Prepared by : Ali rizwan

Reviewed by : Aslam Sheikh

ISSUE : June-2015
 On-line Repair of 02-PRC-8V
 02-PRC-8V is the main feed gas valve to  To ensure no change in valve position during
F-201. The diaphragm of this valve was diaphragm replacement, a clamp was designed,
found ruptured on site. Challenge is to re- fabricated and installed by Instrument team.
place the diaphragm of the valve without al-  Job was completed successfully within thirty
tering valve position, failure to this will re- minutes without any possible production loss.
sult in plant tripping.
Step #1: Engage Hand-jack & Ensure Valve Remains Open Through Clamping.

Area b/w Coupling & Actuator To Be

Clamping In Progress Clamp Successfully Installed
Clamped
 On-line Repair of 02-PRC-8V
Step #2 Step #3 Step #4
Opening The Actuator Housing Replacement Of Diaphragm  Actuator Closed
 Air Supply Reopened
 Clamp Removed
 Hand-jack Disengaged
 01-PCV-4
 01-PCV-4 is located on discharge of P-112 to
control pressure of KW Header.
 Valve was brought against excessive passing.
 After inspection of trim these suspicions were Seat & Body Weld As Found
After Last Maintenance
not confirmed.
 Seat and plug were in ideal conditions, yet they
were machined to ensure proper sealing.

 During its last maintenance it was discovered

that the weld that joined the seat and body
Seat & Body Weld Inspection
was cracked resulting in leakage. Test Passed After DPT
 A welding procedure was made to ensure
proper welding techniques were carried out to
weld the crack.
 This time a DPT test was carried out to check
health of the weld joint which turned out to be
positive.
 This was a testament to the fact that previous
maintenance was successful. Balancing Cage +
Plug Health Found OK Guide
Rehabilitation of 03-LIC-6VC
 The current 03-LIC-6VC is prone to damage
when used . Therefore its older model has been
made ready for its replacement.
 A crack was found on the yoke of the valve.
 After thorough review, welding procedure was
made to rectify this issue.
 Old cage was replaced by a new one.
 Plug and seat were machined
 New gland packing installed.
 The entire actuator was overhauled.
 Diaphragm was replaced.
Crack Through The Yoke
 The hand-jack assembly was thoroughly cleaned
and greased.
 Reclaimed Siemens smart positioner installed
with new mounting.

New Positioner Installed Under

Calibration
Old Cage New Cage Crack Thoroughly Welded
 06-PRC-3
 06-PRC-3V is HS to LS control valve.
 Valve was removed for PMP for the first time in
ten years. Old Plug vs New Plug
 The entire valve was overhauled and thoroughly
inspected.
 The plug was damaged and replaced with new
one. Crack observed throughout the
 Seat was also heavily damaged. It was machined. periphery of the weld surrounding
the mixer plate
 New gland packing was installed.
 Actuator was overhauled. Diaphragm was found
damaged hence replaced with new one.
 The mixer plates were found heavily damaged.
Damage to the mixer plates magnified
Old plates were cut out and newer ones were fab-
ricated in machine shop to replace them.
 The body was checked for cracks through DPT’s.
These cracks were repaired through weld build-
up.

A very special appreciation to Machine Shop, Fab Seat found heavily damaged

Shop, Inspection and Project Departments for their

consistent round the clock support in wrapping
Cage & Seat
this valve’s tedious maintenance in only five days.
 Repair of 06-PRC-3

Damaged plates being cut out on As found condition of mixer plates after removal
Previous weld grinded by baby grinder boring machine

Unwanted Cavity discovered being filled with Newly fabricated plates of SS-316 vs older plates
Plates fitted and
inconel buildup
welded within the body
 06-PRC-4
 06-PRC-4V is HS to LS control valve.
 Valve was removed for PMP for the first time in
twenty years.
 The entire valve was overhauled and thoroughly
New trip relay and its respective tubing installed in area
inspected.
 The body was checked for cracks through DPT’s.
 The plug, cage and seat were found to be in per-
fect health.
 New gland packing was installed.
 Actuator was overhauled and diaphragm was re-
placed.
 Lock-up relay replaced with new one.
 Actuator stem and plug stem were polished.
External Mixer Plate OK Top Vew Of Seat & Cage
 The health of mixer plates was checked through
boroscopy.
 The mixer plates were a little damaged but com-
pared to some of the other Bomafa valves re-
ceived in the past, their condition can be summa-
rized as excellent.

