SCORE (EUROPE) LIMITED

Engineering Research, Design, Manufacture & Repair

FLUSHING & LUBRICATION INJECTION

WORKSCOPE FOR
VARIOUS BALL VAVES

Originator: Score (Europe) Limited

Prepared by: D. Archer

Score Job No: 481843 SIT

0 16/04/18 For Approval DA AL JG Turkstream Southstream B.V.

Company
Rev Date Description Made Check Project Client
Director
Company Director

Signature:
Document Number: ENG-SC01-ZF-2987 Rev 0
Printed Name: James Geddes
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FLUSHING & LUBRICATION

INJECTION WORKSCOPES FOR
VARIOUS BALL VALVES

CONTENTS

1.0 INTRODUCTION & BACKGROUND

2.0 VALVE DETAILS
3.0 PLANNING
4.0 SAFETY NOTICE
5.0 FLUSH & LUBRICATION DETAILS
6.0 METHOD SUMMARY
7.0 SEAT FLUSHING AND LUBRICATION METHOD
8.0 CAVITY FLUSHING METHOD
9.0 TOOLS & CONSUMABLES
10.0 DISTRIBUTION LIST

LIST OF FIGURES

FIGURE 1: Valve Injector Identification

FIGURE 2: Valve and Injector Non-Return Systems
FIGURE 3: Typical Injector Double Block and Bleed Isolation Assembly
FIGURE 4: MacScott Bond Pump System
FIGURE 5: Switch for Lines ‘A’ and ‘B’
FIGURE 6: Instructions for use of MacScott Bond Pump System
FIGURE 7: Quick Fill Pump

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FLUSHING & LUBRICATION

INJECTION WORKSCOPES FOR
VARIOUS BALL VALVES

CONTENTS (Continued)

LIST OF TABLES

TABLE 1: Flush, Lubricant & Injection Equipment

TABLE 2: Recommended Flush and Lubricant Quantities
TABLE 3: Generic Ball Valve Seat Flushing and Lubrication Injection Capacities
TABLE 4: Valve Flushing Injection Pressures for ANSI Rated Valves
TABLE 5: Valve Lubrication Injection Pressures for ANSI Rated Valves

LIST OF APPENDICES

APPENDIX 1: Service Datasheet

APPENDIX 2: General Assembly Drawing (Vavitalia Fully Welded Body MOV)
APPENDIX 3: General Assembly Drawing (Valvitalia Top Entry MOV)
APPENDIX 4: General Assembly Drawing (Valvitalia Top Entry ESV)
APPENDIX 5: General Assembly Drawing (Cameron Top Entry MOV)
APPENDIX 6: General Assembly Drawing (Cameron Top Entry ESV)
APPENDIX 7: Val-Tex QS2000A Lubrication Injection Unit
APPENDIX 8: Schematic for MacScott Bond Pump System
APPENDIX 9: Val-Tex Valve Flush Specification & Material Safety Data Sheet
APPENDIX 10: Val-Tex Grade 700 Material Safety Data Sheet
APPENDIX 11: Val-Tex Grade 2000 Material safety Data Sheet
APPENDIX 12: Val-Tex Grade 85 Material Safety Data Sheet
APPENDIX 13: Val-Tex Valve Lubrication Packaging
APPENDIX 14: Galaxy Generator for MacScott Bond Pump System

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FLUSHING & LUBRICATION

INJECTION WORKSCOPES FOR
VARIOUS BALL VALVES

1.0 INTRODUCTION & BACKGROUND

This document provides a method statement for the flushing and lubrication injection
operations on 18 off various Ball Valves utilised for critical isolation purposes as part of
the Turkstream pipeline project (see Appendices 2 to 6). This document has been prepared
by Score (Europe) Ltd at their Peterhead works.
The valves have recently been subject to low pressure pneumatic air seat test where
through bore leakage was identified by onsite personnel. As a result Turkstream have
requested Score to compile a method statement to allow the flushing and lubrication
injection of the valves in an attempt to improve the current through bore leakage witnessed.
There is no guarantee with such injection scopes that a marked improvement will be
witnessed, however, the steps detailed in this document must be followed in order to
provide the best opportunity for an improved through bore leakage rate.

2.0 VALVE DETAILS

2.1 Tag Numbers: To be confirmed onsite

Valve Details
Manufacturer: Valvitalia
Size: 24” Full Bore (MOV)
Class: 2500#
Type: Fully Welded Body, Ball Valve
End Connection: Butt Weld
Body Material: A350 LF2
Actuation: Manual Gearbox
Quantity: 7-off

Injection Point Detail

Vent: 1” 2500# RTJ (Material: ASTM-A350-LF2)
Drain: 1” 2500# RTJ (Material: ASTM-A350-LF2)
Seat Injection: 1/2” NPT Button Screw Cap (Material: AISI 316)
3/8” BSPP NRV (Material: AISI 316)
Stem Injection: 1/2” NPT Button Screw Cap (Material: AISI 316)
3/8” BSPP NRV (Material: AISI 316)

See Appendix 2 for full general assembly drawing complete with bill of materials.

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Tag Numbers: To be confirmed onsite

Valve Details
Manufacturer: Valvitalia
Size: 24” Full Bore (MOV)
Class: 2500#
Type: Top Entry, Ball Valve
End Connection: Butt Weld
Body Material: A352 LCC
Actuation: Manual Gearbox
Quantity: 3-off

Injection Point Detail

Vent: 1” 2500# RTJ (Material: ASTM-A350-LF2)
Drain: 1” 2500# RTJ (Material: ASTM-A350-LF2)
Seat Injection: 1/2” NPT Button Screw Cap (Material: AISI 316)
3/8” BSPP NRV (Material: AISI 316)
Stem Injection: 1/2” NPT Button Screw Cap (Material: AISI 316)
3/8” BSPP NRV (Material: AISI 316)

See Appendix 3 for full general assembly drawing complete with bill of materials.

