AAS-010 REV A

OPERATION & MAINTENANCE MANUAL

API 6A EXPANDING GATE VALVE
AAS-011 REV A
INTRODUCTION page 3

GATE VALVE FOR WORKING PRESSURES 3,000 THROUGH 5,000 (Figure 1)

Manually operated valves are standard with expanding split gate design and non-rising stems. Fittings are
provided for body lubrication, bearing lubrication and renewal of stem packing. The wedging action of the gate
provides a positive mechanical gate seat seal on both the upstream and downstream sides of the valve; however,
the valve has a preferred direction of installation. The preferred direction of flow is clearly marked with an arrow
on the valve body.

GATE VALVE FOR WORKING PRESSURES 10,000 THROUGH 15,000 (Figure 2)

Manually operated valves are standard with expanding split gate design and pressure balancing stems. Fittings
are provided for body lubrication, seat lubrication, bearing lubrication and renewal of stem packing. The
wedging action of the gate provides a positive mechanical gate seat seal on both the upstream and downstream
sides of the valve; however, the valve has a preferred direction of installation. The preferred direction of flow is
clearly marked with an arrow on the valve body.

Figure 1 Figure 2

Valves are also available prepared for an actuator of the customer's choice or equipped with an Array Products
Pneumatic Diaphragm, Pneumatic Piston, or Hydraulic Actuator. The standard configuration for an actuated
valve includes a slab gate, floating seats and a blind bonnet in place of the lower bonnet on manually operated
valves. Actuator/bonnet assemblies and actuated valve assemblies also include an optional manual override device.
INSTALLATION AND OPERATING INSTRUCTIONS page 4

INSTALLATION INSTRUCTIONS
Once an Array gate valve has been assembled and tested it is fully lubricated. Protective coatings are applied to
flange seal surfaces and threads which are exposed to the environment. Gates, seats, stems and other internal
parts are also coated with a lubricant such as Molybdenum Disulfide, Xylan, etc., prior to assembly. Every effort
should be made to preserve the protective coatings and lubricants prior to installation.

To prevent damage to gate and seat sealing surfaces, all valves are shipped in the open position. The valve
should be left in the open position until installation is complete. Should it be necessary to transport the valve, it
should always be placed in the open position.

If a hydrostatic test is performed prior to installation, the valve cavity should be drained of test fluids and refilled
with a suitable lubricant. CAUTION: If hydrostatic tests that exceed the working pressure are required, they
must be performed with the valve in the open or partially open position.

OPERATING INSTRUCTIONS
Array expanding gate valves must be fully open or closed to properly wedge the gate segments against the
seats. Once fully opened or closed, do not back off on the handwheel. Doing so will release the mechanical
wedging action of the gate segments. The appropriate number of turns to operate each Array valve is shown in
Table 1 and Table 2.

3,000 Through 5,000 WP 10,000 Through 15,000 WP

Nominal Size No. of Turns Nominal Size No. of Turns
(Inches) (Inches)
21/16" 13 113/16” 12
29/16" 16 21/16” 14
31/8" 20 29/16” 15
41/16" 25 31/16” 18
51/8" 31 41/16” 23
71/16" 42

Table 1 Table 2
MAINTENANCE page 5

When shipped, all Array valves are fully lubricated and serviced. Once installed, well clean up, cementing
operations, hydrofrac, acidizing, etc., can displace lubricants from the body cavity. This may leave particles and
fluid which can be damaging to the gate and seat sealing surfaces. It is recommended to drain, vent and
lubricate valves following such operations.

A routine program of draining the valve body is the best approach to increasing the effective life of the valve.
A minimum of lubrication maintenance will enhance the life and trouble free operation of the valve. Array Field
Service Personnel are available to assist you with Valve Maintenance Programs.

The maintenance tools and accessories, as well as, the procedures to be followed for each model of Array valve
will follow.

1. Maintenance Equipment
1.1. To facilitate the necessary valve maintenance we recommend the following equipment: Pressure
releasing tool for Alemite grease fittings, Alemite grease gun, Alemite P/N 6713, with needle valve and
adapter or equivalent.

Figure 3 Figure 4

Safety Pressure Releasing Tool Alemite Grease Gun

2. Identification of Servicing Fittings
page 6
2.1. In the lubrication and servicing procedures, references to fittings may be identified and located per the
following figures.

Lubrication Fitting Identification

1 Bearing Lubrication Fitting
2 Packing Injection Fitting
3 Drain Port / Cavity Lube Port
4 Seat Sealant Injection Port

3
2

3 4

3
Figure 5 Figure 6
3. Stem Bearing Lubrication
page 7
3.1. Valves are equipped with a standard 1/8” Alemite grease fitting for stem bearing lubrication. A good
grade of #3 grease is recommended for this lubrication. Only a small amount of grease is required. Over
lubrication will result in leakage around the stem. CAUTION: Array gate valves must be removed from
service to perform any work on bearings.

