model hx/hwx hydraulic piston actuator valve assembly · 2019. 10. 19. · 2017 omni valve company,...

© 2017 Omni Valve Company, LLC, | OMM-HX/HWX Rev: 6 page 1

OPERATION & MAINTENANCE MANUAL

Model HX/HWX Hydraulic Piston Actuator Valve Assembly


TABLE OF CONTENTS

Introduction 3

Actuator Operation 4

Internal Configuration & Parts List 5

Removal and Replacement of Model HX Hydraulic Actuator (REMOVAL) 6

Removal and Replacement of Model HX Hydraulic Actuator (RE-INSTALL) 7

Sub Assembly Instructions/Removal and Replacement of Seals 8

Cylinder/Upper Shaft Seal Retainer 9

Assembly of Actuator Complete 10-11

Omni Actuated Bonnet Assembly 12

Attachment of Gate to Actuated Bonnet Assembly 13

Setting Gate Valve Drift Shims 14

Spring Housing Assembly/Disassembly 15

Servicing of Actuator Assemblies & Bonnet Vent Identification & Usage 16

Testing Before Returning Assembly to Service 17

Servicing of Actuated Gate Valve Assemblies 17

CS-R 18

Disassembly 19

Assembly 20

Maintenance 21

Maintenance (Cont ) 22

FS-R 23

Disassembly 24

Assembly 25

Maintenance 26

Maintenance (Cont ) 27

Trouble/Probable Cause/Remedy Table 28

Warranty 29


INTRODUCTION

Omni Model HX hydraulic actuators are designed as a piston type, hydraulically-powered gate valve actuator that operates surface

safety or shutdown valves on oil & gas wellhead, transmission, storage, manifold or other applications where fail-safe capability

is required

Model HX actuators can be used for land or off shore installations and are engineered to provide reliable service in a variety of

operational conditions

Omni can provide Model HX actuators already mounted on valves and ready to deploy, or as actuated bonnet assemblies ready to

mount on valves from other manufacturers Omni also offers a full range of accessories including standard & fusible manual over-

rides, position indicators, and standard & fusible lock open devices


ACTUATOR OPERATION

Control Pressure Control Pressure

Control Pressure Control Pressure

When no control pressure is applied to ac-tuator, valve is in closed position (gate all the way up)

Valve remains in fully open position as long as adequate control pressure is present (gate all the way down)

Upon loss of control pressure, valve begins to close (gate moves up)

Valve fully closes and remains closed until ap-plication of control pressure to the actuator (gate all the way up)

Upon application of adequate control pressure to the actuator, valve begins to open (gate moves down)

With continued application of adequate control pressure, valve moves to the fully open position (gate all the way down)

FAIL-SAFE OPERATIONFail “closed” operation is depicted Fail “open” operation is available upon request

OMNI GATE VALVES PREPARED FOR ACTUATOR:

Omni offers a complete line of cast and forged body reverse acting slab gate valves prepared for actuator All Omni valves prepared for actuator are designed to be used as surface safety valves for oil and natural gas wellhead, manifold or other critical service applications with operating pressures from 2,000 to 15,000 psi

Full Assembly


INTERNAL CONFIGURATIONActuator depicted with typical 10,000 / 15,000 psi bonnet See Note 2 below

1

24

37

28

17

Stem Seal Detail

Upper Shaft Seal Detail

22

1116

29

10

27

31

32

33

34

3536

14

13

12

7

18

20

19

15

21

38

39

40

41

25

23

26

9

30

42

8

2

3

4

5

6

(ARK = Actuator Redress Kit Item) (AAK = Actuator Attachment Kit Item) (BRK = Bonnet Redress Kit Item)

Component Description Qty Component Description Qty

1 Upper Shaft 1 22 Cylinder 12 Rod Wiper 1 (ARK) 23 Spring Adjustment Nut (See Note 1) 13 Shaft Seal Retainer Ring 1 (ARK) 24 Spring 14 Wear Band 1 (ARK) 25 Spring Retainer Plate - Inner 15 Upper Shaft Seal Retainer 1 26 Operating Stem 16 Upper Shaft Seal 1 (ARK) 27 Drift Shims 37 Burst Disc 1 (ARK) 28 Packing Retainer 18 Housing Bolts 4 29 Spring Retainer Plate - Lower 19 Housing Washers 4 30 Spring Retainer Snap Ring - Lower 110 Housing Retainer Ring 1 31 Housing 111 Housing Snap Ring 1 32 Bonnet Ring 112 Cylinder Adapter Ring 1 33 Bonnet Retaining Ring - Upper 2 (AAK)13 Upper Shaft Retainer Plate 1 34 Spring Tube Retaining Ring - Lower 4 (AAK)14 Socket Head Cap Screw - Retainer (See Note 3) Varies 35 Bonnet Clamp Ring 3 (AAK)15 Socket Head Cap Screw - Adapter (See Note 3) Varies 36 Socket Head Cap Screw (See Note 3) Varies (AAK)16 Piston Seal 1 (ARK) 37 Bonnet Retaining Ring - Lower 2 (AAK)17 Spring Retainer Snap Ring - Upper 1 38 Packing Retainer O-Ring 2 (BRK)18 Piston Wear Band 1 (ARK) 39 Stem Seal 3 (BRK)19 Piston 1 40 Valve Bonnet (See Note 2) 120 Spring Retainer Plate - Upper 1 41 Bonnet Vent Fitting (See Note 2) 121 Spring Retainer Tube 1 42 Valve Lubrication Fitting (See Note 2) 1