Tag Numbers: To be confirmed onsite

Valve Details
Manufacturer: Valvitalia
Size: 24” Full Bore (ESV)
Class: 2500#
Type: Top Entry, Ball Valve
End Connection: Butt Weld
Body Material: A352 LCC
Actuation: Electro-Hydraulic Actuator
Quantity: 4-off

Injection Point Detail

Vent: 1” 2500# RTJ (Material: ASTM-A350-LF2)
Drain: 1” 2500# RTJ (Material: ASTM-A350-LF2)
Stem Injection: 1/2” NPT Button Screw Cap (Material: AISI 316)
3/8” BSPP NRV (Material: AISI 316)

See Appendix 4 for full general assembly drawing complete with bill of materials.

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Tag Numbers: To be confirmed onsite

Valve Details
Manufacturer: Cameron
Size: 32” Full Bore (MOV & ESV)
Class: PN 300
Type: Top Entry, Ball Valve
End Connection: Welded Ends
Body Material: A352 LCC
Actuation (MOV): Manual Gearbox
Actuation (ESV): Electro-Hydraulic Actuator
Quantity: 4-off (2-off MOV, 2-off ESV)

Injection Point Detail

Vent: 1” 2500# RTJ (Material: UNS N06625)
Drain: 2 1/16” API 5000 RTJ (Material: ASTM-A694-F65)
Seat Injection: 1” 2500# RTJ Flange c/w 3/4” 5000 Screw Cap
Button Head Injection Port
Flange & NRV Material: UNS N06625
Stem Injection: 3/4” 2500# RTJ Flange c/w 3/4” 5000 Screw Cap
Button Head Injection Port
Flange & NRV Material: UNS N06625

See Appendices 5 and 6 for full general assembly drawing complete with bill of
materials.

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3.0 PLANNING

Prior to commencing any further work on site, the following checks must be made:
 All personnel are competent to carry out the work.
 An appropriate work permit has been issued.
 A review of the worksite and any scaffolding or rigging requirements has been
erected.
 The operations will not conflict with the site’s own procedures or work instructions.
 No simultaneous conflicting activities are planned in the vicinity of the work area.
 Barriers have been erected where necessary.
 All components have been received and are correct.
 All appropriate and correctly sized tooling and equipment is available, in good
condition and calibrated where required.
 A suitable laydown area is available at the worksite.
 Personnel are familiar with escape routes, muster points and the nearest emergency
telephone.
 Appropriate PPE is worn at all times during the procedure.

4.0 SAFETY NOTICE

4.1 Never attempt to use valve injectors that are in a poor condition or damaged state.
Where possible, these should be renewed prior to valve flushing and lubrication
injection operations.

4.2 It is imperative that all connectors are compatible.

4.3 It is imperative that the pipeline is isolated and depressurized prior to the removal
of any injector fittings.

4.4 The injecting of valve flushing and lubricating agents into valve bodies whilst
under pressure is potentially hazardous, as this breaks into the pressure envelope.
To allow for the safe operation of the flushing and lubrication injection units, they
must include, as a minimum, the following safety features:
4.4.1 The flushing / lubrication injection unit must incorporate a discharge
isolation valve whereby the pump can be isolated from the process.
4.4.2 Ideally, this should be attached directly to the valve injector assembly.
Refer to Figure 3 for the typical double block and bleed (DBB)
arrangement.
4.4.3 A calibrated discharge pressure gauge.
4.4.4 Means of venting pressure from the pump discharge.

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4.5 The installation of additional isolation systems allows the following:

4.5.1 If the valve injector fails to reseat following flushing operations, the pump
can be isolated, and the valve flush changed out for valve lubricant.
4.5.2 Injecting of valve lubricant into the valve injector should reactivate the
injector and, if fitted, the valve internal NRV system (see Figure 2).
4.5.3 Should the injector continue to leak following the injection of valve
lubricant, the isolating system will allow the pumping unit to be
depressurized and disconnected, leaving a self-contained assembly attached
to the valve injector. This can then remain in place until such time that
injector renewal can be carried out in a safe manner.

The operator should assess the implication of these hazards as part of any formal HAZOP,
Risk Assessment and Toolbox Talk.

5.0 FLUSH & LUBRICANT DETAILS

Score recommends the use of the flush, lubricant and injection units detailed below, in
relation to the specified service information.

 Service Detail: Test Medium: Water/Glycol (Hydro Test)

(Commissioning Stage) Compressed Air (LP Test)

 Service Details: Service Media: Natural Gas

(Online) Operating Pressure: 65 to 283 barg
Operating Temperature: -5ºC to 50 ºC
Details taken from datasheet provided. See Appendix 1.

Please see the below Table 1 for all associated flush, lubrication and injection equipment to
be utilised during this work scope:

Valve Injection
Flush Lubricant
Description Equipment
Valtex “Valve Flush” 700 (Appendix 10)
Valvitala MOVs
(Appendix 9) 85 (Appendix 12) QS2000A
2000 (Appendix 11) (Appendix 7)
Valtex “Valve Flush”
Cameron Valves
(Appendix 9) 85(Appendix 12)

Mascott Bond
Valvitalia ESVs Glycol MEG N/A
(Appendix 8)

Table 1: Flush, Lubricant & Injection Equipment

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Valve
Flush Qty Lubricant Qty
Description
4.3lb per valve 2.0lb per valve
Valvitala MOVs
(see Note 1)
½ of a 2lb bottle per injector 1-off 0.5lb ‘J’ stick per injector

6.4lb per valve 3.1lb per valve

Cameron Valves
(see Note 1)
¾ of a 2lb bottle per injector 1½ 0.5lb ‘J’ sticks per injector

Valvitalia ESVs 300 Litre for entire valve cavity N/A

(see Note 2)

Notes:

1. The recommended Valtex injection values detailed above are based on generic
flushing and injection quantity data as detailed in Table 3 and packaging
information provided in Appendix 12.
2. Glycol to be injected into valve cavity until the cavity is full. Time required to fill
the cavity may vary. Volume stated has been confirmed by Valvitalia.

Table 2: Recommended Flush and Lubricant Quantities

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6.0 METHOD SUMMARY

The details provided in this section provide a summary with regards to the proposed scope
of work required to ensure best results. The method statement in Section 7.0 provides only
the necessary steps for completion of the flushing and injection operations.

