sealing surface of the hub
and cap should now have metal to metal contact and cannot be tightened further. At this point,
make permanent alignment marks on the cap and hub for future reference.
d. Remove cap from hub and check for a clean and consistent transfer of grease or dye from the
sealing face of the cap to the hub. If dye was used, clean it from the sealing surfaces now.
Grease can remain on the closure.
e. After verifying the condition of the closure and O-ring as described in “Part 2 Maintenance
Instructions”, place the o-ring into the o-ring groove and make sure it is seated fully and not
twisted. Apply lubricant to the threads and seal area of the closure. Use anti-galling lubricant,
like light to medium lithium grease. Do not use silicone type grease.
f. Close the cap until the alignment marks on the cap and hub return to their original positions.
Use your ratchet tool or lug wrench if necessary to compress the O-ring. The closure should
now have metal to metal contact between cap and hub with the O-ring in the groove and fully
sealed. Take care not to over tighten the closure after all relative motion stops, or your reference
marks line up. Overtightening may result in damage to closure or tightening tool.
Proper adjustment of the Closure - Horizontal hinged closure
a. 3”-4” Horizontal Hinged closure:
These closures are manufactured with no adjustment mechanism. No adjustment is necessary.
b. Horizontal hinge closures 6 through 14 inch:
Center the cap to hub using the vertical adjustment nut below the hinge arm (PIC#8&11).
c. Horizontal closures 16” and larger:
Vertical adjustment to center the cap to the hub is made by turning the adjustment nut located
under the trolley assembly (PIC#8).
Position the cap close to the hub to inspect parallel alignment. Adjustments aremade bymoving
the hanger arm in or out along the cap pin.
Important: Parallel Adjustment must to be made with the cap threaded on to the hub!
Otherwise the cap may fall when the set collars are loose.
If the cap is closer at the top of the hub, loosen the inside set collar (closure must be closed)
and move the hanger arm in towards the cap. When parallel alignment has been achieved move
the outer set collar in towards the cap accordingly. If the cap is closer at the bottom of the hub,
loosen the outer set collar (closure must be closed) and move the hanger arm away from the
cap (PIC#8). When parallel alignment has been achieved move the inner set collar away from
the cap accordingly and tighten both set collars. Never leave the outer set collar loose!
Note: Set collars may leave a bur on the cap pin due to the set screw in the collar. Remove the
bur with a file or emery cloth to ease movement of the hanger arm.