MOGAS ASME Class 600 User manual

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

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2
Identitifies and explains
sequential procedure to
be performed.
Bold numbers correspond
with items shown in the
Valve Item Reference
Number sections.
Note provides important
information related to a
procedure.
Indicates a hazardous
situation which, if not
avoided, could result in
death or serious injury.
Indicates a hazardous
situation which, if not
avoided, could result in
minor or moderate injury.
Indicates a potential situation
which could result in damage
to the valve or may void the
warranty.
Important User Information
HOW TO READ 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 from around
stem.
Note: It is recommended that operator installation only be
performed by authorized MOGAS service personnel.
WARNING!
Do not perform this task under line pressure.
Make sure the line is not under pressure.
00
CAUTION!
Do not install valve for pressures or temperatures
higher than rated.
NOTICE
The valve operator should be equipped with
position indicators for correct ball bore position.
!
!

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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

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89
Important Valve Information
NOTICE
Information throughout this manual is based on
a valve / actuation package recommended and
provided by MOGAS.
PURPOSE
The MOGAS switching valve is a highly engineered
product that has adopted many successful features
utilized in severe coking applications.
MOGAS has added several customized safety
features into this valve 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 job-specific or general arrangement drawings
provided for your configuration details.
VALVE INFORMATION
Valve information is provided on a nameplate 89
as shown.
The nameplate is wire-fastened to body for easy
access.
1
2
3

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LIFTING LUG LOCATIONS
SPREADER BAR FOR LIFTING
Receiving and Inspection
REMOVE VALVE
Valves are shipped in seaworthy export packed
wooden crates that are plastic lined.
Carefully remove the valve (and operator, if supplied)
from the shipping crate or pallet by using lifting lugs
with spreader bar.
INSPECT VALVE EXTERNALLY
Inspect the general condition of the valve (and
operator, if supplied) for any potential shipping
damage.
Review the valve manual, assembly drawing with the
bill of materials, and the operator manual (if supplied)
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 the valve does not include an operator, the
appropriate adaptor and operator must be installed
to cycle the valve prior to installation.
Note: It is recommended that operator installation only be
performed by authorized MOGAS service personnel.
CAUTION!
Do not lift by the operator alone. Lift using all four
lifting lugs. Use a spreader bar to avoid damage or
contact with operator or motor.
!

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08 15
07C
07
12
09A
09C
09B
09B
11
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 PACKINGBODY, 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.

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05B
05D
52
68
58
16
06
37
14
69
65
67
22
67
65
69
31
60
65
67
69
Valve Item Numbers
Valve Item Number Reference
Item Description Qty Soft
Goods
Kit
Trim
Change
Kit
1A BALL WITH STEM 1 — •
1B SEAT RING 3 — •
1C SPRING DISC 3 — •
1G SEAT OUTER SEAL 6 • —
2B BODY 1 — —
3C BONNET 1 — —
04 BODY GASKET 1 • •
05B STEM ADAPTOR 1 — —
05D INDICATOR ROD 1 — —
06 KEY 2 — —
06A ALIGNMENT PIN, BONNET 1 — —
07 GLAND FLANGE 1 — •
7C LIVE LOAD 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 1 — —
31 MOUNTING FLANGE BOLTING 8 — —
37 MOUNTING FLANGE NUT 8 — —
52 HEX NUT, INDICATOR ROD 1 — —
55 HOIST RING 4 — —
58 STOP PLATE 1 — —
60 WEDGE LOCK WASHER 1 — —
65 STOP PIN 3 — —
67 QUICK-RELEASE PIN 3 — —
68 PIN, STEM ADAPTOR 2 — —
69 EYE BOLT 3 — —
89 NAMEPLATE (SEE PG 4) 1 — —
TOP WORKS

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BP
B
A
Installation
ORIENTATION
Each port description shall be stenciled on the flange
and labeled on top of the actuator, to identify its
direction of flow, such as: (A) Drum A, (B) Drum B,
and (BP) Bypass.
The valve can be installed with the stem in the
horizontal, vertical or angled position. The preferred
installation position is vertical. For motorized gearbox
operators, the mounting hardware shall sufficiently
support the gearboxes without additional support(s).
If the valve is positioned in the horizontal or angled
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 available on customer valve
assembly drawing.
CAUTION!
The entire valve assembly may require support(s)
due to its weight. It is recommended that the
customer review the valve assembly and determine
its proper support system.
THIS WILL AFFECT THE VALVE WARRANTY.
1
2
CAUTION!
Do not install valve for pressures or temperatures
higher than rated.
THIS WILL AFFECT THE VALVE WARRANTY.
!
!