6.1 Seat Flushing and Greasing

Valve Tags: To be confirmed onsite

 Remove operator indicator cap and confirm valve position where possible.
Replace cap and mark closed position at cap to actuator body interface. Operate
and ensure that the valve can fully travel from the open to closed position.
 Adjust the actuator stops associated with the closed position where applicable in
0.5° increments to a maximum of 2.5° passed the original closed position.
(These values are generic and may differ dependent on valve and actuator type)
 Review and prepare the injection fittings.
 Complete flushing operations:
o Flush in the closed position with recommended quantity.
o Allow suitable soak period.
o Operations personnel to operate the valve closed-open-closed
 Closed-30°open-closed may also be acceptable where full operation
cannot be conducted.
o Re-attempt flushing operations.
o Repeat injection and operation 3 times as a minimum.
 Where required complete lubricant operations:
o Inject in the closed position with recommended quantity.
o Operations personnel to operate the valve closed-open-closed
 Closed-30°open-closed may also be acceptable where full operation is
not possible.
o Re-attempt injection operations.
o Repeat injection and operation 3 times as a minimum and where possible.
 Operations personnel to conduct inline testing as per client requirements.
 In the event that testing proves unsuccessful, results should be reviewed and
discussed between all relevant parties to determine a suitable way forward.

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6.2 Cavity Flushing

Valve Tags: To be confirmed onsite

 Remove operator indicator cap and confirm valve position where possible.
Replace cap and mark closed position at cap to actuator body interface. Operate
and ensure that the valve can fully travel from the open to closed position.
 Adjust the actuator stops associated with the closed position where applicable in
0.5° increments to a maximum of 2.5° passed the original closed position.
(These values are generic and may differ dependent on valve and actuator type)
 Review and prepare vent and drain flanges for injection.
 Operate the valve to the open position.
 With the vent open to atmosphere inject the recommended amount of flushing
agent into the drain port and ensure that the cavity is full.
 Allow suitable soak period.
 Connect pump hoses to both vent and drain connections and commence pumping
of the Glycol to flush the cavity. Continual flushing operations to be completed
for a minimum of 30 minutes.
 Hold Point: All relevant personnel to discuss outcome of initial flushing
operations prior to draining. Site supervisor to confirm whether to immediately
drain flush from the cavity or operate the valve to the closed position and return
to open for another rotation of flushing operations.
 When conducting draining of the cavity, the quick fill pump should be used to
flush out the remaining Glycol with a water based solution.
 Operations personnel are to conduct inline testing as per client requirements.
 In the event that testing proves unsuccessful, results should be reviewed and
discussed between all relevant parties to determine a suitable way forward.

6.3 Further Information

It must be noted that due to the nature of the low seat test pressure utilized during
the commissioning testing it is probable that the seat to adaptor seat pocket lipseal
designs may not have provided a positive through bore seal. A series of high
pressure seat testing may be required in order to fully energise these seals and
provide improved sealing performance.

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7.0 SEAT FLUSHING AND LUBRICATING METHOD

Step Action Remarks

Site Preparatory Work
On receipt of equipment, ensure that all
1 components / tools have been received and All relevant certification to be of current date.
are in good order.
Familiarise yourself with the equipment
Identify any potential hazards to the site
2 and surrounding work area for potential
supervisor.
hazards.
3 Identify lay down area for equipment. Erect barriers etc. where necessary.
Complete Toolbox Talk and Risk This should be carried out at the job site
4
Assessment. following survey of the work area.
Ensure permit conforms to work scope
5 Review “The Permit to Work”.
requirements.
Highlight any concerning factors to site
6 Sign Permit to start.
supervisor prior to commencing work.
Injector Preparation – CAP Type (see Figures 1 & 2)
Notes:
 If valve injectors are found to be in a heavily soiled and corroded condition, do not use. Make a
record and replace as necessary.
 Where injectors are fitted with a threaded external protective cap as they are in this instance,
removal shall be carried out as detailed in the following steps (see Figures 1 & 2).
Transfer all equipment to the designated Ensure selected lay-down area is in a safe
7
lay down area prior to commencing work. location and any barriers erected if required.
Using two correct sized spanners, attach
Cameron Valves have flanged injection ports,
one of the spanners to the injector body
8 therefore only require one spanner to remove
hexagon whilst the other spanner is
injector cap.
attached to the injector cap.
Movement of the injector body could create a
leak path. As a consequence, the injector would
Hold firmly the spanner attached to the have to be removed and the threaded portions
9 injector body to prevent it unscrewing reworked. However, it must be noted, that this is
from the main valve. a hold point and can only be completed
following full isolation, vent and a method of
monitoring pressure fitted for use.

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Step Action Remarks

Injector Preparation – CAP Type (see Figures 1 & 2) (Contd.)
Valvitalia Fully Welded Body valves external
protective caps do not incorporate vent holes.
Safety Note
Do not stand in the firing line of the protective
cap.
Use the second spanner as a means of
10 unscrewing the cap and in a controlled For all other injectors, the external protective cap
manner, unscrew the cap by a ¼ turn. incorporates 2 vent holes. The vent holes are a
safety feature of the injector in that they are used
to detect any leakage past the internal NRV
system.
Safety Note
Do not stand in the path of the vent holes.
Monitor injection fitting for signs of
leakage.
For valves on gas duty, a soap solution is If no leakage is detected, Go to Step 14.
11 to be used as a means of detecting leakage.
If leakage is noted, Go to Step 12.
Following the initial breaking of the cap
from the injector body, soak the injector
checking for leakage.
Only once all leakage has ceased can the cap be
Hold the cap in position and allow a period unscrewed fully, Go to Step 14.
12
of time for the leak to decay.
If leak continues, Go to Step 13.
If the leakage does not decrease after a
reasonable settling period, the injector has
Take a note of which injectors have failed and
13 failed. Retighten the cap and move onto
report findings to the site supervisor.
the next injector, repeating procedure from
Step 8.
Continue to unscrew the cap in 1/2 turn Monitor for leakage from the cap holes and
14
increments. threads at all times.
Following satisfactory removal of the
injector cap, clean the injector seating
15
surface to ensure that a good seal will be
achieved.

