VOLUME-12 PIPING, VALVES AND ACCESSORIES Chapter-3

3.1 CAST STEEL VALVES

®
Contents 9/37
• CAST STEEL VALVES
MAINTENANCE MANUAL,
Bolted Bonnet Gate, Globe and Check Valves 2-48", 50-1200 mm

..

VEL-CSVM -97
TABLE OF CONTENTS

GENERAL INFORMATION
INTRODUCTION ......................................................................................•.................................
1.1 General Introduction
1.2 Essential Features of Velan Valves
PAGE
7
7
8
•
II RECEIVING AND PREPARATION FOR INSTALLATION 9
2.1 Receiving Inspection 9
2.2 Quality Control Documentation .. : 9
2.3 Storage 9
2.4 Handling and Preparation 9
2.5 Special Instructions for Gate Valves 9
2.6 Special Instructions for Globe Valves 9
2.7 Special Instructions for Check Valves 10 ~
2.8 Recheck for Bolt Tightness 10 ..

III WARNINGS 11

IV GENERAL MAINTENANCE ...........................................•............................................................ 12

4.1 Trouble Shooting Chart · 12
4.2 Operation 13
4.2.1 General 13
4.2.2 Smoothness of Operation 13
4.3 Recommended Lubrication
4.4 General Assembly Information
4.5 Body/Bonnet or Cover Torquing Procedure
4.5.1 General
4.5.2 Application of Torque
·..· 13
13
14
14
14
.J
~I

V INFORMATION PERTINENT TO GATE AND GLOBE VALVES 17

5.1 Packing 17
5.1.1 Number of Packing Rings Required 17
5.1.2 Packing Ring Replacement on Line 17
5.1.3 Repacking with Graphite Packing Rings for Valves Without Leak Off Connection 18
5.1.4 Repacking with Graphite Rings for Valves with Leak Off Connection (Lantern Ring) 19
5.1.5 Packing Torques 19
5.1.6 Live-Loading Packings 22
5.2 Detailed Maintenance 23
5.2.1 Packing Chamber Leakage 23
5.2.2 Body Bonnet (gasket) Leakage 23
5.2.3 Gasket Bolts Retorquing Procedure 23
5.2.4 Seat Leakage 24
5.2.4.1 General 24
5.2.4.2 Wedge and Disc Repairs - Gate and Globe 24
5.2.4.3 Seat Repairs 25
5.2.4.4 Fitting of Repaired Parts 26
5.2.5 Seat Tightness - Closing Torques 29
5.2.6 Backseat Repairs 30

•
5.3 Torque Values - Actuator, Yoke/Bonnet Bolting 31

2
TABLE OF CONTENTS

• GATE VALVE

VI GATE VALVE
6.1 Types of Gate Valves
6.2 Exploded View
6.3 Partial Disassembly - Gasket Replacement
,
PAGE

32
32
34
35
6.4 Total Disassembly 35
6.4.1 Disassembly of Body/Bonnet and Wedge/Stem 36
6.4.2 Disassembly of Top Works 36
6.5 Assembly 37
6.5.1 Top Works Assembly 37
6.5.2 Bonnet/Body Assembly 37

Globe Valve
e VII GLOBE VALVE 38
7.1 Types of Globe Valves 38
7.2 Exploded View 40
7.3 Partial. Disassembly - Gasket Replacement 41
7.4 Total Disassembly 41
7.4.1 Disassembly of Body/Bonnet and Disc/Stem/Union .41
7.4.2 Disassembly of Top Works 42
7.5 Assembly 43
7.5.1 Top Works Assembly 43

•
7.5.2 Disc and Bonnet/Body Assembly 43

Swing Check Valve

VIII SWING CHECK VALVE 44
8.1 Types of Swing Check Valves 44
8.2 Exploded View 45
8.3 Partial Disassembly - Gasket Replacement. 46
8.4 Total Disassembly 47
8.5 Detailed Maintenance 48
8.5.1 Body/Cover (Gasket) Leakage 48
8.5.2 Seat Leakage 48
8.5.2.1 Disc Repairs 48
8.5.2.2 Seat Repairs 49
8.5.2.3 Bearing Blue or Developer Test 49
8.5.2.4 Paper or Light Test 51
8.5.2.5 Fitting of New Disc 52
8.6 Assembly 52
8.6.1 Disc Assembly Fit-Up · 52
8.6.2 Internal and Mid-Section Assembly 53

