MOGAS Watson Series User manual

Installation, 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

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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
• manual actuation (handlever) • pneumatic actuation
• worm gear actuation (handwheel) • hydraulic 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.
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 ow 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 6on stem 5.
5

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VALVE ITEM REFERENCE 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

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Valve Part Reference Number
Item Description
01 Ball
02 Seat
03 Seat Ring
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
1Quantity 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)

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THIS PAGE INTENTIONALLY LEFT BLANK.

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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
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 8) and continue with the valve
installation.
If the valve does not have a handlever installed, you
must install the appropriate adaptor and handlever to
open and close the valve prior to valve installation.
Pre-Installation
1
2
3
4

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While looking in the bore, open and close the valve.
Note:
If a choice is available, the valves should be installed with the ow of the
media from the end piece to the body.
Note:
The MOGAS Watson Series valve operates counter-clockwise to open,
clockwise to close.
VERIFY OPERATING POSITION
Verify that the ball open / closed position matches the
handlever or actuator open / closed position indicators.
Watson Series Valves are bi-directional valves and
may be installed in either direction.
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. (Seat leakage may
occur when the ball and seat surfaces are not
matched per the engineered design.)
THIS WILL AFFECT THE VALVE WARRANTY.
!
CAUTION!
All welding / grinding debris must be thoroughly
flushed from all associated piping before valve is
installed.
THIS WILL AFFECT THE VALVE WARRANTY.
Fully OPEN position.
Fully CLOSED position.
Installation
1
!

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SECURE VALVE IN PLACE
For raised-face flange connections, install flange
gaskets and bolting per customer requirements. When
securing other end types, please contact MOGAS
Service for proper procedures.
Note:
MOGAS valve anges are supplied in the customary “straddle centerline”
hole orientation, unless otherwise specied.
Straddle centerline hole orientation
PROTECTING THE VALVE
The valve should be lifted with slings around the valve
and not from the stem or actuator.
Flanged raised faces should be protected at all times
prior to installation to prevent 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 rst.
POSITION VALVE IN PIPING
Verify that the valve and actuator / handlever
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.
3
Installation
2
4
CAUTION!
Temperature and media compatibility should be
verified prior to installation to assure the valve is
able to perform in the desired application.
!

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VERIFY OPERATION
The valve should be opened and closed several times
and the packing gland nut or bolts should be checked
to make sure they are snug and applying a sealing
force on the packing prior to applying pressure.
All Watson Series 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
Operation
!

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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
2Body to end connection
3Actuator 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.
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 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.
3
2
1
Maintenance

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PULL VALVE OUT OF SERVICE
Remove all equipment attached to the valve and
disconnect at the ends.
A repair kit is available for the valve, which consists
of two seats, two seat gaskets, a body seal, stem
packing, a ball, and a thrust washer. The 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 valve by
replacing all gaskets, seals, packing, and ball and
seat set.
Replace the Ball and Seat Set
1

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It is best practice to remove the valve from the piping
system before replacing the packing.
If the valve must remain in-line, it must be isolated
using an approporiate block and bleed arrangement
that is consistent with the system’s hazard
classification. There must be no internal pressure
acting upon the valve or adjacent piping and fittings
prior to gland and packing removal.
ACCESS 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 plyers to work the gland flange
thruster 09 off the stem.
Inspect for corrosion, erosion and damaged surfaces.
2
15
10
04
09
CAUTION!
Do not scratch or create any burrs, which could
cause a leak.
THIS WILL AFFECT THE VALVE WARRANTY.
!
Replace Stem Packing

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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. If
possible, blow all old packing pieces from the packing
box.
Clean the stem 07 outter diameter and check for
scratches or burrs. If there is excessive damage to the
stem, the valve must be removed for repair.
3
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
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 the packing rings not to damage them.
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.
Packing configuration for Watson Series
4-in valve.
Flat ends face out
Replace Stem Packing

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INSTALL NEW PACKING RING SET
Apply Krytox™ or equivalent lube inside packing box.
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 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

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16
TIGHTEN GLAND NUTS
Install gland nuts 15 onto gland studs 14. Only finger
tighten the nuts.
6
CAUTION!
The gland flange must be pushed in evenly to
prevent “cocking” or side loading, as this could
cause damage to the packing and prevent the
valve from operating properly.
Watch the gland 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 individual valve serial number.
RE-INSTALL TOP WORKS
Repostion the handle or actuator, being careful of the
alignment.
7
Replace Stem Packing

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!CAUTION!
Verify that the ball is in the fully closed position
prior to valve disassembly.
Before beginning any work, identify the valve model
by checking the number on the side 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
remove all nuts.
2
04
13
Disassembly

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3MARK 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

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Disassembly
5MARK COMPONENTS
Mark centerline on end connection 05 internal face
and on seat 02 inside end connection.
Mark centerline and orientation (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 WARRANTY.
!

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Disassembly
REMOVE GLAND FLANGE / THRUSTER
Remove gland nuts 15 and gland flange 10, followed
by gland flange thruster 09.
8
MARK SEAT LANDING
Mark centerline on end connection 05 seat landing.
7
15
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 work the gland flange thruster 09 off the
stem.
07
04
09
09