Note 1: Actuators for some valve sizes have a counter-bore on the upper portion of the nut - example shows counter-bore Some sizes have all-thread Note 2: The specific configuration of bonnet and operating stem is dependent on valve design Omni Model HWX actuators can be adapted to operate valves from any valve manufacturer

Location and configuration of bonnet fittings is also dependent on valve manufacturer’s design Example depicts standard Omni 10,000 psi bonnet design Note 3: Varies depending on valve size Consult factory for exact quantity


REMOVAL AND REPLACEMENT OF MODEL HX HYDRAULIC ACTUATOR

REMOVAL

1 Disconnect control pressure supply from actuator port and ensure that the actuator is in the fully relieved position (Valve fully closed in a

fail-safe closed application) There should not be any pressure in the actuator Caution: Quick exhaust valves can trap residual pressure in the

actuator The actuator should not have any accessories mounted to the upper boss These include lock open cap, fusible lock open cap, manual

override assembly, and fusible manual override assembly

2 Remove bolts and washers

3 Remove housing retainer ring and housing snap ring

4 Lift cylinder/cylinder adapter ring assembly from the housing

5 Back off spring adjustment nut in counter clockwise direction

6 Remove spring retainer tube and inner spring retainer plate

7 Remove socket head cap screws located on underside of actuator near the bonnet assembly

8 Remove bonnet clamp rings (2 each) held in by bolts on the underside of the actuator Light pressure may be required to pry plates away from

actuator

9 Remove spring tube retaining rings (4 each) from groove located in between the actuator assembly and the bonnet assembly You may have

to push rings out using a pick inserted in the hole of the outside of the spring tube housing

10 Lift actuator housing/spring assembly off of bonnet assembly

11 Remove the bonnet ring retainer ring set lower from underneath the bonnet ring

12 Push the bonnet ring down

13 Remove the bonnet ring retainer ring set upper and lift bonnet ring off of bonnet


RE-INSTALL

1 Place bonnet ring on bonnet flat surface facing down

2 Install upper bonnet retainer ring set in upper groove of bonnet above bonnet ring

3 Pull bonnet ring up to capture upper bonnet retaining ring set This will expose lower groove on bonnet

4 Install lower bonnet retaining ring set Note that there is a chamfer on the OD of the lower ring set The ring set should be installed with the

chamfer facing down

5 Lower actuator housing/spring assembly over bonnet assembly

6 Install spring tube retainer ring set into groove of the spring tube housing Note that the chamfer on the ID of the ring set should be facing

down when installed

7 Install bonnet clamp ring set using socket head cap screws Make sure all bolts are started prior to tightening the bolts

8 Tighten bolts

9 Lower spring retainer tube and inner spring retainer plate

10 Install stem nut by turning clock wise until it reaches a positive stop

11 Lower cylinder/cylinder adapter ring down over housing

12 Install housing snap ring and housing retainer ring

13 Install bolts and washers

14 Reinstall all control pressure piping

15 Stroke actuator to check function

16 Retighten socket head cap screws on underside of actuator


SUB ASSEMBLY INSTRUCTIONS / REMOVAL AND REPLACEMENT OF SEALS

Piston

1 Removal and replacement of piston seals

1 1 Disconnect control pressure supply from actuator port and ensure that the actuator is in the fully relieved position (Valve fully closed in a fail-safe closed application) Be careful not to spill any hydraulic oil There should not be any pressure in the actuator Caution: Quick exhaust valves can trap residual pressure in the actuator The actuator should not have any accessories mounted to the upper boss These include lock open cap, fusible lock open cap, manual override assembly, and fusible manual override assembly

1 2 Remove the hex head bolts and washers that are attached to the cylinder adapter ring

1 3 Remove the housing retainer ring and housing snap ring The housing snap ring should be removed easily If for any reason it is difficult to remove, stop and check the pressure attachment to cylinder and check for trapped pressure

1 4 After removal of housing snap ring lift the cylinder from the housing Set assembly on flat surface

1 5 Clean entire outside surface of cylinder

1 6 Hold cylinder assembly firmly and push upper shaft and piston assembly out of the cylinder bore Clean the piston assembly as hydraulic fluid will be present Remove upper shaft retainer plate, upper shaft and the piston polypack seal and inspect for any unusual wear

1 7 Clean entire piston assembly and lube with hydraulic oil prior to reassembly

1 8 Inspect the piston for dings, nicks, or scratches Clean thoroughly, inspect sealing surfaces

1 9 Inspect the upper shaft retainer plate to determine if it is free of debris and surfaces are clean Lube using hydraulic oil

1 10 Check polypak for marks and cuts Inspect o-ring for surface imperfections Check all the sealing edges carefully by feeling all edges

1 11 Place the piston on a clean flat surface with the tapped holes facing upward Lube sealing diameter and shoulder using hydraulic oil Place polypak over the piston groove and push down gently The polypack o-ring should be facing upwards and ensure that it seats firmly on the shoulder