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Step Action Remarks

Flushing of Ball Valves
Notes:
 The following Steps, 16 to 54 serve as a guide to valve flushing operations. It is the responsibility
of the valve supervisor to evaluate and adjust the procedure where necessary.
 Ensure that the double block and bleed (DBB) assembly shown in Figure 3 is fitted to the unit.
 It is preferred that flushing of the ball valve is carried out with the valve in the closed position.
 In an attempt to improve results, operation of the valve from the fully closed, to fully open and
back to fully closed position should be completed.
 The amount of flushing agent used varies from valve to valve and there is not a specified amount.
It is at the discretion of the valve supervisor to ensure that flushing operations have been
successful. Refer to Table 3 for general guidance with regards to Generic Ball Valve Seat Flushing
and Lubrication Injection Capacities.
To the valve injector, attach and secure the Ensure that the DBB isolation assembly is in the
16 flushing unit complete with DBB closed position.
assembly. Refer to Figure 3 for typical DBB assembly.
Safety Notes:
Where pneumatic powered unit is being Avoid having any of the hoses taut.
used ensure that all appropriate safety
17 All hoses shall be rigged such to prevent trip
devices are in place i.e. air hose whip-lines
and safety R-pins. hazards.
Ensure hoses are free of kinks and twists.
Re-check the system following final
assembly to ensure that all connections
18 Refer to Figure 3 for typical DBB assembly.
have been correctly made and that all
safety devices are in place.
For powered flushing units, ensure that the
unit is isolated from the power supply so
19
that it will not inadvertently start pumping
when the unit is switched on.
Line up the flushing unit to the valve
20 injector by opening the appropriate
isolations.
In a controlled manner, commence with The maximum allowable pressure table is given
21
valve flushing operations. in Table 4.

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Step Action Remarks

Flushing of Ball Valves (Contd.)
Safety Note
The maximum initial injection pressure to Do not exceed the recommended maximum
22 ascertain the internal condition of the valve allowable pressure (see Table 4). If greater
injection system shall be 50 psig (3.5 barg) pressure required please consider notes detailed
for Tables 4 & 5.
Possible causes for static pressure are:
Monitor for pressure decay.
 The flushing agent may require a longer soak
If a pressure decay is observed, then period in order to dissolve any old hardened
indications are that the injection ports are sealant / sealant.
free from obstructions. Go to Step 33.
23  The valve injector NRV system may be
If there is no pressure decay, allow a seized closed.
reasonable soak period before increasing
 The valve internal NRV system (if fitted)
the discharge pressure. Refer to
may be seized closed.
“Remarks” column.
 A higher pressure is required. Go to Step 24.
If after an extended soak period there is
still no pressure decay, go to Step 25.
24
If however after a reasonable soak period a
pressure drop is seen, go to Step 33.
Safety Note:
Increase injection pressure by 50 psig Do not exceed the recommended maximum
25 increments, repeating Step 23 at each allowable pressure (see Table 4). If greater
interval. pressure required please consider notes detailed
for Tables 4 & 5.
On reaching the maximum allowable
pressure, and if there are no signs of
pressure decay, the injector cannot be Possible causes for failure:
used. To allow for safe removal of the
flushing assembly it will be necessary to  Internal NRV system may be seized.
26
test the integrity of the valve injector.  Sealant / sealant in the valve has hardened off
Go to Step 27. and the flushing agent is unable to dissolve it.
If however, a pressure decay is noted,
Go to Step 33.
27 Close the DBB isolation assembly.

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Step Action Remarks

Flushing of Ball Valves (Contd.)
Depressurise the inter-space between the
28 flushing unit and DBB isolation assembly
via the flushing unit vent / drain facility.
29 Close the flushing unit vent / drain facility.
Open the valve injector to the flushing unit
by opening the DBB isolation assembly
30
and monitor for pressure build-up via the
pressure gauge.
If a pressure build-up is noted then the
valve injector has failed to reseat. Go to
31 Step 32.
If no leakage noted disconnect the flushing
unit in line with Step 37.
It will be necessary to inject the valve
injector with a valve lubricant in a bid to
32 reactivate the internal NRV system.
Go to the "Contingency Procedure"
Step 39.
As the old valve sealant begins to dissolve, the
Displace as a minimum the recommended rate at which the discharge pressure decays will
amount of valve flush. Refer to Table 3 – increase.
33
Generic Ball Valve Seat Flushing and
Lubricating Capacities. Allow for an appropriate soak period. This
period is at the discretion of the lead technician.
On injection of the required amount it is
required to operate the valve from closed A reduced 30 degrees open position can be
34
to open and return to closed to remove the considered where full operation is not possible.
dislodged debris from the valve seats.
Displace as a minimum the recommended
amount of valve flush. Refer to Table 3 –
Following successful operation re-inject Generic Ball Valve Seat Flushing and
35 with valve flush and repeat operations as Lubricating Capacities.
per steps 21 to 34. Injection and subsequent operation must be
repeated 3 times in order to optimise flushing
activities.
Following satisfactory completion, it will
36 be necessary to test the integrity of the
injector. Follow Steps 27 to 31.

