MOGAS T Series User manual

Installation, Operation
and Maintenance Manual
PREPARE THE VALVE FOR
INSTALLATION
ACTUATE THE VALVE
INSTALL THE VALVE
PROPERLY
MAINTAIN THE VALVE FOR
OPTIMAL OPERATION
AND PERFORMANCE
for the
MOGAS T-Series (Trunnion) Ball Valve

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2
All MOGAS valves operate counter-clockwise to open, clockwise to close.
MOGAS valves are supplied in a variety of operator configurations based
upon customer requirements, and may be operated by
• pneumatic actuation • manual operation (handlever / handwheel)
• hydraulic actuation • worm gear actuation (handwheel)
• electric actuation
Each of these operator configurations may be installed and tested prior to
shipping, or shipped separately, depending on customer requirements.
Some valves are supplied with a bare stem or stem adaptor kits to
accommodate a variety of manual or actuated operators supplied by others.
Please note the configuration of each individual valve and proceed with any
necessary operator adaption procedures prior to installing the 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 information:
General information or
an alternate / variation
procedure.
Read Before Installing Valve
How to Read this Manual
Note:
The normal direction of flow is from the higher pressure end
(upstream) to lower pressure end when the valve is closed.
CAUTION!
Ensure key length provides and maintains full
engagement.
THIS WILL AFFECT THE VALVE WARRANTY.
!
PRE-INSTALLATION STORAGE
Valves shall remain stored in their shipping crates
with the lids secured.
INSTALL STEM ADAPTOR
Align stem adaptor 13 so the keyways on stem
adaptor correspond with the keys 06 on stem 05.
5

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VALVE ITEM REFERENCE NUMBER ..................................... 4
TRANSPORT AND STORAGE ........................................8
PRE-INSTALLATION ...............................................9
INSTALL OPERATOR
ACTUATOR ADAPTION ............................................... 10
INSTALLATION ..................................................15
MAINTENANCE....................................................... 18
REMOVE OPERATOR
ACTUATOR ADAPTION ............................................... 19
REPLACE STEM PACKING .........................................25
DISASSEMBLY...................................................30
REWORK COMPONENTS ..........................................37
RE-ASSEMBLY ..................................................39
LOCATE VALVE INFORMATION .....................................50
RETURN MERCHANDISE AUTHORIZATIONS (RMA) ....................51
SERVICE CONTACT ..............................................51
Contents

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4
14
6A
78
5
8A
70A
8
70
12
22
7
7C
16A
15
16B
9B 9C
21
78
55
55
2
75
77
20
22
10
11
341C 1E
1A 1C
1B 1E
1B
Valve Item Reference Number

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Valve Part Reference Number
Item Description
1A Ball
1B Seat Ring
1C Disc Spring
1D Seat Insert for soft-seated valves
1E Seat O-Ring
1H Backup Ring for ASME Class 900 and up
2Body
3End Connection 2-piece design (qty 1);
3-piece design (qty 2)
4Body / End Connect Seal or spiral wound gasket
4A Backup Ring for ASME Class 900 and up
5Stem
6A Drive Pins
7Gland Plate / Flange
7C Live Load Springs
8Stem Thrust Bearing standard for graphite sealed
8A Stem Bearing
9A Stem Packing Backup Ring for soft-seated valves
9B Stem Packing graphite or polypac
9C Stem Packing Anti-Extrusion Ring
10 Body Stud
11 Body Nut
12 Gland Stud
14 Mounting Flange
15 Gland Nut
16A Mounting Flange Bushing
16B Mounting Flange Bearing
20 Plug Trunnion
21 Trunnion Seal O-ring or spiral wound gasket
22 Bonnet & Trunnion Capscrews bonnet fastners not shown
55 Hoist Ring
70 Bonnet
70A Bonnet Seal O-ring or spiral wound gasket
75 Trunnion Bearing
77 Trunnion Thrust Bearing
78 Anti-Static Device
Valve Item Reference Number

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45
44
42
43
41
40
46
Valve Item Reference Number
Actuator Adaption

