METHOD STATEMENT OF GATE Affective

Date
VALVES AUG 19, 2019
Project Title Document
Code
SHUQAIQ IWPP ARC-102-MS-002

METHOD STATEMENT OF GATE VALVES

Customer: Nomac

Project Name: Shuqaiq Independent Water & Power plant

Location: Abha, Kingdom of Saudi Arabia

Rev. No.

Project Engineer Project Manager Operations Manager

Name

Date

Sign

Page 1 of 8
 METHOD STATEMENT OF GATE Affective
Date
VALVES AUG 19, 2019
Project Title Document
Code
SHUQAIQ IWPP ARC-102-MS-002

TABLE OF CONTENT

1. Scope of Work ................................................................... Error! Bookmark not defined.

2. Applicable Regulations and Standards ............................ Error! Bookmark not defined.

3. Responsibilities...................................................................................................................3

4. Equipment’s........................................................................................................................3

5. Consumables ..................................................................... Error! Bookmark not defined.

6. Type of Actuator ............................................................... Error! Bookmark not defined.

7. Precautions ....................................................................... Error! Bookmark not defined.

8. Inspection for the Gate Valves ......................................... Error! Bookmark not defined.

9. Checklist for Pneumatic Gate Valve of Steam-Water System ........................................8

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 METHOD STATEMENT OF GATE Affective
Date
VALVES AUG 19, 2019
Project Title Document
Code
SHUQAIQ IWPP ARC-102-MS-002

1. Scope of Work

The purpose of this Method statement is to provide a controlled procedure for overhauling and
testing of gate valve in line with industry standards.

2. Applicable Regulations and Standards

 API 6D - Design, Manufacturing, Testing of Valves

 API 598 - Valve Inspection and Testing
 ASME B16.5 - Pipe Flanges and Flanged Fittings
 ASME VIII - Pressure Vessels & Inspection.

3. Responsibilities

A. Test Engineer

Coordinates with the client. Supervises the overall activities. Allocating time for each job and
maintaining the outage time

B. Supervisor

Identifying the nature of repair work to be carried out. Execution of job. Maintaining the right
methodology of work. Coordinating work, the technicians and the engineer. Recording all the
work carried out.

C. Technician

Performing the inspection, disassembling and assembling job with expertise

4. Equipment’s

 Lapping machine
 Multimeter
 Hart Communicator.
 General Spanners
 Box spanner
 Chain Block

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 METHOD STATEMENT OF GATE Affective
Date
VALVES AUG 19, 2019
Project Title Document
Code
SHUQAIQ IWPP ARC-102-MS-002
 Eye bolt
 Torque wrench
 Gland puller
 Seat ring puller
 V block
 Magnetic stand
 Dial gauge

5. Consumables

 Cleaning Agent – WD 40, Diesel

 High Temperature Grease – Molykote HSC
 Emery Paper – 220 Grade

6. Type of Actuator

 Single acting pneumatic actuator

 Double acting pneumatic actuator
 Motor Operated Actuator

7. Precautions

 Before dis assembling the valve , make sure there is no pressure in the valve body.
 Removing the packing without removing the actuator is difficult and is not recommended
 Do not try to blow out the old packing rings by applying pressure to the lubricator hole in
the bonnet.
 Careful that the stem threads do not damage the packing rings
 Stem threads should not be damaged while working
 While boxing up make sure the inside should be free of foreign particles which will
damage the seat

8. Inspection for the Gate Valves

 The gate valves will undergo general visual inspection.

 Valve accessories like positioners, relays, boosters, limit switches, will be inspected and
reported
 Careful examination of the valve body, flange face will be carried out.

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 METHOD STATEMENT OF GATE Affective
Date
VALVES AUG 19, 2019
Project Title Document
Code
SHUQAIQ IWPP ARC-102-MS-002
i. Initial Functional Test

 Actuator functional test is carried out first. The actuator will be given min and max
operating pressure. The findings will be recorded
 Stroke test is carried out for positioners and the travel of the valve stem is noted at open
and close by giving 4-20 mA signal through the feeder.

ii. Disassembling

 Prior to dismantling the valve will be punched.

