ACECO Valve P.O. Box 9 Mounds, Oklahoma 74047 PV4 - Compact Shut Off Style Pig Valve IOM - Installation, Operation & Maintenance Doc. No.: IOM-PV4-.0 Date: 6/0-00 Revision: A Contents: Installation Operation - Bill of Materials 4-5 - 6 Maintenance 7-8 Installation: Install the valve in the system using the proper size and type mating Flanges, Ring Type Gaskets or Weld End Pipe. Before Installation note the position of the Pig Stop plate for Receiving Valves and orient the valve so the Plate is downstream. The Launcher valve does not use a Pig Stop Plate. The standard valve rotation is Counter Clockwise to Open (launch or receive) and Clockwise to close (Install Pig or Remove Pig). The Valve should be installed with the Entry Plug (with or without a Davit) vertically up as shown in the image to the left. Never hold or lift the valve by the Davit Assembly. Never hold or lift the valve by the Operator. Use the flange bolt holes, lifting e or put straps around the valve body. The valve is not balanced and care should be taken when lifting to prevent the valve from shifting or spinning around. Use proper lifting equipment and techniques. After the valve is installed, the Entry Plug and Davit Assembly should be fully operated to ensure they are in proper working condition. Before applying pressure to the valve verify that the Ball is in the open position. Verify that the bleed fittings are closed. Verify that the Entry Plug is screwed down tight. Rotate the ball and verify that the valve functions properly. Counter clockwise to accept or discharge a pig and clockwise to launch or Receive. previously or subsequently sold. 6//00 Phone: 98-87-669
Page No.: IOM-PV4-.0 Operation: The ACECO Compact Shut Off Style Pig Valve is designed to be used as either a Launcher or a Receiver. The Installation determines how the valve will be used. Below are basic diagrams outlining the steps required to either Launch or Receive. Not all Valves have Davits. Launching Procedures Before opening any fittings or the Entry Plug, first review the orientation of the ball verifying the valve is closed. Follow the instructions below carefully and use every precaution to verify the valve is in the right position and the ball cavity pressure has been fully vented and relieved. Do not pollute the environment when opening fittings or the valve. FIG FIG FIG Davit Entry Plug Pig - Nose down Pig Chamber Close the Ball and open the Body Vent fittings to verify that the Upstream seat is sealing and to release any pressure from the pig chamber. Remove the Body Entry Plug and if a Davit is installed rotate it out of the way. Install the pig with the nose pointed downward. FIG 4 FIG 5 Gear Hand wheel Make sure the pig is all the way down into the valve pig chamber. It is always good practice to verify all seals are clean and undamaged. All threaded components should also be inspected to assure they are in good working condition. Never Rotate the Ball when the Entry Plug is open or loose. This will cause a sudden release of pressure from the piping system. Serious injury may occur. Rotate the Entry Plug over the opening and lower into place. Rotate the Plug until it closes tight onto the body. Do not use a hammer to force the Plug closed. Rotate the Ball counter clockwise to launch the pig downstream. When Opening the Entry Plug always make sure that precautions are taken to not pollute the environment. Wear Proper safety equipment when operating this product. previously or subsequently sold. 6//00 Phone: 98-87-669
Page No.: IOM-PV4-.0 Receiving Procedures Before opening any fittings or The Entry Plug, first review the orientation of the ball and verify that it is in the closed position. Follow the instructions below carefully and read the Caution notes. CAUTION NOTES Opening any fittings or the Entry Plug is dangerous. Make sure to follow all safety precautions when operating this valve. Take measures not to pollute the atmosphere or ground when opening the vent, drain fittings or Entry Plug. These valves are under high pressures so re-verify that the pig chamber is vented before opening the Entry Plug. Improper use may result in serious injury or death. FIG 6 FIG 7 To receive pigs the valve may be installed as shown or upside down and the ball must be open to flow. The Pig Stop must be down stream to allow the pig to enter fully into the ball cavity. FIG 9 After the pig has entered the ball cavity the valve is ready to be operated. Rotate the Valve Stem clockwise to close the Ball and orient the pig vertically. FIG 8 After the pig chamber pressure is vented, the pig is ready to be removed. Unscrew the Entry Plug and lift off the valve. A Davit may or may not be supplied. If one is, rotate the Plug out of the way. FIG 0 Knob used to grab and remove pig Once the Entry Plug is removed the pig may be retrieved from the valve. Most pigs should have a knob that can be grabbed and used to lift the pig up and out. Caution: Fluids or gases will be released to atmosphere when opening vent fittings unless other precautions or connections are made. After the pig has been removed replace the Entry Plug and tighten until the Plug is flush with the Body. Verify that all fittings are closed. Rotate the Ball counter clockwise as shown. The valve is ready to receive the next pig. It is always good practice to verify all seals are clean and undamaged. All threaded components should also be inspected to assure they are in good working condition. Never Rotate the Ball when the Entry Plug is open or loose. This will cause a sudden release of pressure from the piping system. Serious injury may occur. When Opening the Entry Plug always make sure that precautions are taken to not pollute the environment. Wear proper safety equipment when operating this product. previously or subsequently sold. 6//00 Phone: 98-87-669
Item Numbers refer to Bill of Material on Page 5. General Assembly Drawing with Davit ACECO PV4 Compact Shut Off Style Pig Valve: Page 4 No.: IOM-PV4-.0 previously or subsequently sold. 6//00 Phone: 98-87-669