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Valve Part Reference Number
Item Description
40 Actuator Key
41 Stem Adaptor
42 Actuator Mounting Bolts
43 Actuator Mounting Flange Nut
44 Actuator Mounting Flange
45 Actuator Mounting Flange Bolts
46 Stem Adaptor Keys
Note:
Actuator adaptation kit may vary depending on the actuator.
Valve Item Reference Number
Actuator Adaption

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These procedures outline the general requirements for
storage of MOGAS valves.
TRANSPORT
For export shipping, valves will be shipped in sea-
worthy, export-packed, plastic-lined wooden crates.
Upon arrival at the site, inspect the general condition
of the valve (and actuator, if supplied) for any potential
shipping damage.
PRE-INSTALLATION STORAGE
Valves shall remain stored in their shipping crates, or
on their pallets, with the lids secured.
Valves are shipped with corrosion-resistant paint
and desiccant dries (dryer bags) for storage up to six
months.
For long-term storage, the machined internal parts of
carbon and low alloy steel valves should be sprayed
with a rust preventative.
Keep all protective covers and plastic liners in place.
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 of the valve should be
either steamed cleaned or power washed to remove
slurry and debris.
Rotate the valve to the fully open position to drain
and dry. A petroleum-based rust inhibitor should be
applied through the bore of the valve immediately
after the valve is dry.
Flange protectors need to be secured to each end of
the valve to prevent any foreign debris from entering
the valve. It is recommended to place desiccant dryer
bags inside the valve before storage.
The valve should be stored in the vertical position, out
of the weather (inside), until repairs can be made.
Transport and Storage

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REMOVE VALVE
Remove the valve (and actuator, if supplied) carefully
from the shipping crate or pallet using lifting lugs
or nylon straps around the valve body and sturdy
section of the actuator. Do not lift by the actuator
alone.
INSPECT VALVE
Inspect the general condition of the valve (and
actuator, if supplied) for any potential shipping
damage.
Review the valve manual, assembly 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
If the valve was ordered with a manual operator or
actuator from MOGAS, it should arrive pre-assembled
and tested from the factory. If already assembled,
proceed to Installation (page 15) and continue with
the valve installation.
If the valve does not have a manual operator or
actuator installed, you must install the appropriate
adaptor and operator to open and close the valve
prior to valve installation.
Place the valve and actuator in the full open position
to validate stop adjustment and proper operation.
Return the valve to the full open position for
installation.
Pre-Installation
1
2
3
4

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Verify that the keyway nearest the stamped Ton the
end of the valve stem 5is oriented properly (‘T’ to the
top).
When the valve is closed, the keyway nearest the
stamped Tshould face the end connection 3, or
bolting side of valve.
When the valve is open, the keyway nearest the
stamped Tshould face 90° counter-clockwise from
the end connection 3, or bolting side of the valve.
STEM ORIENTATION
VALVE ORIENTATION
Secure the valve in a horizontal position.
The bore should be horizontal, with the stem in a
vertical position.
The mounting flange should be level.
These procedures apply to hydraulic, pneumatic
and worm gear actuation supplied by MOGAS or a
MOGAS authorized distributor. Otherwise, refer to the
actuator manufacturer’s manual for specific operator /
actuator removal procedures.
Note:
Valve item numbers shown in bold correspond with items shown in the
Valve Item Reference Number, section (pages 4-7) of this document.
CAUTION!
It is extremely important to follow these steps to
ensure maximum valve performance.
THIS WILL AFFECT THE VALVE WARRANTY.
!
Stem shown in OPEN position.
5
Install Operator
Actuator Adaption
1
2

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Insert stem adaptor keys 46 into stem keyways.
INSERT KEYS
tooltip
CAUTION!
Ensure stem adapter keys 46 length provides and
maintains full engagement. Supplier of adaption
package should provide stem adaptor key
specifications.
THIS WILL AFFECT THE VALVE WARRANTY.
!
ACTUATOR MOUNTING FLANGE
Lower the actuator mounting flange 44 over the stem
adaptor 41 and onto the valve mounting 14 flange.
OPERATING POSITION
Verify that the valve and actuator are in the same
operating position (open or closed).
STEM ADAPTOR
Note:
Some installations may not require a stem adaptor.
Align the stem adaptor 41 so the keyway on the stem
adaptor corresponds with the keyway on the actuator.
tooltip
46
41
44
Install Operator
Actuator Adaption
3
6
4
5