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Step Action Remarks

Flushing of Ball Valves (Contd.)
Isolate and depressurise the flushing unit. Ensure that there is no pressure trapped between
Disconnect the equipment from the valve the valve injector and the flushing unit by
37
injector and move onto the next valve ensuring that all isolation valves are open to the
injector. Restart at Step 7. pressure gauge.
Where valve lubrication injection is
38 required proceed to Step 55, “Seat
Lubrication Injection Procedure”.
Flushing of Ball Valves – Contingency Procedure

 Injecting valve lubricant into the failed injector should reactivate the integral non-return system.
Ensure that the intermediate DBB isolation
assembly is closed and that the remainder
39
of the discharge assembly is open to the
pressure gauge and injection unit.
Via the appropriate flushing unit vent /
Monitor the pressure gauge to ensure that all the
40 drain facility, depressurise the flushing
pressure has been vented.
unit. Refer to “Remarks”.
Remove all flushing media from the
41 injection unit reservoir and replace with
valve lubricant.
In a controlled manner inject valve
lubricant into the inter-space between the
42 intermediate isolation assembly and the
injection unit and pre-charge to a pressure
similar to that within the valve.
Once pressure applied and balance
43 achieved, open the intermediate isolation
valve to the injection unit.
If lubricant injection is a requirement, then
displace the minimum amount of valve lubricant
Discharge the lubrication into the injection
44 into the valve. Refer to Table 3 – Generic Ball
fittings. Refer to “Remarks”.
Valve Seat Flushing and Lubrication Injection
Capacities.
On satisfactory completion it will be
necessary to test the integrity of the
45
injector before being able to disconnect the
injection unit from the valve injector.

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Step Action Remarks

Flushing of Ball Valves – Contingency Procedure (Contd.)
Close the intermediate DBB assembly
46
isolation.
Depressurise the inter-space between the
injection unit and the intermediate
47
isolation valve via the injection unit vent /
drain facility.
Close the injection unit vent / drain
48
facility.
Open the valve injector to the flushing unit
49 and monitor for any pressure build-up via
the pressure gauge.
If a pressure build-up is noted then the
valve injector has failed to reseat.
Go to Step 51.

50 If no leakage noted, isolate and Refit injector fitting’s protective cap.

depressurise the flushing unit. Disconnect
the equipment from the valve injector and
move onto the next valve injector.
Restart at Step 7.
Close the intermediate DBB isolation
assembly and depressurise the flushing
51 Monitor pressure decay via the pressure gauge.
unit via the flushing unit vent / drain
facility.
Disconnect the flushing unit from the DBB
isolation assembly. The intermediate DBB
isolation assembly is to remain attached to
52 Notify site supervisor of the current condition.
the valve injector until such time that it can
be safely removed and the failed injector
replaced.
As an additional precautionary measure,
remove from the exposed end of the
53 intermediate DBB isolation assembly the Notify site supervisor of the current condition.
screwed connector. To the opening, fit and
secure a full rated bleed plug.
Where applicable, move onto the next
injector. Where possible, refit the injector fitting’s
54
protective cap if one was present.
Restart at Step 7.

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Step Action Remarks

Seat Lubrication Injection Procedure

Safety Notes:
 It is preferred that lubricant injection of the ball valve is carried out with the valve in the closed
position.
 The maximum lubrication volume specified must be distributed evenly between the injection
points.
 Ensure that the double block and bleed (DBB) assembly shown in Figure 3 is fitted to the
injection unit.
 In an attempt to improve results, operation of the valve from the fully closed, to fully open and
back to fully closed position should be completed. Re-injection should then be attempted
following this operation.
See Section 8.0 Cavity Flushing Method for
Work scope not to be carried out on
55 procedure of completion of flushing on these
Valvitalia ESV valves.
valves.
Refer to “Injector Preparation” Steps 7 to
56
15.
If flushing operations have been
performed, change over the unit or
57
consumable to valve lubricant and proceed
to Step 58.
It is preferred that lubricant injection of the
58 ball valve is carried out with the valve in
the closed position.
The amount of lubricant required will vary
by valve type and size. Matrices supplied
by the various valve lubricant
manufactures serve as guidance only. It is Refer to Table 3 –Generic Ball Valve Seat
59
at the discretion of the Valve Supervisor to Flushing and Lubrication Injection Capacities.
ensure that sufficient lubricant has been
injected into the valve to achieve the
required results.
To the valve injector, attach the injection
unit complete with intermediate DBB Ensure that the associated DBB isolation
60 isolation assembly. assembly is in the closed position.
Refer to Figure 3 for typical assembly.

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Step Action Remarks

Seat Lubrication Injection Procedure (Contd.)
Safety Notes:
Where a pneumatic powered unit is being Avoid having any of the hoses taut.
used, ensure that all safety devices are in
61 All hoses shall be rigged such to prevent trip
place i.e. air hose whip-lines, safety
R-pins. hazards.
Ensure hoses are free of kinks and twists.
Re-check the system following final
assembly to ensure that all connections
62 Refer to Figure 3 for typical assembly.
have been correctly made and that all
safety devices are in place.
For powered injection units, ensure that the
unit is isolated from the power supply so
63
that it will not inadvertently start pumping
when the unit is switched on.
Where applicable and in a controlled
64
manner, power up the injection unit.
Line up the injection unit to the valve
65 injector by opening the appropriate
isolations.
In a controlled manner, commence with
the injecting of the valve lubricant into the The maximum allowable pressure table is given
66 valve. in Table 4.
Refer to “Remarks”.
The following Steps, 68 to 75 serve as a
guide to valve lubrication injection
67 operations. Each new task of this nature
requires the procedure to be reviewed for
suitability.
Safety Note:
The maximum initial injection pressure to
Do not exceed the recommended maximum
ascertain the internal condition of the valve
68 allowable pressure (see Tables 4 & 5).
injection system shall be 50 psig
(3.5 barg) If greater pressure required please consider
notes detailed for Tables 4 & 5.

