How Do I Rebuild and Maintain an RDI Plug Valve?

A plug valve is a type of valve which is opened or closed by the turning of conically or cylindrically shaped plugs that contain hollow passageways through which water can flow. The plug valves sold and manufactured by Red Deer Ironworks Inc. (RDI) are used for a variety of applications, such as in flowback, production, and pressure pumping.

We provide 602 and 1502 plug valves in North America with branches from Texas to Alberta, and we are committed to ensuring that our clients understand how to properly rebuild and maintain them.


Rebuilding a 3” RDI Plug Valve

The first step to rebuilding an RDI plug valve is to install the spiral snap-ring onto the valve's male end. The wingnut is also slid over the male end, as are the set of 3 segments. Hold the three segments in place and slide the wingnut forward. Secure the wingnut kit by prying the spiral snap-ring into the machine groove.

Next, the union seal must go into its designed groove on the plug body's threaded end. Then, apply a small amount of RDI6430 valve assembly grease into the o-ring before installing it into the cap body groove.

Now you'll want to use a thin layer of assembly grease to lubricate the valve pocket. You should also coat your two sets of o-rings with assembly grease. The o-rings can then be installed onto the seat carrier body, which in turn can be set into place down in the plug valve body. Make sure you engage the roll pins.

Place the spacer body set on either side of the seat carrier body, and apply a layer of assembly grease to both body surfaces, as well as to the plug body's stem end. The upper plug seal can now be installed, and a thin layer of assembly grease must be applied to the upper plug seal and the plug body's outer surface.

Next, you can insert the plug body all the way into the body of the plug valve. Ensure that the valve is open, and apply assembly grease over the top of the plug body so that the lower plug seal can be installed over top.

Coat the lower plug seal with assembly grease, and apply anti-seize compounds to the cap body's threads and to the plug valve body. Seal all surfaces of the cap body with a thin layer of assembly grease, and then install the cap body onto the plug body, tightening until a snug fit is achieved.

Turn the plug valve by 180 degrees and apply anti-seize compounds to the button grease fitting threads. Screw the button grease fittings onto the side of the plug valve and toque them to 80 ft-lbs. Now you can affix the socket head cap screw on top of the plug valve body and place the stop plate against it.

All that's left is to attach the plug valve handle, install the spiral snap ring overtop, and grease the valve.

Maintaining an RDI Plug Valve

RDI plug valve maintenance is all about making sure the valve is always adequately greased. Grease acts as a seal, as a hydraulic medium, and as a lubricant, ensuing proper pump operation. A plug valve should be sealed at least after every five cycles, but needs to be greased immediately if it begins to stick.

RDI plug valves should be greased in an open position. Grease should be pumped only until it reaches the recommended 3,000 PSI. Pressures over 4,000 PSI can result in damage. Once greased, the valve needs to be functioned from the open to the closed position. Listen for popping sounds, which indicate trapped air. If the sound does occur, the greasing processes needs to be repeated.

1502 Plug Valves in North America
Red Deer Ironworks Inc. offers a great selection of plug valves for all your needs. Furthermore, at Red Deer Ironworks Inc. we don't just supply standard 602 and 1502 plug valves throughout Colorado, Texas, and Alberta, we can also repair plug valves and custom-manufacture the right products for your project.

If you need any more information about plug valve rebuilding and maintenance, or if you're interested in our products and services, then don't hesitate to contact Red Deer Ironworks Inc. today.

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