OPERATING AND MAINTAINENCE MANUAL

1" & 2 "INCH TOP ENTRY PLUG VALVE

PROC.: PIK/PRO/PV/01
 SAFETY INFORMATION

IMPORTANT SAFETY INFORMATION ENCLOSED. READ THIS OPERATING AND MAINTENANCE

INSTRUCTIONS MANUAL BEFORE OPERATING PRODUCT.

IT IS THE RESPONSIBILITY OF THE PURCHASER TO PLACE THE INFORMATION IN THIS MANUAL

INTO THE HANDS OF THE OPERATOR.

FAILURE TO READ, UNDERSTAND AND FOLLOW THE OPERATING AND MAINTENANCE

INSTRUCTIONS MANUAL COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.

TABLE OF CONTENT
SECTION TITLE PAGE

1. PRODUCT DESCRIPTION 1

2. SAFETY PRECAUTION & WARNINGS 2-3

3. OPERATING INSTRUCTIONS 4

4. MAINTAINENCE INSTRUCTIONS 4

4.1 RECOMMENDED ROUTINE MAINTAINENCE 4

4.2 BILL OF MATERIAL 6

4.3 DISASSEMBLY 7

4.4 ASSEMBLY 7-8

5.0 STORAGE INSTRUCTIONS 9

PRODUCT DESCRIPTION

ACT Plug Valves are designed to regulate the transport of fluid through a flow line. By rotating the plug 90°,
the flow can either be terminated, or allowed to flow through the Plug Valve Bore. They require minimum space,
are simple to operate, exhibit a fast response, and add relatively little internal disturbance to the flow. Therefore
pressure drop across the valve is low.

Operation is accomplished by a 90° rotation of the plug. This can be performed manually, or with pneumatic or
hydraulic actuators.

These plug valves are available for standard and H2S service. The H2S Plug Valves conform to NACE
MR0175 for exposure to H2S. It is important that the correct Plug Valve be used for the specific application.
Characteristics

· No need to remove valve from line for maintenance.

· No special tools needed for operation or maintenance.
· High finish floating seal segments insure positive seal between fluid stream and cylindrical plug.
· Excellent sealing provided by precision ground metal-to-metal seal between seal segments and plug.
· Pressure-enhanced sealing between segments and body provided by molded rubber static segment
seal.
· Segment design ensures easy operation up to the full working pressure of the valve.
· Nitriding is done on the plug to protect against wear protection.
· Quality components throughout unit including forged heat-treated alloy steel body for greater
dependability, minimum weight and maximum strength.
· Handle has visible indication of open or closed position and detent spring to insure valve stays
open or closed.
· Hydraulically-actuated models optional.
· Remote-control actuator available.
· Each valve is thoroughly tested prior to shipment.

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WARNING
WARNING: IMPORTANT SAFETY INFORMATION ENCLOSED. READ THIS OPERATING AND
MAINTENANCE INSTRUCTIONS MANUAL BEFORE OPERATING PRODUCT.
WARNING: THIS INFORMATION MUST BE AVAILABLE TO ALL PERSONNEL THAT WILL OPERATE
AND MAINTAIN EQUIPMENT. FAILURE TO READ, UNDERSTAND AND FOLLOW THE OPERATING
AND MAINTENANCE INSTRUCTIONS MANUAL COULD RESULT IN

SEVERE PERSONAL INJURY OR DEATH!

WARNING: MISUSE, SIDE LOADING, IMPROPER MAINTENANCE, OR DISASSEMBLY UNDER

PRESSURE CAN CAUSE SERIOUS INJURY OR DEATH!

DO NOT EXPOSE STANDARD SERVICE PRODUCTS TO SOUR GAS FLUIDS. DON NOT CHANGE SOUR
GAS WITH STANDARD SERVICE COMPONENTS

NOTE:- The following information is given in good faith and should aid in the safe use of your ACT products.
This information is not meant to replace existing Company's safety policies or practices. It is important to read and
understand the safety instruction given in this manual.