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Step Action Remarks

Seat Lubrication Injection Procedure (Contd.)
Possible causes for static pressure are:
Monitor for pressure decay.
 The valve injector NRV system may be
If pressure decay is observed, then seized closed.
indications are that the injection ports are
69  The valve internal NRV system (if fitted)
free from obstructions. Go to Step 72.
may be seized closed.
If there is no pressure decay, refer to
“Remarks” column.  A higher pressure is required to displace the
lubricant. Go to Step 78.
Safety Note:
Increase the discharge pressure in 50 psig Do not exceed the recommended maximum
70 (3.5 barg) increments with a hold period allowable pressure (see Tables 4 & 5).
between each pressure rise.
If greater pressure required please consider notes
detailed for Tables 4 & 5.
If on reaching the specified maximum
Possible causes for failure:
allowable pressure and there is still no
pressure decay, the injector cannot be  The internal NRV system may be seized.
used. To allow for the safe removal of the
71  The valve has been previously injected with a
injection unit, it will be necessary to test
compound that cannot be dissolved.
the integrity of the valve injector. Go to
Step 76. Make a record of the injector and notify site
supervisor.
If a pressure decay is noted, go to Step 72.
Displace as a minimum the required Refer to Table 3 – Generic Ball Valve Seat
72
amount of valve lubricant as specified. Flushing and Lubrication Injection Capacities.
On injection of the required amount it is
required to operate the valve from closed A reduced 30 degrees open position can be
73
to open and return to closed prior to further considered where full operation is not possible.
injection activities.
Displace as a minimum the recommended
amount of valve flush. Refer to Table 3 - Valve
Following successful operation re-inject Seat Flushing and Lubricating Capacities.
74 with valve lubricant and repeat operations
as per steps 66 to 73. Injection and subsequent operation must be
repeated 3 times in order to optimise flushing
activities.
On satisfactory completion it will be
necessary to test the integrity of the
75 injector before removal of the injection
unit.
Go to Step 76.

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Step Action Remarks

Seat Lubrication Injection Procedure (Contd.)
Close the intermediate DBB isolation
76
assembly.

Depressurise the interspace between the

injection unit and the intermediate DBB
77
isolation assembly via the lubricating vent
/ drain valve.

Close the injection unit vent / drain

78
facility.

Open the valve injector to the injection

unit by opening the intermediate DBB
79
isolation assembly and monitor for
pressure build-up via the pressure gauge.

If a pressure build-up is noted then the

valve injector has failed to reseat. Go to
Step 81.
80 If no pressure build-up is noted, isolate and
depressurise the injection unit. Disconnect
the equipment from the valve injector. Go
to Step 85.

Close the intermediate DBB isolation

81
assembly.

Depressurise the interspace between the

intermediate DBB isolation assembly and
82
the injection unit via the injection unit vent
/ drain facility.

Disconnect the injection unit from the

DBB isolation assembly. The intermediate
DBB isolation assembly is to remain
83
attached to the valve injector until such
time that it can be safely removed and the
failed injector replaced.

As an additional precautionary measure,

remove from the exposed end of the
Notify site supervisor of the current condition.
84 intermediate DBB isolation assembly the
screwed connector. To the opening, fit and
secure a full rated bleed plug.

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Step Action Remarks

Seat Lubrication Injection Procedure (Contd.)
Where applicable, move onto the next
valve injector. Where possible, refit the injector fitting’s
85
protective cap if one was present.
Restart from Step 56.
Following completion of the prior seat
lubrication injection steps, it must be
Refer to Table 3 – Generic Ball Valve Seat
86 ensured that sufficient lubricant as per
Flushing and Lubrication Injection Capacities.
recommended values has been applied as a
minimum.
Pressure testing to be carried out by
87 competent offshore personnel, while
monitoring for any leakage.
If leakage is noted, further lubrication
The lead technician to decide if further
88 injection may be attempted as per Steps 60
lubrication injection should be carried out.
to 86.
Reinstate the work area by tidying up all
89
tooling and equipment.
90 Sign and return appropriate permits.

8.0 CAVITY FLUSHING METHOD

Step Action Remarks

Site Preparatory Work
On receipt of equipment, ensure that all
91 components / tools have been received and All relevant certification to be of current date.
are in good order.
Familiarise yourself with the equipment
Identify any potential hazards to the site
92 and surrounding work area for potential
supervisor.
hazards.
Ensure suitable area for the MacScott
93 Bond pump has been located in order to
connect electric supply.
94 Identify lay down area for equipment. Erect barriers etc. where necessary.
Complete Toolbox Talk and Risk This should be carried out at the job site
95
Assessment. following survey of the work area.

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Step Action Remarks

Ensure permit conforms to work scope
96 Review “The Permit to Work”.
requirements.
Highlight any concerning factors to site
97 Sign Permit to start.
supervisor prior to commencing work.
MacScott Bond Pump Preparation
Notes:
 The following steps, serve as a guide to preparing the MacScott Bond pump for flushing
activities.
 Ensure all personnel involved have read and understood the ‘Operating Instructions’, prior to
commencing flushing activities (see Figure 6).
Transfer all equipment to the designated Ensure selected lay-down area is in a safe
98
lay down area prior to commencing work. location and any barriers erected if required.

Ensure all personnel have read and

99 understood the ‘Operation Instructions’ Reference: Figure 6
prior to commencing work.

Remove the filler cap on the reservoir tank

100
on the MacScott Bond pump.

Using the quick fill pump, (see Figure 7),

101 fill the reservoir tank with Glycol from the
drum provided.
Once the required amount has been
102 displaced, close off the reservoir tank with
the filler cap.
Follow instructions of the ‘Operating
Ensure a trial run is completed prior to
103 Instructions’ to ensure the pump is
connecting to the relevant valves.
working correctly prior to use for flushing.
Flushing Preparation
Notes:
 Cavity Flushing Method to be carried out on Valvitalia ESV valves only.
Transfer all equipment to the designated Ensure selected lay-down area is in a safe
104
lay down area prior to commencing work. location and any barriers erected if required.

Ensure no trapped pressure is within the

Monitor pressure to ensure cavity of the valve
105 valve cavity prior to removal of drain &
has been relieved of any trapped pressure.
vent flanges.

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Step Action Remarks

Using a correct sized spanner, remove the
Bolt and seal dimensions to be taken and
drain / vent flange nuts and place in a safe
106 materials confirmed. Send to Engineering for
location, as these will be used to secure the
confirmation of torque figure for refitment.
tapped flange.
Flushing Preparation (Cont’d)

Remove the blind flange and place in a

107
safe location.