1 12 Install upper shaft vertically into counter bore of piston and seat firmly by hand Set upper shaft retainer plate over and down on top of piston Align four holes on the upper shaft retainer plate to the four holes on the piston and apply anti-seize lightly to the threads Install the socket head cap screws and tighten in a clockwise direction

1 13 Wipe wear band surface clean and install the wear band It must fit snugly and not overlap Stand the piston assembly in a vertical position Lift the cylinder assembly over and down onto the piston assembly Align the upper shaft and bore of cylinder and gently lower the cylinder and piston assembly The piston movement into the cylinder should be smooth Push piston assembly into bore until the upper shaft is exposed

1 14 Lift the cylinder assembly and lower it into the housing until the cylinder shoulders on it

1 15 Insert housing snap ring in ring groove in the ID of the cylinder

1 16 Insert housing retainer ring between housing snap ring and cylinder adapter ring groove to secure housing snap ring

1 17 Thread hex bolts and flat washer in cylinder adapter ring holes and tighten

1 18 Caution: Over tightening bolts will cause damage

1 19 Reinstall control pressure line Pressure up actuator and check for leaks prior to reinstalling any of the accessories


CYLINDER / UPPER SHAFT SEAL RETAINER

2 Removal and replacement of cylinder seals

2 1 Disconnect control pressure supply from actuator port and ensure that the actuator is in the fully relieved position (Valve fully closed in a fail-safe closed application) There should not be any pressure in the actuator Caution: Quick exhaust valves can trap resid-ual pressure in the actuator The actuator should not have any accessories mounted to the upper boss These include lock open cap, fusible lock open cap, manual override assembly, and fusible manual override assembly

2 2 Remove shaft seal retainer ring from top of the upper shaft seal retainer in a counter clockwise direction Rotate slowly as pressure could be trapped inside the cylinder If you hear a hissing noise, and hydraulic fluid is escaping, loosen upper shaft packing retainer slowly until disengaged Caution: Never work over actuator when disassembling

2 3 Remove polypak with extraction tool

2 4 Inspect sealing ID and OD with fingertips

3 Cylinder/Upper Shaft Seal Retainer Sub Assembly

3 1 Inspect all surfaces on cylinder threads for tears and burrs Inspect bore with hand for tears, high spots, and surface finish Check lead in angle at large opening for smooth entry In-spect the two NPT tapped holes for tears or burrs Clean entire cylinder and grease lightly

3 2 Place cylinder in a vertical position with threads at the top

3 3 Fit the cylinder adapter ring over the cylinder Thread socket head cap screws with wash-ers in bottom of cylinder adapter ring and tighten

3 4 Inspect the upper shaft seal retainer threads and sealing surface Ensure that the bore is smooth and wear band groove is free of debris

3 5 Inspect rod wiper for tears Install rod wiper into the top groove of the upper shaft seal retainer Do not grease

3 6 Install wear band into internal groove of upper shaft seal retainer Ensure that the wear band is seated into the groove properly No overlap is permitted The upper shaft will not move freely through the upper shaft seal retainer if the wear band is not seated properly

3 7 Use hydraulic oil to grease top sealing bore generously Insert a polypack with the o-ring facing downward towards the pressure The polypack will stop on the shoulder

3 8 Apply anti-seize to threads on the upper shaft seal retainer Insert the upper shaft seal retainer into the top threaded bore of the cylinder Rotate in a clockwise direction to a positive stop Using a wrench, torque the upper shaft seal retainer firmly

3 9 Install shaft seal retainer ring into the groove located at the top of the threaded boss in the cylinder Ensure retainer ring is seated in groove

3 10 Reinstall control pressure line Pressure up actuator and check for leaks prior to reinstalling any of the accessories


ASSEMBLY OF ACTUATOR COMPLETE

1 Bonnet Retaining Ring - Upper

2 Bonnet Ring

3 Bonnet Retaining Ring - Lower

4 Actuated Bonnet Assembly

5 Spring Tube Retaining Ring - Lower

6 Bonnet Clamp Ring

7 Socket Head Cap Screw

8 Spring Adjustment Nut

9 Spring Retainer Plate - Lower

10 Spring Retainer Tube

11 Spring/Housing Sub-Assembly

12 Housing Washer

13 Housing Bolts

14 Housing Retainer Ring

15 Housing Snap Ring

16 Cylinder Adapter Ring

17 Cylinder Sub-Assembly

18 Burst Disc

19 Socket Head Cap Screw

20 Washers

1

8 12

13

14

15

16

1718

19

20

9

10

11

2

3

4

5

6

7


ASSEMBLY OF ACTUATOR COMPLETE

1 Place Bonnet Ring on bonnet flat surface facing down

2 Install upper bonnet retainer ring set in upper groove of bonnet above bonnet ring

3 Pull bonnet ring up to capture upper Bonnet Retaining Ring Set This will expose lower groove on bonnet

4 Install lower bonnet retaining ring set Note that there is a chamfer on the OD of the lower ring set The ring set should be installed with

the chamfer facing down

5 Lower spring housing assembly over bonnet ring with drain holes down Spring housing assembly is installed at the factory using a shop

press This assembly should only be taken apart and repaired at the factory If parts become damaged and need immediate repair, follow

the instructions provided in spring housing assembly/disassembly section provided in this manual