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CAUTION!
Ensure actuator key 40 length provides and
maintains full engagement. Supplier of adaption
package should provide key specifications.
THIS WILL AFFECT THE VALVE WARRANTY.
!
MOUNT ACTUATOR
Align the actuator key 40 of stem adaptor 41 with
keyway of actuator.
Carefully place the actuator on the valve mounting
flange 14 (or stem adaptor 41).
CAUTION!
Do not force actuator onto stem adaptor. Proper
alignment is critical to ensure the actuator slides
gently into position.
If stem is forced into valve, severe damage could
occur.
THIS WILL AFFECT THE VALVE WARRANTY.
INSTALL KEY
Insert actuator key 40 into stem adaptor keyway.
Note:
Some installations may require inserting the key through an access port
in the actuator, after actuator is in position.
!
SECURE FLANGES
Attach flanges using actuator mounting flange bolts
45 and nuts 43.
CAUTION!
Torque the bolting per the specifications included
with the test certificate for each individual valve
serial number.
THIS WILL AFFECT THE VALVE WARRANTY.
40
43
45
Install Operator
Actuator Adaption
9
8
7
!

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CAUTION!
If the actuator is supplied by MOGAS, refer to the
torque values in the test certificate provided for
each individual valve serial number. Otherwise,
refer to the manufacturer’s specifications.
THIS WILL AFFECT THE VALVE WARRANTY.
!
INSTALL BOLTS
Install the actuator mounting bolts 42 and torque as
required.
VERIFY OPERATION
Note:
The MOGAS valve operates counter-clockwise to open, clockwise to
close.
The actuator should be stroked to ensure that the ball
1A is rotating properly, and the ball position matches
the open / closed indicators on the actuator.
If the ball requires alignment, the actuator stops
should be reset at this time, per the manufacturer’s
specifications.
Stroke the ball to ensure proper
rotation.
1A
42
Install Operator
Actuator Adaption
10
11

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The fully open position is the most important position
to set. It is preferred that the open position be set
before the valve is installed in the pipeline.
The fully open position should properly align the bore,
ensuring that no edges of the ball 1A are exposed to
the flow.
For visual verification of open / closed, locate the
scribed lines on the stem 5and gland flange 7.
These lines are approximate locations and should not
be used for setting the open stop. For best results,
ensure the lines never under travel — a minimum
travel of 96° is required.
When the actuator is properly set, the scribed lines on
the stem and gland flange should match.
CAUTION!
Misalignment can result in valve under- or over-
stroke, creating a potential leak path.
THIS WILL AFFECT THE VALVE WARRANTY.
!
SET STOP POSITIONS
Note:
The actuator stops may be reset per the manufacturer’s specifications to
achieve fully open and / or fully closed position.
Fully OPEN position.
Set stop positions.
Install Operator
Actuator Adaption
12

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While looking in the bore, open and close the valve.
CAUTION!
The actuator 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 remain match. (Seat leakage may
occur when the ball and seat surfaces are not
matched per the engineered design.)
Refer to Rotate Operator – Actuator Adaption
(page 19) for proper procedures to rotate the actuator.
THIS WILL AFFECT THE VALVE WARRANTY.
The fully open position is the most important position
to set. It is preferred that the open position be set
while the valve is not installed in the pipeline. This
allows for the bore to be properly aligned, ensuring
that no edges are exposed to the flow.
Note:
Misalignment can result in valve under- or over-stroke, creating a
potential leak path and affecting warranty.
Note:
The MOGAS valve operates counter-clockwise to open, clockwise to
close.
VERIFY OPERATING POSITION
Verify that the ball open / closed position matches the
operator’s open / closed position indicators.
Verify that the scribed lines on the stem 5align with
the scribed lines on the gland flange 7. These lines are
approximate indications. For best results, make sure
the lines never under travel — a minimum travel of 96°
is required.
Note:
Larger valves may require the actuator to be in place to rotate the ball.
Fully OPEN position.
Fully CLOSED position.
Note:
Valve item numbers shown in bold correspond with items shown in the
Valve Item Reference Number section (pages 4 – 7) of this document.
Installation
1
!