 Remove the accessories & tubing’s from the actuator and positioner.
 De couple the coupling and remove actuator from valve body
 Remove compression on actuator spring by screwing spring adjuster until the actuator
tension is free.
 Loose the bolts of the Actuator casing and remove the actuator.
 Remove O-rings, seals and any soft parts
 Remove the bonnet or side casing from the valve body.
 Take out the complete stem set from the body along with the gate
 Separate out gasket, packing, valve trim components and place them is separate trays for
inspection.

iii. Inspection Stage

All the parts will be carefully inspected and the inspection findings will be entered in the report.
Necessary repair work will be carried out.

a) Internal Inspection

 Carefully examine contact area and seating area of the gate

 Conduct Blue matching for the seating surface
 Lapping will be carried out if required for the gate and seating faces
 Examine stem gland area.
 Examine stem thread area.
 Examine gasket sealing surface.
 Inspect for spindle bend by checking the runout and check the run out is with in the limits

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 METHOD STATEMENT OF GATE Affective
Date
VALVES AUG 19, 2019
Project Title Document
Code
SHUQAIQ IWPP ARC-102-MS-002

b) Body inspection:

 External and Internal body is carefully examined for cracks and cavitation.
 Examine seat pocket area.
 Examine gland area and gland packing. Replace gland packing if necessary.
 Examine gland studs, gland follower, gland bush.
 Examine all the greasing point and apply grease where ever necessary.
 Examine body studs and nuts.

c) Actuator Inspection:

 Check for bends and score marks.

 Advice for painting if it’s in bad condition.
 Check for corrosion
 Check for cracks in casing.
 Check for conditions of pressure and sealing soft goods.
 Diaphragm condition
 Spring tension for the single acting actuator
 Loop checking for the actuator

d) Gear Box Inspection

 Gear Drive Inspection

 Hear the noise
 Measure the clearance (backlash)
 See the condition of tooth flank for surface damage
 Surface damage could be in the form of pitting, spalling, scoring, ridging, rippling or other
visual sign of deterioration.
 Check the gearbox oil level
 Check the bearings
 Check alignment of gears, lubrication with semi synthetic oil or grease

iv. Overhauling Stages

All parts will be placed in separate trays. Trays will be tagged by the valve tag No or serial number
for identification. Heavy valve body will be placed in separate stand in upright position.

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 METHOD STATEMENT OF GATE Affective
Date
VALVES AUG 19, 2019
Project Title Document
Code
SHUQAIQ IWPP ARC-102-MS-002
a) Cleaning

All the parts will undergo cleaning by using appropriate cleaning agent.

b) Soft spares:

 Bonnet Gasket
 Packing

c) Assembly

 Identifying the spares

 Assemble the stem set, gate
 Conduct the final blue matching for the seating surface
 Place the gland packing and gland follower.
 Close the bonnet of the valve with all the soft parts installed.
 Apply Molykote HSC on all threaded parts
 Assemble the actuator on the valve body.
 Place the O ring on the actuator stem.
 Place the diaphragm plate and the diaphragm.
 Close the casing.
 Adjust the spring tension screw.
 Tighten the yoke lock nut screw.
 Recalibrate the actuator.

d) Final Testing

 Actuator functional test is carried out first. The actuator will be given min and max
operating pressure. The findings will be recorded
 Record the readings for full open and full closing for the valve
 The findings will be recorder in test report.

Page 7 of 8
 METHOD STATEMENT OF GATE Affective
Date
VALVES AUG 19, 2019
Project Title Document
Code
SHUQAIQ IWPP ARC-102-MS-002

9. Checklist for Pneumatic Gate Valve of Steam-Water System

KKS NAME LOCAL REMOTE TIME REMOTE DATE SIGNATURE REMARKS

POSITION
Direction Feedback O C
Correct Correct
LAE13 DS/HTG
AA001 1 SPRAY
I-VALVE
LAE14 DS/HTG
AA001 1 SPRAY
S/OVAL
VE
LAE15 DS/HTG
AA001 2 SPRAY
S/OVAL
VE

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