6 Install Spring Tube Retainer Ring Set into groove of the spring tube housing Note that the chamfer on the ID of the ring set should be

facing down when installed

7 Set bonnet clamp ring set under the bonnet ring with chamfer up and align holes Thread socket head cap screws and tighten Ensure

that the rings and plates are flush

8 Set spring retainer tube inside of the upper spring retainer plate and spring Insert the inner spring retainer plate down inside the spring

retainer tube

9 Install stem nut by turning clock wise until it reaches a positive stop

10 Place piston sub-assembly on a flat surface Lift cylinder/cylinder adapter sub-assembly up

11 Align upper shaft on piston with bore of cylinder and lower the cylinder down over the piston The piston should enter the cylinder

smoothly After the piston has entered the bore of the cylinder, lay the cylinder and piston assembly on its side Continue pushing the

piston by hand into the bore of the cylinder until the upper shaft has extended through the upper shaft seal retainer

12 Place piston assembly in spring housing assembly

13 Insert housing snap ring in ring groove in the ID of the housing

14 Insert housing retainer ring between housing snap ring and cylinder adapter ring groove to secure the housing snap ring

15 Thread hex bolts and flat washer into the cylinder adapter ring holes and tighten

16 Wrap Teflon on a Burst Disc Fitting and install in one of the two NPT ports in the top of actuator assembly

17 Stroke actuator a minimum of three times at operating pressure

18 Retighten bolts in the bonnet clamp rings on lower part of actuator

19 Check actuator for leaks and proper operation Operation should be smooth


OMNI ACTUATED BONNET ASSEMBLY

1 With the bonnet neck facing up clean and inspect the packing bore for dam-

age Carefully check the ID threads for damage

2 Lightly lube the polypaks and insert in the packing bore with o-ring facing

down

3 Lightly lube both o-rings and install on the ID and OD of the packing retainer

4 Lube threads of the packing retainer and thread into the bonnet until the

flange of the packing retainer stops on the neck of the bonnet Tighten using

a spanner wrench or strap wrench

5 Install bonnet vent in the side of the bonnet Use pipe dope or pipe tape on

threads of bonnet vent fitting

6 Lube entire sealing surface and back-seat area of stem and insert into the

bonnet Take care not to damage the packing with the threads of the stem or

the nose of the stem Push stem up until it back-seats


ATTACHMENT OF GATE TO ACTUATED BONNET ASSEMBLY

1 Push the bonnet stem down until the lower threaded portion is exposed

2 Thread gate on to stem Depending on design this may or may not require installation of a gate nut

3 Thread gate as far on to the stem as possible and still be able to install the gate pin

4 The gate pin should be fully captured by the slot in the end of the stem

5 Support the gate or gate nut while driving in the gate pin Caution: Damage could be caused to the stem or bonnet if not supported

6 Lube gate with assembly lube prior to installing in body

7 Install new bonnet seal ring in the valve body and then carefully lower the gate into the valve body, between the seats and allow the

bonnet to pass over the valve body studs

8 Install the valve body/bonnet nuts on the studs and make up the connection as required by the valve manufacturer

9 Pull the bonnet stem up into the fully closed and back-seated position


GATE VALVE DRIFT ADJUSTMENT

1 Setting the drift can only be accomplished after the bonnet assembly has been installed on the gate valve and all studs and bolts have

been torqued with all stem to gate connections completed

2 With the gate valve in the vertical position, place three drift shims on top of the packing retainer

3 Place spring retainer cup over stem and install washer and heavy hex nut

4 Push down on the stem to bottom out the spring retainer nut on top of the shims

5 Check the drift alignment by running the appropriate size drift tool through the bore If the gate is not aligned with the valve bore, pull up

on stem to the fully closed position and remove the spring retainer cup and add or subtract shims as required to properly align the gate

with the gate valve bore

6 The stroke length is now set Proceed with actuator installation

Add Shims Remove Shims


SPRING HOUSING ASSEMBLY/DISASSEMBLY

Warning: This procedure should never be done for general maintenance and only performed at the factory. If immediate

attention is needed in the field, follow the guidelines below.

Disassembly

1 The housing assembly must be removed from the bonnet ring assembly

2 Remove cylinder and piston assembly from the actuator The stem adjustment nut, inner spring retainer plate, and spring retainer tube

may remain in the assembly to aid in compressing the spring

3 Place spring housing assembly under the shop press Apply enough pressure to compress the spring below the housing snap ring

groove Once there is plenty of room, carefully remove the housing snap ring

4 Release the shop press slowly: Use EXTREME caution, spring forces can be in excess of 10,000 lbs

Assembly

1 Place housing on table with relief holes down Insert lower spring retainer snap ring in the bottom of the housing where the relief

holes are located

2 Insert lower spring retainer plate in housing with flat side down

3 Place spring in housing sitting on the lower spring retainer plate

4 Place upper spring retainer plate on top of spring with the flat side down

5 Press spring down with shop press until appropriate ring groove is visible

6 Insert snap ring in groove and release the shop press

ACTUATOR SIZE MINIMUM AMOUNT OF TRAVEL ON SHOP PRESS

HX 20 1 75”

HX 30 1 75”

HX 40 3”

HX 60 7”

HX 90 Consult Factory


1 Prior to servicing the actuator assembly, it is recommended that this manual be read in its entirety Should the service technician have any questions or

feel that a certain procedure cannot be performed safely, contact Omni Valve for assistance