SAFETY INSTRUCTION
Safety Guide for Plug Valves

Personal Responsibilities:

When using these assemblies, appropriate protective equipment is required: safety glasses, approved safety shoes
and hard hat must be worn. Hammering and lifting these assemblies must be done with caution. Where unions are
present, please be careful not to mix fig.602 aand fig.1502 connection.

Personnel should only hammer on makeup lugs and not strike union nut or valve body. Fractures can occur
from repeated misuse. Excessive hammering can damage components.

Proper leg lifting should be used when lifting. Back lifts should be avoided.It is a personal responsibility to
become knowledgeable and trained in the proper use and handling of this tool.Do not hammer on, or be around
valve assemblies when pressure is present.Hand actuation (with the appropriate actuator bar) should be done only
by specially trained personnel under direct supervisory instruction; and only when necessary due to application.

Proper transportation of plug valves is important. Racks that will secure valves and prevent accidental
unloading are critical.

Never transport any ACT valve in a fashion that would allow it to become dislodged and cause an accident.
Valve unions should be clean and lightly oiled prior to each use. A visual inspection for damage should also
be performed at this time. Union seals should be checked, and replaced when worn or damaged.

Each valve has a size and pressure code designated on the valve. Use this code for proper mating and pressure
limits.

CAUTION: SINCE PLUG VALVES MAY BE REPAINTED IN DIFFERENT COLORS FOR VARIOUS
APPLICATIONS, DO NOT USE FACTORY COLOR AS PRIMARY MEANS OF IDENTIFICATION.

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PRECAUTION DURING USAGE

It is sometimes necessary to turn valves when pressure is present. It is recommended that remote control actuators
be used for this purpose. If this is not feasible, then only experienced specially trained personnelunder direct
supervisory instruction should perform this task.

Prior to applying pressure, valves should be greased in both the opened and closed position. This should be done
before each use. If valve is excessively hard to operate, it should be removed and not used until repairs are made.

It is sometimes necessary to turn valves when pressure is present. It is recommended that remote control actuators
be used for this purpose. If this is not feasible, then only experienced specially trained personnel under direct
supervisory instruction should perform this task.

When opening a plug valve under pressure, the initial torque to start the stem turning is always greater than the
moving torque. You must position your body to be able to compensate for this change.

Do not position any part of your body in the path of exit flow of the valve.
Do not position the exit of any plug valve, used for bleeding, where rocks or debris may be picked up by the exit
stream.

If any valve becomes plugged, or does not operate properly, contact a supervisor immediately. DO NOT look
into the end of the valve to check for debris, blockage, or for any other reason.

If valve is slow to open or close, remove it from service. Do not hammer on the valve's actuator cap.
It is recommended that a rate in excess of 42 feet per second be avoided. Rates above this will cause a more
rapid wear and erosion.

RECOMMENDED PRECAUIONS

Welding, brazing, or heating on ACT plug valves is prohibited.

Valve operation sometimes requires personnel to be around pressured lines. Experienced personnel only should be
dispatched for this purpose. Exposure time should be a minimum. Always use remote controlled valves whenever
possible. Never look into, or position yourself in, the path of the exit flow of the valve.

Never alternate a valve's service. Acid service should never be followed by cold temperature service. When
acid etching or erosion is present, replace the valve.

Each integral union connection is clearly marked with a pressure code (i.e. "1502", 15,000 psi) on the nut. This
pressure must not be exceeded. This code should also be used with mating unions. Improper mating can result in
failures. All integral union connections must match (according to size, pressure rating, etc.). These connections
must also match the service of the designated string they are installed in.

INSPECTION AND REPAIR

Valves should be greased after each use.Inspect all sealing parts and rubber parts. Recoomedation is to replace all
rubber parts after each job.
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OPERATING INSTRUCTION

ACT Top entry plug valves are primarily used as isolation valves. This plug valve is bi-directional; it can isolate
flow from either direction.