Health Of Pl;ug Found OK

Side View Of Seat &
Equal % Cage
 Extensive Inspection of 06-PRC-4

Material Analysis being done to verify the material of body.

DPT carried out on the body. Health Boroscopy results showing damage
was found OK as no cracks were to the mixer plates at one end
detected
 08-SD-2VA
 08-SD-2VA is installed on LS steam to
TP-800B.
 Valve removed because it was nonresponsive.
 Complete body and actuator overhauled.
 Diaphragm was replaced as it was found severely
damaged.
 Seat and plug were machined.
 Gland packing was replaced.

Reduced trim is an undersized orifice. Re-

Seat and Plug After Machining
duced or restricted capacity trim is used for
several reasons:
 It adapts a valve large enough to handle in-

creased future flow requirement with trim

capacity properly sized for present needs.
 A valve with a large body using restricted

trim can be used to reduce inlet and outlet

fluid velocities.
 Errors in over sizing can be corrected by
Damaged Diaphragm Cage
use of restricted capacity trim.
10-SD-101VB

 10-SD-101VB is installed on inlet of instru-

ment air dryer MD-1002B.
 The actuator was replaced with new one.
 The body was overhauled.
 The butterfly disk was found damaged which
consequently damaged the liner.
 Both the disk and liner were replaced with new
one

Disk & Liner Liner found damaged

 In this particular case it is advisable to switch

to a ball valve as they are more reliable.
 Ball valves provide better shut-off compared
to butterfly valves.
 Ball valves are also low maintenance com-
pared to butterfly valves.
New Butterfly Disk Damaged Butterfly Disk
 Installation of Limit Switch on 09-SD-53

 Valve received in PSV shop against leakage in

actuator.
 Entire actuator overhauled.
 V-gasket found expired hence replaced with new
one.
 Spring was found broken. Also replaced with
new one.
 Limit switch was also installed on demand.
Guide Pin to be used for
09-SD-53
mounting switch lever

 The guide pin is used for indication purposes.

 In this particular case we have used this pin to
our benefit by mounting a lever on to the
guide pin.
 When the valve opens or closes, this lever ac-
tuates the limit switch and reassures board-
man of the state of the valve.

Limit switch in close position Limit switch in open position

 09-PSV-1
 09-PSV-1 is installed on discharge of a poly-
electrolyte pump, P-921A.
 PSV removed against PMP.
Special Disk Nozzle inside body
 The disk seating surface was machined.
 Nozzle was lapped.
 Set pressure was adjusted at 4 kg.

 This disk is designed like a control valve’s

plug and is hence treated as one when PMP is
performed.
 In this case the disk is machined rather than Disk being seated onto the nozzle
Special Disk
being lapped.
 The heavy part on top of the disk is acting as a
guide to ensure proper seating. 1

2 3 4

1. Nozzle, 2. Disk, 3. Spring, 4. Bonnet

 15-PSV-3A

 15-PSV-3A is installed on natural gas line to

township.
 PSV removed against PMP.
 Disk and nozzle were lapped.
 Pressure tested at 3.5 kg.

NOZZLE & DISK AFTER MACHINING

 The blowdown ring is responsible for adjust-

ing popping force of PSV incase of over pres-
sure. 1 2 3 4

1. NOZZLE, 2. BLOWDOWN RING, 3. DISK, 4 . DISK HOLDER