2 Proper personal protective equipment should be worn at all times during servicing any equipment Actuator valves assemblies contain pressurized fluids

and contained compressed springs

3 Do not attempt to remove any components or perform any service work with the actuator under pressure Bleed off all control pressure and disconnect

control pressure supply lines before performing any service to the actuator Failure to do so could result in damage to equipment or serious personal

injury

4 Keep all elastomers and or replacement parts in original packaging until ready to install

5 Inspect all parts new or used, for burrs, sharp edges or damage prior to reassembly Special attention should be given to all sealing surfaces for damage

6 All parts should be clean and properly lubed prior to reassembly

BONNET VENT IDENTIFICATION AND USAGE

The bonnet vent is used to verify the integrity of the backseat seal when an Omni safety valve is in the closed position The bonnet vent is located above the

backseat on the bonnet for an Omni safety valve and appears as shown in the corresponding figure

To verify the integrity of the backseat seal:

1 Remove control pressure from the actuator so the valve will close

2 Open the stinger in the bonnet vent using a hex key

3 If there is no visible leakage, the backseat is sealed

4 Close the stinger in the bonnet vent using a hex key

SERVICING OF OMNI VALVE ACTUATOR ASSEMBLIES

MAINTENANCE OPERATION CHART INTERVAL

Cycle actuator under normal operating conditions Monthly

Inspect pressure relief device for damage and proper operation Monthly

Inspect upper shaft sealing surface for damage Monthly

Check upper shaft packing retainer and retainer ring in top of actuator Monthly

Replace all seals and diaphragm Every five years or when leakage occurs

PERIODIC MAINTENANCE

Recommended service intervals for Omni Valve Actuators are as follows


TESTING BEFORE RETURNING ASSEMBLY TO SERVICE

Caution : Verify that all mechanical lock open devices are removed prior to performing any operational and pressure testing for the actuator A

mechanical override is the only mechanical device that is allowed to be used during testing It may be used during shell testing of the valve

assembly to hold the valve in the partially open position Use of the shipping cap for this operation is strictly prohibited

Valve Testing Procedures

1 All valve testing should be performed in accordance API-6A testing requirements for the appropriate pressure class and PSL

Testing Procedures

1 Verify that the burst fitting is removed and that the pressure port is plugged prior to beginning any actuator testing procedures Accidental over pressurization of the burst fitting will permanently damage the burst fitting These fittings are not covered under warranty

2 The actuator should be stroked to the fully open position and back to the fully closed position three times The function should be smooth and with no pauses or interruptions

3 The actuator should then be pressured up to the MOP stated on the actuator tag for a minimum of 3 minutes This pressure test should be performed twice while stroking the valve to fully closed position in-between pressure cycles During the hold period, any external leak-ages or significant pressure drops on the gauge should be noted and corrected/repaired

4 If there are not any leakages noted the pressure can be returned to zero

5 The burst fitting should be reinstalled with thread sealant

6 The actuator should then be pressured to the Required Control Pressure(RCP) noted on the actuator nameplate The pressure should be held there for 10 minutes Any leakages observed should be noted and repaired If no leakages are observed the pressure can be reduced to zero

7 Actuator should be stroked from fully closed to fully open and back to fully closed Operation should be smooth and without any pauses or hang-ups If the operation is satisfactory the actuated valve can be returned to service


Model CS-R

Component Description Qty

1 Valve Body 1

2 Slab Gate 1

3 Gate Nut 1

4 Roll Pin 1

5 Seat Assembly 2

6 Gate Guide 2

7 Bonnet Seal Ring 1

8 Nut *

9 Stud *

10 Body Grease Fitting (Not Shown) 2

* Varies according to valve size

7

4

6

8

9

1

3

5

2


DISASSEMBLY

1 Ensure that all pressure is bled off of the valve before disassembling

2 Remove bonnet vent fitting CAUTION: Pressure may be trapped

3 Loosen and remove the nuts that attach the bonnet to the gate valve body and remove the bonnet assembly with gate attached

4 Remove gate from stem by removing the roll pin and unscrewing the stem from the gate/gate nut Inspect sealing surface of gate for scratches, dents or

dings and replace if necessary

5 Pull out seats and gate guides Inspect all parts and replace if necessary

6 Remove bonnet seal ring

7 Clean and inspect seat pockets

8 Examine all parts for any wear and tear and replace if necessary


ASSEMBLY

1 Brush anti-seize on studs

2 Thread studs into valve body

3 Lube seat pockets in valve body

4 Place o-ring or Teflon on seat

5 Lube o-ring and place seats in seat pockets with the o-ring toward flange

6 Place gate guides, long end up with sides facing toward gate on seat flanges

7 Install the gate nut into the gate with the pin hole down towards the through bore




11 Lube gate with assembly, lube prior to installing in body

12 Install new bonnet seal ring in the valve body and then carefully lower the gate into the valve body between the seats and allow the bonnet to pass

over the valve body studs

13 Install the valve body/bonnet nuts on the studs and make up the connection

14 Align the bonnet vent fitting hole in center front of body

15 Tighten nuts to achieve seal between body and bonnet Torque according to Table 1 0

16 Wrap bonnet vent fitting with Teflon and thread into bonnet and tighten with a wrench or ratchet

17 Wrap Teflon around body grease fittings and impact tightly into the body

Thread Size Torque (ft-lbs)