Page 5 No.: IOM-PV4-.0 Generic Bill of Material Use the Assembly Drawing and the Bill of Materials shown to reference parts. The repair and maintenance procedures reference these item numbers. The recommended spare parts are listed in the Bill of Material. For other materials and part numbers consult the Factory. Item 4 5 6 7 8 9 0 4 5 6 7 8 9 0 4 5 6 7 8 9 0 4 5 Qty ~ ~ Description Body Retainer Bonnet Entry Plug Ball Stem Seat Assy Trunnion Block Trunnion Bearing Trunnion Shim Thrust Bearing Wave Spring Pig Stop Seat Seal Seat Seal Backup Stem Seal Stem Backup Bonnet Seal Bonnet Backup Retainer Seal Retainer Backup Retainer Thread Seal Retainer Face Seal Catcher Seal Entry Plug Seal Entry Plug Backup Entry Plug Weather seal Bonnet Bolts End Flange Flange Bolts Bleed Fitting Handle Pin Davit Assy Socket Head Locking Bolt Grease Fitting Spares previously or subsequently sold. 6//00 Phone: 98-87-669
Page 6 No.: IOM-PV4-.0 Davit Assembly The Davit should not need to be serviced. The main lifting and turning components are either Teflon Composite bearings or Xylan Coated for lubricity and corrosion protection. Use the drawing and Bill of Material when referencing the Davit and it s components. Item 4 5 6 7 8 9 0 4 5 6 Qty Description Pivot Shaft Pivot Bar Shaft Lock Cap Washer Cap Handwheel (SG 400-0) Pivot Bearing Thrust Bearing Hand wheel Bolt Roll Pin Shaft Bolt /4-0 UNC x lg Pivot Shaft Bolt -8 UN x.5 lg /4 x.75 Roll Pin /4 x -/4 lg Hex Bolt with Nut /8 NPT Grease Fitting previously or subsequently sold. 6//00 Phone: 98-87-669
Page 7 No.: IOM-PV4-.0 Valve Assembly/Dis-assembly Procedures The ACECO Compact Shut Off Style Pig Valves may be rebuilt to new condition with the proper tools and parts. Standard shop tools and lifting equipment are required. ACECO is not responsible for improper assembly or disassembly including injury, wrong materials, bad repair practices or other unforeseen actions. Consult the factory prior to working on any valve. Reconditioning Valve Caution! Prior to dis-assembly, valve must first be isolated from system pressure and flow and removed from the piping. Also, with the valve ball at approximately half open, internal pressure must be bled to 0 psi. Finally, as a safety precaution open all bleed fittings. Use proper lifting equipment and tools when working on the valve. Valve components are heavy and care must be exercised when handling components. Even valves removed from the piping can trap pressure. Use every precaution to ensure that there isn t any trapped pressure. After observing the above caution, dis-assembly may begin. Dis-Assembling the Valve To dis-assemble the valve, follow the instructions shown on the following page. Care must be taken to protect parts as they are removed from the valve. Prepare a safe and clean work area before beginning. After the valve has been dis-assembled the parts should be inspected for unusual wear and tear. Any unusual signs may indicate that the valve has been operated incorrectly or that it is not suitable for the service conditions. Please consult the factory with any observations that are of concern. ACECO always wants to know how their valves are performing in the field and all feedback is appreciated and used to improve our products. Rebuilding Valve To rebuild the valve, first make sure all seals are in good working condition. Have a grease lubricant handy and use it on all seals. Caution: Make sure any lubricant is compatible with the Seals and the intended valve service conditions. To rebuild the valve, just reverse the instructions above. Install all o-rings and seals on the various components according to the assembly drawing. Some Seals may have back-up rings. These are not shown in the assembly drawing. Use a copper based anti-seize compound on all threads. Make sure all bolts and nuts are tightened securely. Use the proper thread sealant for all Bleed Fitting and Grease Fittings. Rotate the Ball to verify its operation. Unscrew the closure and lift the davit to verify they are in proper working condition (see launching and receiving instructions for this). Test the valve prior to using in service. Valves used for Launching do not require a Pig Stop Plate. Valves used for Receiving will use the Pig Stop Plate. The plate should be installed in the right hand Flange when looking at the Stem with the Davit pointed up (see the picture on the front of this IOM). previously or subsequently sold. 6//00 Phone: 98-87-669
PAGE 8 Doc. No.: IOM-PV4-.0 Step Step Unscrew Locking Bolt Valve assembly instructions Step Remove End Flange Bolts and the End Flange. The flange may contain a Pig Stop. Unscrew Lock Cap Step 4 Remove End Flange Bolts and the End Flange on the other end. Davit Assy Remove Davit Assy End Flange End Flange Bolts Pig Stop Step 5 Step 6 Step 8 Step 7 Remove Entry Plug Bleed Fitting Handle Pins Remove Bonnet Bolts Remove Body Bleed Fittings if required Seals Remove the Bonnet. The Stem assembly will come out as well. Bonnet Bolts Remove and inspect Seals from the Entry Plug. Remove Handle Pins and Bleed Fitting if Required. Step 9 Bleed Fittings Step 0 Step Remove the Bonnet Seals. Remove the Stem Seals and the Thrust Washer. Push the Stem down through the Bonnet Thrust Bearing Stem Seals Bonnet Seals Step Step Step 4 Remove Seat Assembly from the Retainer. Remove the Wave Spring and Seals from Seat. Remove the Seals from the Retainer Remove the Retainer Remove the Ball and Trunnion Supports. Retainer Seat Assembly Wave Spring Seat Seal Retainer Seal Retainer Thread Seal Step 5 Step 6 Slide the Supports off the Ball. Remove the Bearings and Shims if required. Support Bearing Shim Repeat Steps, and 4 for the other Retainer. Now that the valve is completely apart inspect all parts for wear and tear. Clean all parts thoroughly. Replace all seals with new seals and inspect grooves. Inspect the Ball surface for any scratches, dings or areas that may keep it from sealing or functioning properly. Only use original ACECO parts when Rebuilding. previously or subsequently sold. 6//00 Phone: 98-87-669