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Straddle Centerline Hole Orientation
POSITION INDICATOR
KEY (x2)
21
BP
Installation
OPERATOR ADAPTION / ACTUATION
If the valve does not include an operator, the
appropriate adaptor and operator must be installed
to perform switching operations.
All new operators will require machining modifications
to the top plate for indicator rod, limit switches and
actuator key slots.
Note: It is recommended that operator installation only be
performed by authorized MOGAS service personnel.
SECURE 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 Ato Bto BP,
and then from BP to Bto A.
Repeat procedure 2 times.
Note: Check indicator rod to ensure ball bore position.
All indicator locations should match ball bore position.
CAUTION!
If the valve was supplied with an operator, the
operator must not be re-oriented without prior
notice to MOGAS or without supervision by
authorized service personnel.
THIS WILL AFFECT THE VALVE WARRANTY.
3
4
5
!

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10
14
2
1
BP
NOTICE
Due to the potential for packing consolidation,
verify proper packing torque adjustment prior to
placing the valve in service. 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.
LOCATE POSITION INDICATORS
The valve operator should be equipped with position
indicators for correct ball bore position.
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 to prevent switching
once a position is selected. All pins and keys are
tethered to the mounting flange via cables.
Note: Positional stops include Bypass (BP) Lock/Stop Pin,
Lockout Pin 1 and Lockout Pin 2.
Secure lock-in pins are provided, and should be
used once lockout pins are engaged into their proper
location.
1
2

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INNER VIEW OF STOP PLATE
AND PINS DURING SWITCHING.
GROOVE INDICATES
PORT SELECTION.
2
1
BP
BP
1
2CW
CCW
Switching
Process
Disengage
Pins
Ball
Rotation
Engage
Pins
Ato B1 + BP CW 2 + BP
Bto A2 + BP CCW 1 + BP
Ato BP 1 + BP CCW 1 + 2
Bto BP 2 + BP CW 1 + 2
BP to A1 + 2 CW 1 + BP
BP to B1 + 2 CCW 2 + BP
Operation
START-UP
Disengage all positional stops.
Rotate bore of ball to desired starting position.
(Drum Aor B.)
Insert BP Lock/Stop Pin fully into position, to prevent
accidental switching to Bypass Port.
For Drum Aoperation, insert Lockout Pin 1and keep
BP Lock/Stop Pin in locked position.
For Drum Boperation, insert Lockout Pin 2and 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 OPERATIONS
This table provides a reference for all switching
operations between Drum A, B, and BP.
3
4
CAUTION!
It is extremely important to follow these steps to
ensure maximum valve performance and safety.
THIS WILL AFFECT THE VALVE WARRANTY.
!

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12
TYPICAL PURGE LOCATIONS
TYPICAL DRAIN LOCATIONS
Purging and Draining
PURGING
MOGAS coker switching valves are typically equipped
with steam purges.
To prevent valve lockup and ensure continuous
operation of these valves, it is highly recommended
that the purging process be continuous in the body
cavity area.
Note: Review any job-specific or general arrangement drawings
provided for purge locations and procedures.
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.
CAUTION!
It is extremely important to follow these steps to
ensure maximum valve performance and safety.
THIS WILL AFFECT THE VALVE WARRANTY.
NOTICE
Some MOGAS switching valves may have
automated purge and drain procedures. Consult
a MOGAS representative to learn more about
these options.
!

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15
Maintenance
ACTUATOR LUBRICATION
Keep hydraulic, pneumatic and worm gear actuators
fully lubricated according to actuator manufacturer’s
specifications.
VERIFY BOLTING TORQUE
After the first exposure to elevated temperature
and / or pressure, and the valve has completely
cooled, verify bolting torque at these locations:
• Packing gland flange
• Body to bonnet connection
• Actuator to valve mounting
Check the bolting at these same locations periodically.
CAUTION!
It is extremely 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 torqued to specified values
on the test certificate provided for each individual
valve serial number.
Note: There should be no reason to replace the stem packing
during normal operation. The packing should be replaced when
the valve is removed from service for repair. Replace with factory
recommended packing to maintain appropriate compression.
!
!