0 375”-16 12

0 500"-13 40

0 562"-12 55

0 625"-11 75

0 750"-10 135

0 875"-9 200

1 000"-8 350

1 125"-8 500

1 250"-8 675

1 375"-8 900

1 500"-8 1200

1 625"-8 1600

1 750"-8 2000

1 875"-8 2500

2 000"-8 3000

2 125"-8 3600

2 250"-8 4400

2 500"-8 6000

TABLE 1 0 TORQUE VALUES

Torque tolerances are ± 10%

Torque tolerances are with bolts lubricated


MAINTENANCE

All Omni valves are shipped fully lubricated and serviced Once installed, well clean up, cementing operations, hydrofrac, acidizing, etc , can displace lubri-

cants from the body cavity This may leave particles and fluid which can be damaging to the gate and seat sealing surfaces It is recommended to drain, vent

and lubricate valves following such operations

To increase the effective life of the valve, regularly drain the valve body A minimum of lubrication maintenance will enhance the life and trouble free operation

of the valve

1 Maintenance Equipment

1 1 To facilitate the necessary valve maintenance we recommend the following equipment

2 Body Lubrication

2 1 Regular body lubrication will help keep valves operating freely and prolong their service life Lubchem 50-400 or comparable grease which is not soluble in the media being handled is recommended for body lubrication Approximately one pound of grease per inch of valve bore size will ade-quately lubricate the valve body It is not necessary to completely fill the valve body

2 2 CAUTION: Lubricating pressure must not exceed the rated working pressure of the valve being lubricated A pressure gauge should be used to monitor lubricating pressure

Each valve is equipped with two safety ball check grease fittings installed on the body of the valve Lubrication requires the use of pressure relief tool and a high pressure grease gun equipped with a coupling and needle valve The needle valve may be used to shut off flow in the event that the ball check in the fitting fails to reset

2 2 1 Operate the valve to the fully open or the fully closed position

2 2 2 Remove the safety caps from the body grease fittings and install the pressure relief tool to one fitting and the grease pump to the other fitting

2 2 3 Install the pressure relief tool with the stinger retracted Turn the stinger until it contacts the ball check, then ½ turn further to bleed body pressure

2 2 4 Inject lubricant through the additional body grease fitting

2 2 5 Once lubrication is completed, remove both the pressure relief tool and the grease pump

2 2 6 Reinstall the safety caps securely on both lubrication fittings

Figure 1

Pressure Relief Tool

Figure 2

Grease Pump


MAINTENANCE (CONT )

3 Venting and Draining

3 1 Routine draining of valve bodies will increase valve life and reduce damage to the valve caused by accumulation of foreign material The ac-cumulation of foreign material may settle out of the flow stream and into the lower section of the valve body This can prevent the gate segment from reaching the full downward position and closing fully against the seat This could result in severe erosion and damage to the seats and gate segment assembly

3 1 1 Put the valve in the fully open or the fully closed position

3 1 2 Remove one of the body grease fitting safety caps and install the pressure release tool with the stinger retracted Turn the stinger until it contacts the ball check, then ½ turn further to bleed body pressure

3 1 3 Continue venting until the body pressure reaches atmospheric pressure

3 1 4 After venting, back the stinger of the pressure relief tool out to reseat the ball check

3 1 5 If the initial draining is not sufficient, it may be necessary to repeat the procedure

3 1 6 Once completed, the valve should be lubricated per Section 4 of this operation and maintenance manual

4 Regular Preventive Maintenance

4 1 A program of routine draining, body lubrication and inspection of seals and replacement is mandatory for trouble free operation The following

is recommended for each service type

4 1 1 Normal Service (15°F to 225°)

4 1 1 1 At 120 operations or every 2 years, whichever comes first, lubricate per the following:

•Pump1cubicinchofgreasethroughthebonnetflangegreasefitting.

4 1 2 Extended temperature Service (-20°F to 250°)

4 1 2 1 At 60 operations or every 18 months, whichever comes first, lubricate per the following:

•Pump¾cubicinchofgreasethroughthebonnetflangegreasefitting.

4 1 3 Extreme temperature Service (-50°F to 350°)



4 1 3 2 At 30 operations or every 12 months, whichever comes first, replacement of seals are recommended per the following:

•Removebonnetassemblyandthoroughlycleaninteriorofvalveandallsealingsurfaces.Inspectandreplacegate,seats,

and stem if any signs of wear


FS-R

Component Description Qty

1 Valve Body 1

2 Slab Gate 1

3 Seat Ring 2

4 Body Bushing 2

5 Seat Ring/Body Bushing Seals 4

6 Retainer Plate 2

7 Gate Guide 2

8 Bonnet Seal Ring 1

9 Nut *

10 Stud *

11 Body Grease Fitting (Not Shown) 2

* Depends on Valve Size

10

5

4

6 7

2

3

1

8

9


DISASSEMBLY

1 Ensure that all pressure is bled off of the valve before disassembling

2 Remove bonnet vent fitting and body grease fitting CAUTION: Pressure may be trapped Sting the fitting to remove pressure prior to removing the fitting