4. Body Lubrication
4.1. Regular body lubrication will help keep valves operating freely and prolong their service life. Generally,
Desco 111 (HS) is recommended for body lubrication. Any good grade #3, #4 of #5 grade lubricant that
is not soluble in the media being handled may be substituted as a body lubricant. Approximately one
pound of grease per inch of valve bore size will sufficiently lubricate the valve body. It is not necessary to
completely fill the valve body.

CAUTION: Lubricating pressure must not exceed the rated working pressure of the valve being lubri-
cated. A pressure gage should be used to monitor lubricating pressure.

Each valve is equipped with two safety ball check grease fittings installed on the body of the valve.
Lubrication requires the use of a safety pressure release tool and a high pressure grease gun equipped
with a coupling and needle valve. The needle valve may be used to shut off flow in the event that the ball
check in the fitting fails to reseat.

4.1.1. Operate the valve to either its fully open or fully closed position.

4.1.2. Remove safety caps from body grease fittings and install the pressure releasing tool to one and
the grease pump to the other.

4.1.3. Operate the pressure release tool to bleed body pressure and leave the stinger in this position.

4.1.4. Inject lubricant through the other body grease fitting.

4.1.5. Once lubrication is complete, remove the pressure release tool and grease pump.

4.1.6. Reinstall the safety caps securely on both lubrication fittings.

5. Stem Packing
5.1. Plastic packing may be injected into the valve stem packing box through the stem packing fitting located
in the valve bonnet in order to stop or prevent leakage that may occur around the stem or packing gland.
Caution should be used if this procedure is being done while the valve is in service and under pressure.
This packing is supplied in easy-to-use stick form and is available for all service conditions. A 3/4" socket
with a speed or ratchet wrench is recommended for this operation.

5.1.1. Run the hex head stinger all the way into the stem packing fitting and then back out when you are
sure that the ball check has seated. Ball check leakage can be detected through the small hole in the
side of the fitting prior to completely removing the stinger.

5.1.2. Remove the stinger and insert one stick of packing.

 5.1.3. Reinstall the stinger to inject the packing.
page 8
5.1.4. Repeat if necessary, inserting only as much packing as is required to stop any leakage. CAUTION:
Excessive packing pressure will cause the stem to bind, making operation of the valve difficult.

6. Venting And Draining

6.1. Routine draining of valve bodies will increase valve life and reduce damage to the valve caused by
accumulation of foreign matter. The accumulation of foreign matter may keep the valve from fully
closing which could result in damaged seat and gate segment sealing surfaces.

6.1.1. Put the valve in a fully open or fully closed position.

6.1.2. Remove one of the body grease fitting safety caps and install a pressure release tool.

6.1.3. Screw the stinger of the pressure release tool into the fitting to bleed body pressure and allow the
valve to vent or drain.

6.1.4. A
 fter venting or draining, back the stinger of the pressure release tool out to reseat the ball check.

6.1.5. If the initial draining is not sufficient, it may be necessary to repeat the procedure.

6.1.6. Once draining is completed, the valve should be lubricated (Section 4).

7. Regular Preventative Maintenance

7.1. A program of routine draining and body lubrication is the most positive way to prevent problems caused
by foreign matter in the valve body. If a routine program cannot be followed, it is recommended that valves be
drained at the following times:

• After a well has come in and has been cleaned up.

• After any cementing or fracturing operation.

• Anytime the valve becomes hard to operate or will not fully open or close by the required number of
handwheel turns. Run the hex head stinger all the way into the stem packing fitting and then back
out when you are sure that the ball check has seated. Ball check leakage can be detected through
the small hole in the side of the fitting prior to completely.
PARTS LIST
3,000–5,000 PSI VALVES
page 9

# DESCRIPTION
1 Bearing Lubrication Fitting
2 Packing Injection Fitting
6
3 Drain Port/Cavity lube Port
4 Handwheel
5 Handwheel nut
6 Washer
7 Stem 8
8 Bearing Retainer Nut 7

9 Bearing 9

10 Bearing Retainer Sleeve

10
11 Packing Set 1

12 Packing Retainer Bushing

11
13 Stud 12

14 Nut 13 2
15 Bonnet
16 Gate Assembly 14 21
17 Valve Body
15 16
18 O-Ring
19 Seat Assembly
18 17
20 Gate Guide
21 Bonnet Seal Ring