1. Prior to use, the valve should be inspected for proper operation. The valve should be free of contamination and
the valve should actuate from open to close position freely.

WARNING: Never look into the valve bore while the valve is in a flowline. Pressure and fluids could escape
from the valve causing bodily injury.

2. The valve should be thoroughly flushed with clean fresh water after each use and the bore of the valve should
be sprayed with a light oil or comparable corrosion inhibitor.

MAINTAINENCE INSTRUCTION

The 2" Plug Valve is made from high quality materials selected to provide the best service to the customer.
However, the application of this product subjects it to handling fluids which are by their very nature corrosive and
abrasive. These fluids operate at high velocities and usually at high pressures. Some fluids may also require being
conveyed at elevated temperatures. Combinations of any and all of these conditions will speed up the deterioration
of internal surfaces including seals and seal surfaces.

RECOMMEDED ROUTINE MAINTAINENCE & INSPECTION

Due to widely varied applications, no specific frequency of maintenance or in-service inspection for the plug
valves can be recommended. Periodic and frequent inspection of each valve will provide a basis for predicting the
life or usefulness of the plug and inserts. Replacing these parts when they are eroded or worn will help prevent
any erosion of the body.
To prevent leakage, malfunctions resulting from internal wear or seal degradation, the user must establish a
preventative maintenance and inspection program according to the usage. This program must include:

A. Inspection of parts to detect loss of wall thickness that may result in decreased pressure capacity.
B. Routine replacement of seals and inspection for proper operation.

Scheduled re-greasing is very important. Normal working operations will allow for grease loss if the plug valve is
not maintained. This can create voids within the assembly. These voids will quickly accumulate sand and
proppants thus increasing the force required to open/close the valve. Frequent greasing will prevent the voids from
occurring and will ensure easy operation of the valve.

Periodic Inspection must include but not limited to the following:

· Inspection of sealing surfaces, evidence of wear and pitting of all components.
· Cleaning
· New Kitting
· Ultra-Sonic Inspection / Minimum Wall Inspection
· Pressure testing to 100% the product’s normal working pressure as per this proceure

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 15

6
7

13
11
4
12
5
8

2.2

2.1

3.2
14

9.1 3.1

16
19 18

10 17

EXPLODED VIEW

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BILL OF MATERIAL

STAR(*) ITEMS ARE IN INCLUDED IN REPAIR KIT

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TOOLS REQUIRED

1. Body Cap Wrench(shown in the right)

2. 400 Grit Sandpaper
3. Soft Face Mallet
4. Grease Gun
5. Lubricant
6. Assembly Grease Climax 900K or VAL-TEX 972K
7. Protective Clothing and Safety Glasses
8. Fixture for Plug installation (Optional)
9. Screwdriver

DISASSEMBLY

1. Make sure there is no pressure on the valve.

2. Remove grease fitting 15 from plug.
3. Remove Hex nut 6 holding Handle 7 .
4. Remove Handle 7 and Grease Retainer packing gland 13 .
5. Using the proper body cap wrench (as shown above), remove the body cap 5 .
6. Remove plug 4 by lifting while twisting it back and forth. Sometimes it is necessary to hammer lightly from
the bottom.
7. Remove the side segments 2.2 and then the seal segments 2.1 . (The segments may have to be rotated
and lightly pried or pulled on by a screwdriver or pliers)
8. Remove segment seal o-rings 3 , plug seal rings 9.2 and back-up rings 9.1 , body cap seal ring 8 .
9. Clean all grease and foreign material from the valve and components parts.

ASSEMBLY

It is vitally important that the workstation you are using to assemble the plug valve is clean and free of any and
all contaminants such as metal shavings, dirt, etc. Do not sand or de-burr any items while at the assembly
workstation.