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POSITION VALVE IN PIPING
Verify that the valve and actuator orientation is
correct.
Verify that the valve is in the open position to prevent
any damage to the ball surface from debris.
Position the valve in line with mating flanges.
Note:
Support or lift as required, using lifting lugs or nylon straps around the
valve body. Do not lift or support by the actuator alone.
CAUTION!
All welding / grinding debris must be thoroughly
flushed from all associated piping before valve is
installed.
THIS WILL AFFECT THE VALVE WARRANTY.
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.
Straddle centerline hole orientation
These procedures are for raised-face flange
connections. When securing other end types, please
contact MOGAS Service for proper procedures.
Installation
2
!
3

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VERIFY OPERATION
After installation, open and close several times to
ensure smooth operation.
All MOGAS ball valves are designed for on / off
services only.
To 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 of the valve.
THIS WILL AFFECT THE VALVE WARRANTY.
Fully CLOSED position.
Fully OPEN position.
Partially OPEN position
(not recommended).
CLOSE
OPEN
Installation
4
!

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18
CAUTION!
It is extremely important to follow these steps to
ensure maximum valve performance.
THIS WILL AFFECT THE VALVE WARRANTY.
!
VERIFY BOLTING TORQUE
After the first exposure to elevated temperature and
the valve has completely cooled-down, verify bolting
torque at these locations:
1Packing gland flange / bonnet capscrews
2Body to end connection
3Trunnion capscrews
4Actuator to valve mounting (if present)
Check the 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.
Bolting torque should be applied to the specified
values in three equal steps utilizing a ‘star’ pattern,
followed by one last check applying the specified
torque to each fastener sequentially in a clockwise
pattern.
THIS WILL AFFECT THE VALVE WARRANTY.
!
OPEN / CLOSE VALVE REGULARLY
Valves remaining open or closed for a long period of
time should should be, at a minimum, partially stroked
every six months.
In potentially fouling services, valves should always
be fully opened and fully closed to wipe away any
accumulation on the sealing surfaces.
ACTUATOR LUBRICATION
Keep hydraulic, pneumatic and worm gear actuators
fully lubricated according to actuator manufacturer’s
specifications.
4
2
3
1
Maintenance

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These procedures apply to hydraulic, pneumatic
and worm gear actuation supplied by MOGAS or a
MOGAS authorized distributor. Otherwise, refer to the
actuator manufacturer’s manual for specific operator /
actuator removal procedures.
Note:
Valve item numbers shown in bold correspond with items shown in the
Valve Item Reference Number section (pages 4-7) of this document.
CAUTION!
It is extremely important to follow these steps to
ensure maximum valve performance.
THIS WILL AFFECT THE VALVE WARRANTY.
!
REMOVE BOLTING
Remove actuator mounting bolts 42 holding actuator
to valve mounting flange 14 (or actuator mounting
flange 44, if provided).
LIFT ACTUATOR
Lift the actuator straight up and off the valve mounting
flange 14 (or actuator mounting flange 44).
CAUTION!
The actuator 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. (See page 38, step 2 for
matching clarification.) Seat leakage may occur
when the ball and seat surfaces are not matched
per the engineered design).
THIS WILL AFFECT THE VALVE WARRANTY.
!
42
Rotate Operator
Actuator Adaption
1
2

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ROTATE ACTUATOR
After the actuator is removed, rotate the actuator to
the desired position.
Note:
As a standard practice, MOGAS adaption is designed to be rotated in 90°
increments.
STEM ADAPTOR POSITION
Verify the position of the stem adaptor 41, if present.
If the slot or keyway does not match the slot or
keyway in the actuator, the stem adaptor 41 must be
rotated as well.
REMOVE BOLTING
Remove actuator mounting flange nuts 43 and bolts
45 holding the actuator mounting flange 44 to the
valve mounting flange 14.
REMOVE ACTUATOR MOUNTING
FLANGE
Lift the actuator mounting flange 44 straight up and
off the valve mounting flange 14.
Note:
Rotating the stem adaptor may require removal of the actuator mounting
flange, if present.
REMOVE KEY
Remove the actuator key 40.
4
41
43
45
40
44
Rotate Operator
Actuator Adaption
3
5
6
7