Place tapped flange / isolation valve

assembly on to drain / vent port and secure Replacement RTJ seal ring to be utilised once
108
using the nuts previously removed from flushing activities have been completed.
the blind flanges.
Ensure fitting in tapped flange is clean
109
prior to fitment of flushing pump
Ensure hose from drain port is connected Hose from vent port to be left open to safe
110 to MacScott Bond pump, and hose from location to determine when the valve cavity is
vent port is not connected to the pump. full.
Cavity Flushing Method
Notes:
 The following Steps, 111 to 130 serve as a guide to valve flushing operations. It is the
responsibility of the valve supervisor to evaluate and adjust the procedure where necessary.
 Ensure that the suitable isolation is fitted to both flanges prior to commencing flushing activities.
 It is preferred in this instance that flushing of the ball valve is carried out with the valve in the
open position.
 In an attempt to improve results, operation of the valve from the fully open, to fully closed and
back to fully open position should be completed where deemed necessary.
 The valve cavity volume has been stated by Valvitalia as 300L. This is an approximated volume
and hence, the time allocated to filling the cavity may vary.
To the drain port, attach and secure the
111
hose from Line ‘A’ to the assembly.
To the vent port, ensure the isolation Ensure the hose is directed to a safe location to
112 assembly is connected and the hose is not store excess Glycol.
connected to the pump. Line ‘B’ will be used for the vent port.
Safety Notes:
For powered flushing units, ensure that the Avoid having any of the hoses taut.
unit is isolated from the power supply so
113 All hoses shall be rigged such to prevent trip
that it will not inadvertently start pumping
when the unit is switched on. hazards.
Ensure hoses are free of kinks and twists.
Step Action Remarks

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Line up the flushing unit to the valve

114 injector by opening the appropriate
isolations.
Although this should not be reached as the cavity
In a controlled manner, commence with is vented to atmosphere a maximum pressure of
115
filling valve cavity with “Glycol”. 341 barg for flanged ports, see note 9 for Table 5
should not be exceeded.
Cavity Flushing Method (Cont’d)
The maximum initial injection pressure to
116 ascertain the internal condition of the
fitting shall be 50 psig (3.5 barg)
Increase the pressure from the pump to
117
allow the Glycol to fill the valve cavity.
The cavity will be deemed full when
Glycol begins to flow out the vent port.
118
Once full, shut off flow line ‘A’ and attach
hose from vent port to Line ‘B’
Switch the Flow Line from ‘A’ to ‘B’ in
119 See Figure 5 for confirmation of switch.
order to reverse the pumping action.
In a safe manner, commence flushing of Flushing activity to commence for
120
the valve cavity. approximately 30 minutes.
HOLD POINT: All relevant personnel to discuss outcome of initial flushing operations prior to
draining. Site supervisor to confirm whether to immediately drain flush from the cavity or operate the
valve to the closed position and return to open for another rotation of flushing operations.
Remove the hose from Line ‘B’ and leave
121 open to atmosphere to aid in the draining
of the Glycol.
Switch the pump from ‘B’ to ‘A’ and
122 commence draining of the Glycol from the
cavity.
Once valve cavity is drained, if available,
a borescope or similar should be used to
123 view the internals of the valve cavity to
check for any excess debris that has
remained in the valve cavity.
If debris has remained within the cavity, Discussion should be had with lead technician as
124 operate the valve and repeat flushing to whether the flushing activities should be
activities from step 111 to 122. repeated.

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Step Action Remarks

If no debris is witnessed using the
125
borescope, then continue to step 126.
Isolate and depressurise the MacScott
126
Bond pump system.
Disconnect the hoses from the vent and
127
drain ports.
Attach the quick fill pump to the vent port
128 and flush out the Glycol with water
through the drain port to a safe location.
Open DBB at drain port to allow any
129 remaining Glycol to be flushed out the
cavity.
Once complete, disconnect the quick fill
130
pump from the vent port.
Ensure that there is no pressure trapped between
Using a correct sized spanner, remove the
the valve injector and the flushing unit by
131 flange nuts from the vent and drain flanges
ensuring that all isolation valves are open to the
and place in a safe location.
pressure gauge.
Remove the tapped flange and RTJ seal These components will not be used in the valve
132
ring and place in a safe location. assembly.
Place new RTJ seal ring and original blind
133
flange on to the vent / drain port.
If in doubt dimensions and material to be
Place the flange nuts on to the bolting and provided to Engineering for confirmation.
134
torque to appropriate figure. Dimension should have been noted during step
106.
Reinstate the work area by tidying up all
135
tooling and equipment.
136 Sign and return appropriate permits.

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9.0 TOOLS AND CONSUMABLES

Item Description Qty.

1 QS2000A Pump (inc hoses, fittings and pressure gauge) 1
2 Double Isolation Block and Bleed Manifold (complete with gauge) 2
3 Val-Tex Valve Flush 23 boxes
4 Val-Tex 700 21 boxes
5 Val-Tex 85 7 boxes
6 Glycol MEG (Purchased by Client) TBC
7 Mascott Bond Flushing Pump/Unit (Hire Only) 1
8 Generic Toolbag 1

10.0 DISTRIBUTION LIST

Bruce Buchan Score (Europe) Limited, Peterhead

Ally Marshall Score (Europe) Limited, Peterhead
James Geddes Score (Europe) Limited, Peterhead
Mike Billington / File Score (Europe) Limited, Stowmarket

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Capped Button Type

Capped Screwed Head Type

Exposed Button Head Type

Figure 1: Valve Injector Identification

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Figure 2: Valve and Injector Non-Return Systems

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Pressure
Gauge

DBB

Coupling to Valve DBB

Injection Fitting

1 2 3

1: Valve to Manifold Isolation

LEGEND

2: Vent
3: Pump to Manifold Isolation

Button Head Button Head

Coupling Coupling

Figure 3: Typical Injector Double Block and Bleed Isolation Assembly

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Operating Instructions
See Figure 7

Figure 4: MacScott Bond Pump System

Indicator Plate for Lines

Switch for lines ‘A’ and ‘B’

Figure 5: Switch for Lines ‘A’ and ‘B’

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Figure 6: Instructions for use of MacScott Bond Pump System

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Figure 7: Quick Fill Pump

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Table 3 – Generic Ball Valve Seat Flushing and Lubrication Injection Capacities