19

20
DIMENSIONAL DATA
3,000–5,000 PSI VALVES
page 11
G

A
E

THREADED VALVES
SIZE Working (PSI) A E F G J WT
in mm in mm in mm in mm in mm lbs kgs
2 1⁄16 2000, 2.06 52 4.81 122 19.25 488 11.00 279 9.62 244 90 40
3000–5000 2.06 52 5.06 128 19.43 493 13.00 330 9.62 244 125 56
2 9⁄16 2000, 2.56 65 5.62 142 20.18 512 13.00 330 10.25 260 125 56
3000–5000 2.56 65 5.93 150 20.43 519 16.00 406 10.25 260 160 72
3 1⁄8 2000, 3.12 79 6.93 176 22.50 571 13.00 330 11.37 288 190 86
3000–5000 3.12 79 7.31 185 22.75 577 16.00 406 11.37 288 230 104
4 1⁄16 2000, 4.06 103 8.62 219 25.93 658 16.00 406 13.00 330 320 145
3000–5000 4.06 103 9.06 230 26.37 669 20.00 508 13.00 330 420 190

A
E

FLANGED END VALVES

SIZE Working (PSI) A E F G J WT
in mm in mm in mm in mm in mm lbs kgs
2 1⁄16 2000 2.06 52 4.81 122 19.25 488 11.00 279 11.62 295 120 54
3000–5000 2.06 52 5.06 128 19.43 493 13.00 330 14.62 371 125 56
2 9⁄16 2000 2.56 65 5.62 142 20.18 512 13.00 330 13.12 333 180 81
3000–5000 2.56 65 5.93 150 20.43 519 16.00 406 16.62 422 220 99
3 1⁄8 2000 3.12 79 6.93 176 22.50 571 13.00 330 14.12 358 220 99
3000 3.12 79 7.31 185 22.75 577 16.00 406 17.12 434 300 136
5000 3.12 79 7.31 185 22.75 577 16.00 406 18.62 437 340 154
4 1⁄16 2000 4.06 103 8.62 219 25.93 658 16.00 406 17.12 358 360 163
3000 4.06 103 9.06 230 26.37 669 20.00 508 20.12 511 520 235
5000 4.06 103 9.06 230 26.37 669 20.00 508 21.62 549 560 254
5 1⁄8 2000 5.12 130 11.62 295 32.50 825 21.00 533 22.12 561 800 362
3000 5.12 130 11.62 295 32.50 825 23.50 596 24.12 612 900 408
5000 5.12 130 11.62 295 32.50 825 23.50 596 28.62 727 980 444
7 1⁄16 2000 7.06 179 13.87 352 33.10 840 13.00 330 20.00 666 1021 463
3000 7.06 179 13.87 352 34.10 866 16.00 406 24.00 714 1118 507
5000 7.06 179 13.87 352 34.10 866 20.00 508 30.00 812 1398 634
TROUBLESHOOTING page 13

TROUBLE PROBABLE CAUSE REMEDY

Will not open or close Restriction in body cavity Work handwheel back and forth. If ice
is suspected, see procedure below.

Insufficient lubricant See lubrication procedure

Accumulation of mud, sand or See draining and lubrication procedure

other foreign matter in valve body

Hard to operate Stem thread damaged Repair or replace

Gate spring broken or off Repair or replace

Pressure in body greater See venting procedure

than upstream or downstream
pressure

Restricted bore in valve Gate not properly aligned with Stroke valve fully several cycles from
the bore of seats full open to full close position

Bearing needs to be lubricated Lubricate bearings

Bearings are broken Replace bearings

Erratic Operation Stem threads damaged Back up from hard operating spot
before continuing in one direction.
Replace at first opportunity

Gate spring broken or off Repair or replace

Leaking bonnet flange Loose bonnet connection Isolate from pressure, bleed down
cavity and tighten bonnet bolting

Damaged bonnet seal ring Replace seal ring

Leaking around stem Packing and/or stem damaged Inject with plastic

Replace packing or stem

Will not seal downstream Worn or damaged gate and seats Inject grease in body. Replace seat at
first opportunity

Grease fitting leaking Safety cap not tight Tighten safety cap or replace fitting
 when practical.
TROUBLESHOOTING page 14

If ice or hydrates cause the valve not to operate, use the following procedure:

1. Remove the safety cap from the body grease fitting and attach a test pump to the open fitting.

2. Pump methanol or glycol into the valve body to dissolve ice.

3. Work the valve handwheel back and forth to break up the ice block.

4. Continue working the handwheel until the valve can be operated to the fully open and closed position.

5. Remove the test pump and reinstall the safety cap.

6. Drain the test pump and flush the pump hoses clean with hydraulic oil.