Plug Valve SS 1/4 Modified Creation

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Disassemble

1. Remove and store the circlip for later reassembly.
2. Remove the plug and handle from the valve body.
   • Press bottom of plug on hard surface to release it.
3. Remove all three O-rings using the ultimate o-ring removal tool.
4. Use lab wipes to clean the plug and body of all grease.
5. Remove the spring pin and plastic knob.
   • Store the spring pin for later reassembly.
   • Discard the knob to surplus.

Add Orientation Marks

1. Insert the plug into marking tool for plug valve 4PV (TL-MTPV4V) with a 0.113 gauge pin through the passage hole.
2. With a sharp carbide scribe, follow the marking tool guide slots to scribe "passage direction" and "upstream closed" lines into the bottom of the plug.
   • The diameter line indicates the direction of the fluid passage through the plug.
   • The short radial line at the edge indicates the the port-sealing O-ring.

Remove Stop Pin

1. Clamp the valve body in soft-jaw vise with the stop pin facing up.
2. Using specially ground bite-tip vise grip and surface protector, bite the pin at its base in contact with protector and in the center of the vise grip jaws.
   • The surface protector is a perforated steel shim.
3. Twist the vise grip about the pin's axis, pulling up to remove it.
4. Remove any burr raised at the edge of the stop pin hole.
   • Otherwise it will later dig into coupling face.

Hone the Barrel

1. Obtain or make two hones, one coarse and one fine.
   • Each hone consists of an abrasive pad inserted into a Plug Valve Hone Shaft (TL-PVHT).
   • The coarse hone requires a maroon abrasive pad (part of a Scotch-Brite 7447).
   • The fine hone needs a gray abrasive pad (part of a Scotch-Brite 7448).
   • Cut the stock abrasive pads repeatedly in half to make pieces about 2.25" x 1.5".
2. Insert the hone into a drill.
3. Wrap the flaps of the pad away clockwise around the hone shaft, forming an S-shape.
   1. Hold the abrasive pad down so that it will fit into the barrel of the plug valve.
   • Spin the drill a little bit so the tool will actually fit inside of the barrel.
   1. Move the valve back and forth on the tool slowly.
      • If the valve moves too quickly there will be scratches that will spiral towards the ends of the valve.
   2. Turn the plug around and repeat the steps on the other side.
   3. Switch to the green abrasive pad and repeat the previous steps.
   4. Check for scratches, if any of them are vertical then the plug valve needs to be honed again.
   5. Blow the dust out of the plug valves.
4. Clean the plug valve.
   1. Run the valve under water to remove loose grit, giving attention to all three openings.
   2. Place valves into a sonicator with clean IPA and run for 180 sec.
      • This step helps remove excess debris, but is not crucial if a sonicator is not available.
   3. Remove valves from IPA and place into a bath of water to prevent spots from forming on the surface.
   4. Prepare a small cup of water or IPA to dip q-tips into.
      • A cotton tail q-tip is needed for the barrel of the plug valve, regular q-tips will be used for the "T" of the valve.
   5. Soak one end of a q-tip and pass it through the "T" while gently twisting, pass the q-tip completely through the other side.
   6. Repeat until the q-tip comes out completely clean, using a fresh q-tip every time.
   7. Clean out the inside of the fitting on each end of the "T".
      • This is where most of the debris will have collected.
   8. Wet a large q-tip and pass it through the barrel of the valve.
      • It should come out clean on the first pass, but repeat if necessary.
   9. Place the valve into a bath of de-ionized water to prevent water spots and mineral build up from forming.
      • If only cleaning one or two valves, this step is not necessary.
   10. Use compressed air to completely dry the valve.

Finish the plugs:

1. Dust the valve plugs with dry compressed air.
2. Install new Viton 75 O-rings.
   1. 4P valves: 009 & 012.
      • The 009 port-sealing O-ring is prone to pop out of its gland
        • If it won't stay,
          1. Hold it with non-marring tweezers and heat the O-ring to greater than 80 °C with a heat gun.
          2. Quickly press the O-ring into the gland.
          3. Hold it in place with special tool TL-4P009.
          4. Continue to rotate the stem slightly back and forth within the tool until the O-ring cools.
3. Dust the valve plugs and O-rings with dry compressed air.
4. Grease the O-rings again with silicone high vacuum grease
   • Use a small rod or stick to apply small dabs continuously along the exposed O-ring surface.
   • There is no need to smooth, smear, or even-out the grease.
     
     

NOTE: "upstream" and "downstream" refer to the intended direction of flow through the valve

• Downstream is indicated by the arrow on the valve body
• Upstream is the opposite direction