3 Loosen and remove the nuts that attach the actuated bonnet assembly to the gate valve body and remove the bonnet assembly with gate attached

4 Remove gate from stem by removing the roll pin Inspect sealing surface of gate for scratches, dents or dings and replace if necessary

5 Examine all parts for any wear and tear and replace if necessary

6 Pull out seat rings, body bushings, seals, retainer plates and gate guides Inspect all parts and replace if necessary

7 Clean and inspect seat pockets and make sure that the body cavity is free of all foreign particles, such as solid particles, grit, debris, etc

8 Remove bonnet seal ring

9 Inspect all parts for damage and replace if necessary


ASSEMBLY

1 Brush anti-seize on studs

2 Thread studs into valve body

3 Lube seat pockets in valve body

4 Place seals in body bushing ring groove and lube

5 Set body bushing ring in seat pockets with seal towards flange

6 Place seals in seat rings and lube

7 Set retainer plate in valve with relief hole down and lower chamfer toward flanges

8 Set seat rings in retainer plates with seals toward flanges

9 Place gate guides in body along retainer plates, perpendicular to seat pockets with flats toward retainer plates




13 Lube gate with assembly, lube prior to installing in body

14 Apply a thin layer of lube to the bonnet seal ring and install the new bonnet seal ring in the valve body and then carefully lower the gate, into the valve body between the seats and allow the bonnet assembly to pass over the valve body studs

15 Install the valve body/bonnet nuts on the studs and make up the connection

16 Align the bonnet vent fitting hole in center front of body

17 Tighten nuts to achieve seal between body and bonnet Torque according to Table 2 0

18 For 10,000 psi valves- Wrap Teflon around bonnet vent fitting and body grease fittings and impact tightly into the body

19 For 15,000 psi valves – Brush antiseize on auto clave fitting and insert, tighten with a wrench Do not use Teflon Do not impact

Thread Size Torque (ft-lbs)

0 375”-16 12

0 500"-13 40

0 562"-12 55

0 625"-11 75

0 750"-10 135

0 875"-9 200

1 000"-8 350

1 125"-8 500

1 250"-8 675

1 375"-8 900

1 500"-8 1200

1 625"-8 1600

1 750"-8 2000

1 875"-8 2500

2 000"-8 3000

2 125"-8 3600

2 250"-8 4400

2 500"-8 6000

Torque tolerances are ± 10%

Torque tolerances are with bolts lubricated

TABLE 2 0 TORQUE VALUES


MAINTENANCE

All Omni valves are shipped fully lubricated and serviced Once installed, well clean up, cementing operations, hydrofrac, acidizing, etc , can dis-place lubricants from the body cavity This may leave particles and fluid which can be damaging to the gate and seat sealing surfaces It is recom-mended to drain, vent and lubricate valves following such operations

To increase the effective life of the valve, regularly drain the valve body A minimum of lubrication maintenance will enhance the life and trouble free operation of the valve

5 Maintenance Equipment

5 1 To facilitate the necessary valve maintenance we recommend the following equipment

6 Body Lubrication

6 1 Regular body lubrication will help keep valves operating freely and prolong their service life Lubchem 50-400 or comparable grease which is not soluble in the media being handled is recommended for body lubrication Approximately one pound of grease per inch of valve bore size will adequately lubricate the valve body It is not necessary to completely fill the valve body

6 2 CAUTION: Lubricating pressure must not exceed the rated working pressure of the valve being lubricated A pressure gauge should be used to monitor lubricating pressure

6 2 1 Operate the valve to the fully open or the fully closed position

6 2 2 Remove the safety caps from the body grease fittings and install the pressure relief tool to one fitting and the grease pump to the other fitting

6 2 3 Install the pressure relief tool with the stinger retracted Turn the stinger until it contacts the ball check, then ½ turn further to bleed body pressure

6 2 4 Inject lubricant through the additional body grease fitting

6 2 5 Once lubrication is completed, remove both the pressure relief tool and the grease pump

6 2 6 Reinstall the safety caps securely on both lubrication fittings

Figure 1

Pressure Relief Tool

Figure 2

Grease Pump


MAINTENANCE (CONT )

7 Grease Fitting Replacement (10,000 WP)

7 1 Remove the grease fitting cap

7.2.Triptheballinthegreasefittingcheckvalvebyinsertinga1/8”øby¾”longpinintotherunofthefitting.

7 3 Replace the cap gradually until the ball in the fitting is unseated

7 4 If pressure continues to escape, there is pressure in the valve body Pressure should be removed upstream prior to replacement of any fittings

7 4 1 Once removed from service, a new fitting may be installed

8 Grease Fitting Replacement (15,000 WP)

8 1 Model FS 15,000 WP Gate Valves have a single autoclave fitting

8 2 Remove the grease fitting cap

8 3 If pressure continues to escape, there is pressure in the valve body Pressure should be removed upstream prior to replacement of any fittings

8 3 1 Once removed from service, a new fitting may be installed

9 Regular Preventive Maintenance

9 1 A program of routine draining, body lubrication and inspection of seals and replacement is mandatory for trouble free operation The following is recommended for each service type

9 1 1 Normal Service (15°F to 225°)

9 1 1 1 At 120 operations or every 2 years, whichever comes first, lubricate per the following:

•Pump1cubicinchofgreasethroughthebonnetflangegreasefitting.

