Sealweld Sales, Services and Training Saving clients Billions by preventing costly shutdowns and prolonging Valve and Actuator life since 1969 Presented By: Ward Hruza Branch Manager Houston, TX
Knowledgeable Technicians Available and On Call 24hrs a Day, 7 Days a Week 1 Sealweld Valve & Actuator Services o Valve Commissioning o Annual Maintenance & Inspection o Emergency Leak Sealing o Valve & Actuator Repair & Upgrades
Sealweld Valve & Actuator Training ValvePro Certification Class - UT Flex Valve & Actuator Training Flex Training is a customized course to fit attendees knowledge level and to specifically to cover common Valve & Actuator models/styles found on or at your location. 2
Sealant Guns & Pumps NEVER use low-pressure automotive-type grease guns when servicing a valve under pressure! 3
4 Hydraulic Hand Gun Pump Test internal relief valve at least once a year. Up to 10,000 psi injection pressure. 50 strokes = 1 oz. Gun capacity = 12 oz BEWARE: faulty internal relief valve possible. ALWAYS remove lubricant from its shipping packaging BEFORE loading pump! Reload with cartridge, stick or bag sealants. ALWAYS secure the handle.
5 Detecting Air in Fluid Bags Stroking handle - feels spongy or visible signs of handle movement after down stroke. Gun will NOT work in the upright position! Easily remedied.
Hydraulic Hand Pump 6
7 Alemite 6268 or Dualco 11070 o o o o Up to 15,000 psi maximum injection pressure. 25 strokes = 1 oz. Gun capacity = 12 oz. Turn the tail-crank to prime the pump. o Reload with cartridge, stick or bag sealants. o ALWAYS secure the handle. o Inability to build pressure may require head assembly replacement.
Sealweld SuperGun o o o o Reload with cartridge, o Up to 15,000 psi injection stick or bag sealants. pressure. ALWAYS secure handle. o 25 strokes = 1 oz. NOTE release valve on o Gun capacity 16 oz. hose assembly - use it! o Turn the tail-crank to prime the Easy to tell how much pump. sealant is left in the barrel. 8
9 Replaceable Piston Cartridge Sealweld SuperGun
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Sealweld ACTIV-8 Pump Air/ hydraulic sealant pump - 120 psi air. Up to 10,000 psi injection pressure. Discharge 1 lb. of sealant in 2 minutes. Pumps from a 10 lb. pail, reload after 1 lb. Trip foot petal to OFF to reload. Each stroke on jack delivers 2oz. to barrel. Pedal has 3 positions: ON, OFF & PUSH. Run cleaner through pop valve to clean. 11
12 Rockwell Hypregun & Hypregun Plus Pneumatic 100:1 ratio sealant pump. Recommended 100psi inlet air pressure = 10,000 psi. Pumps from a 10 lb. pail. Use air or gas pressure. Original Hypregun: Discharge 1 lb./5 Min. Repairs to this type of unit can be costly! Updated Hypregun Plus: Discharge 1 lb./1 Min.
13 Hypregun Down-tube Assembly Air rams lower the pumping mechanism into the sealant pail. The sealant passes through a series of narrow passages. BEWARE of air pockets. ALWAYS bleed the air out of a new pail. Keep sealant clean, dirt and grit will damage seating surfaces in down-tube assembly.
14 High-Pressure Hose Assemblies ALWAYS use a high-pressure (HP) gauge on ALL guns. Use ONLY high-pressure (HP) fittings, swivels and hoses. Replace ALL broken or damaged components. BEWARE of vent hole in Release Valve! Hose length affects overall injection pressure. ALWAYS relieve pressure BEFORE removing coupler from the grease fitting!