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14
!
14
Disassembly
NOTICE
Operator packages will vary based on customer
requirements. Operators should be equipped with
position indicators for correct ball bore position.
If position indicators are not visible, the scribe line
on the gland plate 07 can be used to determine the
position 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 ball bore is
in alignment to any of three ports.
CAUTION!
If you disassemble, rework and re-assemble this
ball valve, YOU WILL VOID YOUR WARRANTY.
1
2

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KEY (x2)
INDICATOR
SOCKET HEAD
SCREW
37
14
31
05D
05D
52
60
Disassembly
REMOVE OPERATOR ASSEMBLY
Detach the indicator from indicator 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

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16
!
15
07C
12
09A
09B
09B
09C
11
03C
21
06A
04
07
Disassembly
REMOVE GLAND FLANGE
Remove gland hex nuts 15.
Remove live load springs 07C.
Remove gland flange 07.
Remove packing gland studs 12.
REMOVE STEM PACKING
Using a small pick or scribe, carefully remove packing
rings 09A and anti-extrusion rings 09B from around
stem.
Make 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 seal 21 and discard. Seal must be
replaced at re-assembly.
Remove body gasket 04 and discard. Gasket must be
replaced at re-assembly.
Remove bonnet alignment pin 06A and save for
re-assembly.
6

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01B 01G
01G
01C
16A
01C
01B
08
REMOVE STEM BUSHING AND BEARING
Remove any remaining debris around stem bushing
area to prevent damage to stem packing area.
Remove stem bushing 16A.
Remove stem thrust bearing 08.
Inspect for any excessive wear or damage, and replace
if needed. If parts are reusable, clean for later reuse.
7
8REMOVE SPRINGS AND SEAT RINGS
Note: Depending on the severity of coke buildup, the springs
may possibly be removed using an S-hook rod. For heavier
coke buildup, a spring removal tool may be required to remove
springs. It is recommended that spring 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 ports.
With seat rings 01B removed, inspect for excessive
wear or damage, and replace if needed. If seat rings
are reusable, clean for later reuse.
Remove old graphite rings 01G and discard. Graphite
rings must be replaced at re-assembly.
Seat springs 01C must be replaced at re-assembly.
Disassembly
NOTICE
Make sure bore of ball is aligned to spring 01C of
selected port, and the S-hook rod is in contact with
only the spring, not seat 01B.

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18
01A
08E
09D
08C
07F
REMOVE BALL AND STEM ASSEMBLY
Attach lifting lug to top of ball and stem assembly 01A.
Lift straight up to remove from body.
Remove ball sleeve bearing 08E. Sleeve bearing must
be replaced at re-assembly.
Inspect ball and stem for any excessive wear 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, clean for later
reuse.
Remove sleeve spring 07F from body and discard.
Sleeve spring must be replaced at re-assembly.
10
9
Disassembly

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SPARE PARTS KIT
If you have purchased a spare parts kit from MOGAS,
prepare the parts for assembly now.
The soft goods kit should include any gaskets, seals,
and packing required.
The trim change kit should include a ball and matched
seats, in addition to any springs, bearings, 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 may be necessary.
Evaluation and Rework
CAUTION!
If you disassemble, rework and re-assemble this
ball valve, YOU WILL VOID YOUR WARRANTY.
!

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20
01A
08E
09D
08C
02B
07F
INSPECT AND CLEAN ALL PARTS
Ensure that any soft goods kits and / or trim change
kits contain the correct parts and quantities.
Ensure all parts that are to be re-used are clean
and have no signs of excessive wear or other
abnormalities.
POSITION VALVE BODY
Prior to assembly, verify that the valve body 02B is
resting on a flat surface in the vertical position with
the inlet-end down and body cavity upright.
INSTALL BALL SLEEVE AND SPRING
Place sleeve spring 07F in the bottom of body 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. Ensure
bore of ball is aligned with any of three ports.
Re-Assembly
CAUTION!
If you disassemble, rework and re-assemble this
ball valve, YOU WILL VOID YOUR WARRANTY.
1
2
3
4
Note: All seals, gaskets, springs and packing must be replaced
with new materials during assembly to ensure proper valve
operation. Refer to Valve Item Reference Number section for
all parts identification.
!