1. Check parts pulled out of warehouse against assembly print to insure correct parts are used to assemble valve.
Follow parts list. Do not mix components.

2. Clean inside of valve body with clean rag soaked in solvent. Blow remaining dirt out of body with compressed
air.

3. Using 400 grit sandpaper, clean all other seal surfaces.Visually inspect all new parts and remove any foreign
contaminates.Deburr sharp corners if required(outside the workshop).

4. Clean two seal segments (2.1) using a clean rag . Blow dry with compressed air.

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4. Install both segment seals (3.1) & (3.2) on seal segments.

5. Apply a very thin film of plug valve grease to the surface of the seal segments (2.1) which contacts the body.
Install both seal segments in valve body.

6. Apply a liberal amount of plug valve grease to exposed surface of seal segments (2.1) and to exposed portion of
body cavity which will contact side segments. Install both seal segments in the body cavity.

7. Clean side segments (2.2) with clean rag.

8. Apply a liberal amount of plug valve grease to side segments (2.2) and install them half way in the body cavity
between the seal segments (2.1).

9. Clean plug with clean rag. Blow dry with compressed air. Blow all dirt out of grease passageways.

10. Apply liberal amount of plug valve grease to outside diameter of plug (4) and to stem seal areas of plug. Place
Plug seal o-rings (9.2) and nylon backup ring (9.1) on top and bottom of plug.

11. Orient the plug in a fully closed position (plug bores facing the side segments).Using the side segments (2.2)
as guide, install the plug (4) by applying firm pressure to plug. After the plug is partially installed by hand, a soft
face mallet may be used to drive the plug the remaining distance into valve. After installation,
check to assure that the top of the outer seals (3.2) stay in the groove. Use a blunt object such as blade type screw
driver to push top of the seal back in the groove if necessary.
WARNING: Hammering plug before it is properly strted will chip leading edge of plug and score seal segments

12. Push side segments (2.2) into body cavity until they reach bottom.

13. Install o-ring (8) on body cap (5). O-ring should fit firmly in groove in body cap (5).

14. Remove excess grease from the body cap shoulder area of body. Apply antiseize compound (or lithium
molybdenum disulfide grease) to body cap threads and install body cap into body. Tighten body cap (5) by hand
using proper body cap wrench.

15. Finish tightening body cap (5) using impact or hammer wrench. Mark line on body cap and body and tighten
body cap until no movement is noticed between the body cap and body.

16. Check both detent spring retaining pins (12) for tightness. If loose, lightly tap pinwith hammer until tight.

17. Install Handle(7) on plug (4), and tighten Hex nut (6) until snug.

18. Apply thread sealant or Teflon tape (two wraps maximum) to 3/8” NPT grease fitting (15). Install grease
fitting on plug (9). Tighten fitting to 50-60 ft-lbs.

19. Grease the plug valve number of times by rotating the Plug(4) using Handle(7).

Over greasing between segment seals will increase effort to push the plug in which can cause plug/segment
damage or displacement of the outer seal.
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TESTING PROCEDURE

Refer latest API-6A edition for applicable testing requireemnts as per PSL.

STORAGE

1. Drainage after testing:- All plug valves should be drained and lubricated after testing and prior to testing.

2. All components should be cleaned of oil, dust, metal particles and other contaminants

3. Rust Prevention:- Equipment should be exposed metallic surfaces, protected with a rust preventer which
will not become fluid and run at a temperature less than 125 degrees fahrenheit(52 deg. C)

4. Sealing Surface Protection:- Exposed sealing surfaces should be protected from mechanical damage.

5. When not in use, the valve should be stored in an area that protects it from sun, rain, sand, and other debris.

6. During long-term storage keep the valve dry and painted to prevent corrosion.

HOUSTON OFFICE

1255 Grand Plaza Dr,

Houston, TX 77067, USA
Phone: (281)-894-5213
Fax: (281)-894-5217