The Mongoose Pump 15
Valve Inspection & Maintenance 16
Verify Valve Identification Utilize Companies most recent documentation: Valve Sheet, Company I.D., Name Plate, Valve Numbering Schematic. Verify Valve ID Number, Name Plate Tag, Valve Size, Valve Manufacturer & or valve type matches documentation. VALVE NUMBER SECURE AND LEGIBLE ON THE VALVE! If Valve ID Name Plate is missing, replace following company Specifications. Inspect External Valve Components for Corrosion & Damage Valve Body, Flanges, Mounting Bolts, Valve Bonnet, Any & ALL threaded connections including Lubricant Fittings, Body Bleed Fitting, Etc. Chipped Paint can lead to Atmospheric Corrosion! 17
Valve Operation- Prior to operating a valve, Personal MUST verify which valve is to be operated & Identify its location in the operators pipeline system. OPENING or CLOSING the WRONG valve could lead to unsafe conditions, Plant Shutdown, or Damage to equipment. Make note of the position of the Valve!! If applicable fully stroke or operate Valve! Always follow Company Spec. s which will determine how far a valve can be operated. If Applicable, contact Gas Control! Document A.O.C. Valve Security- Inspect & Verify all Locks, Chains, Gates are in good working Condition! Lubricate Locks with Lubricant Replace Damaged Locks 18
External Leaks- If Pipeline Carries Liquids, Spot the drip or run-off & Trace it to its origin on the Valve & DOCUMENT! (Stem Leak, Bonnet Leak, Etc.) If Pipeline Carries Gas, check for bubbling in the water, dead vegetation, hissing or whistling sound of escaping gas! DOCUMENT ALL EXTERNAL LEAKS!!! A.O.C. s Note: With Some Gaseous Materials, it may be necessary to use a mechanical Gas detector or Sniffer to verify External Leaks!
Valve Accessibility- ALL EMERGENCY or CRITICAL Valves MUST be READILY ACESSIBLE!! Make sure Valves in Units & Valve Boxes are not covered with Dirt or Debris! Documentation- Verify All A.O.C. s are PROPERLY and CLEARLY stated on Company Inspection Sheets. Stem, Bonnet, Flange Leaks & Fittings Valve UNOPERABLE ANY BROKEN OR MISSING COMPONENTS Corrosion LEAVE VALVE IN OPERATING POSITION THAT YOU FOUND IT IN!! 20
Preventative Maintenance is a program in which wear, damage, etc. are anticipated and continuous corrective actions are taken to ensure peak efficiency and minimize damage. PM involves a planned and controlled program of systematic inspection, adjustment, lubrication, and replacement of components! The dictionary defines Maintenance as follows : The work of keeping something in proper condition: UPKEEP 21
Topping Up Routine maintenance often consists of topping-up the lubricant/ sealant level in a valve s sealant system. The sealant system is a network of grooves and channels inside the valve leading to seal points around the ball, gate or plug. Typically ¼ oz. per inch in valve diameter, per seat is a good formula for topping up a valve. For Example: A 8 Ball Valve require 2 ounces of products on the upstream and downstream seat. 22
#1 Question Asked- Q: Why top off if the Ball Valve MANUFACTURER specifies NOT TO unless Valve is Leaking!? A: To verify Sealant passages, Riser Pipes, Fittings, etc. are free flowing. (HP Gauge will Indicate Flow) Example : If a valves normal operating position is open, and 20-30 Years from now, during a project the Valve is finally closed and does not seal we know that secondary sealant grease channel passages are flowing from previous history of topping off. 23
Valve Operation is an important part of Valve maintenance. It will not only verify that the valve is functioning (Opening & Closing) but will also help crush, breakup, or dislodge any buildup on the Ball or Seat Face mating surfaces. 24
In colder Climates, winterize gear boxes by draining water from gear housing. If Valve is operated by a Gearing mechanism, Worm Gears, Bearings, Brass Sleeves should be greased/lubricated to minimize corrosion, binding & Wear. Use a good all purpose or Lithium based Bearing grease. Available in both Low Temp & High Temp. 25
A good practice is to spray a solvent/penetrant (PB Blaster) around the stem area annually. Rock or partially operate valves several times to break rust, paint, or partial debris from valve stem area. 26
When applicable, use body drain fittings to clear body cavities of trash & Liquids. Accumulated trash and debris over time can cause damage to a valves closure member and seat rings. 27
Always wear proper PPE! Safety First Using a backup wrench, verify bleed fitting is functioning & tightly installed! Identify the location of the exhaust port or Drain Hole Keep yourself & other personnel out of the line of fire. Open Body Bleed Fitting & drain any liquid, trash accumulation, line scale, etc. from Ball Valve Cavity. 28
ALWAYS Consult Valve Manufacturer/ Representative for help.