Flushing Flushing Lubricant Lubricant

Size
(Litres) (lb) (Kg) (lb)
½" - - - -
¾" - - - -
1" - - - -
1 ½" - - - -
2" 0.5 1.1 0.11 0.2
3" 0.5 1.1 0.22 0.5
4" 1 2.1 0.34 0.7
6" 1 2.1 0.45 1.0
8" 1 2.1 0.55 1.2
10" 1 2.1 0.75 1.7
12" 1 2.1 0.75 1.7
14" 1 2.1 0.75 1.7
16" 2 4.3 0.75 1.7
18" 2 4.3 0.75 1.7
20" 2 4.3 0.9 2.0
22" 2 4.3 0.9 2.0
24" 2 4.3 0.9 2.0
26" 3 6.4 1 2.2
28" 3 6.4 1.2 2.6

30" 3 6.4 1.2 2.6

32" 3 6.4 1.4 3.1

34" 3 6.4 1.4 3.1
36" 4 8.6 1.8 4.0
38" 4 8.6 2.1 4.6
40" 4 8.6 2.8 6.2
42" 4 8.6 2.8 6.2
48" 6 12.9 4 8.8

Note:

The total lubricant mass stated above is per valve. Divide the mass by the number of lubrication
injectors fitted to the valve. This is the amount to be injected through each injector, ensuring an
even distribution.

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Table 4 – Valve Flushing Injection Pressures for ANSI Rated Valves

Valve Flushing Injection Pressures

Values in Table are as per ASME B16.34 Valve Maximum Allowable Working Pressures
Group 1.1 Body Materials (see Notes 3, 4 & 5)
Temperature
ANSI
-29 to 38°C 50°C 100°C 150°C
Class Rating
psig barg psig Barg psig barg psig barg
ANSI 150 284 19.6 278 19.2 257 17.7 229 15.8
ANSI 300 741 51.1 726 50.1 676 46.6 654 45.1
ANSI 400 987 68.1 969 66.8 900 62.1 871 60.1
ANSI 600 1480 102.1 1453 100.2 1351 93.2 1308 90.2
ANSI 800 1975 136.2 1939 133.7 1802 124.3 1743 120.2
ANSI 900 2221 153.2 2181 150.4 2027 139.8 1960 135.2
ANSI 1500 3702 255.3 3634 250.6 3379 233.0 3268 225.4
ANSI 2500 6170 425.5 6057 417.7 5630 388.3 5446 375.6

Table 5 – Valve Lubrication Injection Pressures for ANSI Rated Valves

Valve Lubricant / Lubrication Injection Pressures

Values in Table are as per ASME B16.34 Valve Maximum Allowable Shell Test Pressures
Group 1.1 Body Materials (see Notes 3, 4 & 5)
Temperature
ANSI
-29 to 38°C 50°C 100°C 150°C
Class Rating
psig barg psig Barg psig barg psig barg
ANSI 150 426 29.4 417 28.8 386 26.6 344 23.7
ANSI 300 1112 76.7 1089 75.2 1014 69.9 981 67.7
ANSI 400 1481 102.2 1454 100.2 1350 93.2 1307 90.2
ANSI 600 2220 153.2 2180 150.3 2027 139.8 1962 135.3
ANSI 800 2963 204.3 2909 200.6 2703 186.5 2615 180.3
ANSI 900 3332 229.8 3272 225.6 3041 209.7 2940 202.8
ANSI 1500 5553 383.0 5451 375.9 5069 349.5 4902 338.1
ANSI 2500 9255 638.3 9086 626.6 8445 582.5 8169 563.4

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Notes for Tables 2 & 3:

1. The pressures stated in the above tables detail the maximum allowable static working and
shell test pressures.

2. A higher injection pressure (recorded at the pump outlet) for injection rate purposes may
be permitted if it can be demonstrated that there is sufficient pressure drop between the
injection unit discharge pressure gauge and the valve injector i.e. good flow through the
valve injection system such that the valve cannot be over-pressurised.

3. ASME B16.34 Group 1.1 Carbon Steel Materials include:

Forgings - A105 / A350 Gr. LF2 / A350 Gr. LF3 / A350 Gr. LF6 Cl.1
Castings - A216 Gr. WCB

4. ASME B16.34 Group 1.2 Carbon Steel Materials include:

Forgings - A350 Gr. LF6 Cl.2
Castings - A352 Gr. LC2 / A352 Gr. LC3 / A216 Gr. WCC / A352 Gr. LCC

5. The pressures stated should be adhered to for valve body materials within ASME B16.34
groups 1.1 and 1.2 detailed in notes 3 & 4 above.

6. For any other valve body materials out with the Material Groups 1.1 and 1.2 specified in
these tables, the specification ASME B16.34 must be consulted.

7. Always ensure that the manufacturer’s maximum pressure rating of any associated
injection equipment is not exceeded.

8. Always ensure that the maximum pressure rating of the valve is not exceeded (i.e. ensure
that the correct rating of the valve to be injected has been confirmed, in order to ensure the
correct maximum pressure is identified and adhered to).

9. Max pressure of 341 barg for Vent and Drain ports in Valvitalia Valves not to be exceeded
when completing flushing activities.

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Appendix 1: Service Datasheet

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Appendix 2: General Assembly Drawing (Valvitalia Fully Welded Body MOV)

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Appendix 3: General Assembly Drawing (Valvitalia Top Entry MOV)

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Appendix 4: General Assembly Drawing (Valvitalia Top Entry ESV)

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Appendix 5: General Assembly Drawing (Cameron Top Entry MOV)

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Appedix 6: General Assembly Drawing (Cameron Top Entry ESV)

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Appendix 7: Val-Tex QS2000A Lubrication Injection Unit

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Appendix 8: Schematic for MacScott Bond Pump System

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Appendix 9: Val-Tex Valve Flush Specification & Material Safety Data Sheet

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Appendix 10: Val-Tex Grade 700 Material Safety Data Sheet

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Appendix 11: Val-Tex Grade 2000 Material Safety Data Sheet

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Appendix 12: Val-Tex Grade 85 Material Safety Data Sheet

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Appendix 13: Val-Tex Valve Lubrication Packaging

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Appendix 14: Galaxy Generator for MacScott Bond Pump

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