9 1 2 Extended temperature Service (-20°F to 250°)



9 1 3 Extreme temperature Service (-50°F to 350°)



9 1 3 2 At 30 operations or every 12 months, whichever comes first, replacement of seals are recommended per the following:

•Removebonnetassemblyandthoroughlycleaninteriorofvalveandallsealingsurfaces.Inspectandreplacegate,seats, and stem if any signs of wear


Control pressure in actuator will not build

Damaged control line Inspect control line for damage and/or leaking fittings

Insufficient pressure in control line Install gauge at pressure source to verify desired available

Faulty pressure gauge Verify pressure gauge is correctly calibrated

Leak around top and or bottom of actuatorReplace and/or inspect seals in accordance with operation manual

Actuator will not stroke from fully open to fully closed position

Gate and seat damaged/galled Repair valve assembly per manufacturer’s operating instructions

Excessive seat to gate friction due to loss of lubrica-tion in gate valve

Lubricate valve in accordance with the manufacturer’s recom-mendations

Quick exhaust valve malfunction Check quick exhaust for leaks Replace if necessary

Actuator will not stroke from fully closed to fully open position or will not stay in the fully open position

Insufficient pressure in control lineVerify pressure availability and regulator settings from source Consult control pressure chart located in the HX tech unit

Gate and seat damaged/galled Repair valve assembly per manufacturer’s operating instructions

Shut in pressure for tree is higher than expectedVerify flow pressure from well and consult HX sizing chart in tech unit

Upper shaft seals leakingApply soapy substance to upper shaft seal area of actuator Replace if necessary

Relief valve malfunction Apply soapy substance to relief valve Replace if necessary

Quick exhaust valve malfunction Check quick exhaust for leaks Replace if necessary

Actuator not properly sized for valve or pressure rating

Consult actuator brochure

Leaking bonnet flange

Loose bonnet connectionIsolate from pressure, bleed down cavity and tighten bonnet

bolting

Bonnet seal ring is worn Replace seal ring

Leaking bonnet weep hole Packing and/or stem damaged Replace packing or stem

Will not seal downstream Worn or damaged gate and seats Replace the gate and seat assembly

Grease fitting leaking Check valve inside the grease fitting is worn Tighten safety cap or replace fitting when practical

Restricted bore in valve Gate not properly aligned with the bore of seats Stroke valve fully several cycles from fully open to the fully

closed position

Leaking bonnet vent fitting

Stinger not fully closed Tighten stinger with hex key

Trash under seat Loosen and flush then retighten stinger

Damaged seat and/or ball Replace fitting

TROUBLE PROBABLE CAUSE REMEDY

TROUBLE SHOOTING


PRODUCT WARRANTY AND CONTACT INFORMATION

All products manufactured or sold by Omni are warranted against defects of material and workmanship for a period of twelve (12) months from the date of instal-

lation or eighteen (18) months from date of shipment, whichever period first expires, when all such products are used in the service and within the pressure range

for which they were manufactured

In the case of products or parts not wholly of Omni’s manufacture, Omni’s liability shall be limited to the extent of Omni’s recovery from the original manufacturer

of such products or parts under its warranty or liability to Omni

Any repair work performed by Omni is warranted for one year from completion of such repairs and applies only to work performed If, within these specified peri-

ods, Omni receives notice from Buyer of any alleged defect in or nonconformance of any product or repair and if in Omni’s sole judgment the product or repair

does not conform or is found to be defective in material or workmanship, then, Buyer shall, at Omni’s request, return the part or product F O B to Omni’s desig-

nated plant or service location

Omni has no liability for removal or reinstallation of products or equipment Omni, at its option and expense, shall repair or replace the defective part or product,

or repay to Buyer the full price paid by Buyer for such defective part, repair or product Any repayment of purchase price shall be without interest

Omni’s warranty liability, including defects caused by Omni’s negligence, shall be limited to such repair, replacement or refund, and shall not include claims for

labor costs, expenses of Buyer resulting from such defects, recovery under general tort law or strict liability or for damages resulting from delays, loss of use, or

other direct, indirect, incidental or consequential damages of any kind

Omni will not be responsible for failures of products which have been in any way tampered with or altered by anyone other than an authorized representative of

Omni, failures due to lack of compliance with recommended maintenance procedures or products which have been repaired or altered in such a way (in Omni’s

judgment) as to affect the products adversely

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, STATUTORY OR IMPLIED, INCLUDING THE WARRANTY OF MERCHANTABILITY AND FIT-

NESS FOR PARTICULAR PURPOSE WHICH EXCEED THE FOREGOING WARRANTY

If you have questions regarding this warranty or if you would like information about other Omni products and services please contact us at the address and phone

numbers below

LIMITED PRODUCT WARRANTY

OMNI VALVE

4520 Chandler Road | Muskogee, OK 74403 | USA

918.687.6100

918.687.6105

sa les@omniv alve.com

qual i ty@omniv alve.com

www.omniv alve.com

Field Trouble Reporting Form

omnivalve.com/support.shtml√

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https://omnivalve.com/support.shtml#trouble-form

https://omnivalve.com/support.shtml#trouble-form

model hx/hwx hydraulic piston actuator valve assembly · 2019. 10. 19. · 2017 omni valve company,...

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