Appendix
IX ApPENDIX 54
9.1 Procedure for Removing Manual Gear Actuator 54
9.1.1 Style 1 54

• 9.1.2 Style 2
9.2 Procedure for Removing Motor Actuators
9.3 Procedure for Removing Motor Hydraulic or Pneumatic Actuators
9.4 Spare Parts

3
55
56
58
59
LIST OF DIAGRAMS AND TABLES

DESCRIPTION

Backseat repair
Body recess-spacer washer gap
Bolt tightening sequence
.
.
.
NUMBER

5.20
8.6C
4.5A
PAGE

30
53
•
16
Blueing test . 5.2F 26
Braided graphite packing ring .. 5.18 17

Cast iron lapping disc . 5.20 26

Check valve: Angle of incline and roll angle . 2.7 10
Clearance verification ..................................................••..•......••••..••••.. 5.21 27

Disc unit . 8.4A 47

Disc assembly clearances . 8.58,8.68 50,53

Examples of coupling . 9.3A 58

Flat style disc .. 5.2L 28

Full seating circumference . 5.2H 27

Gate valve API 600 2-12"

Gate valve API 600 14-24"
Gate valve API 600 26-28"
Gate valve API 603
Globe valve API 6002-12"
.
.
.
.
.
6.1A
6.18
6.1C
6.10
7.1A
32
32
33
33
38
.'
Globe valve API 600 14-16" .. 7.18 38
Globe valve API 603 . 7.10 39
Graphite ribbon packing . 5.1A 17

Insertion of first packing ring . 5.1E 18

Lantern ring configuration .. 5.10 17

Lapping of disc .. 5.28,8.5A 24,49
Lapping of wedge .. 5.2A 24
Leak off connection . 5.1H 19
Live-loading . 5.11 22
Live-loading arrangement type . 5.1J 22
Lapping 'plate . 5.2C 25

4
•
LIST OF FIGURES

• DESCRIPTION

Machining of hanger arm

Manual gear actuator-Style 1
Manual gear actuator-Style 2
.
.
.
NUMBER

8.5F
9.1A
PAGE

51
54
9.18 55
Material removal from disc post . 8.50 50
Motor actuator-Adaptor plate attachment (Assembly) . 9.28 56
Motor actuator-Adaptor plate attachment (Exploded view) . 9.2C 57
Motor actuator- Direct attachment . 9.2A 56

Original stem-disc assembly . 5.2E 26

e Removal of actuators . 9.38 58

Seven packings shown . 5.1C 17

Split packing adaptor . 5.1F 18
Six o'clock contact . 8.5E 51
Six packings installed . 5.1G 19
Stop check valve API 600 . 7.1C 39
Swing check styles . 8.48 47

• Swing check valve API 600 2-24"

Swing checkvalve API 603 2-24"

Tapered disc-Full seating circumference

Tapered disc - Thrust pad
Tapered disc- Hardface deposit
.
.
.
.
...
8.1A
8.18

5.2J
5.2K
5.2M
44
44

28
28
28
.. Types of backseats . 5.2N 30
,., Top works styles-Gate . 6.4A 36
Top works styles-Globe . 7.4A 42
Twelve o'clock contact . 8.5C 50

Wedge dimensions . 5.2G 27

5
LIST OF DIAGRAMS AND TABLES

DIAGRAM DESCRIPTION

Closing torques
DIAGRAM NUMBER

5.2A
PAGE

29 •
TABLE DESCRIPTION TABLE NUMBER PAGE

Body/bonnet bolting torque 4.5A 15

Packing flange stud/nut torques for Graphite and Teflon packings/Gate ....5.1A 20
Packing flange stud/nut torques for Graphite and Teflon packings/Globe ..5.1B 21

Quantity of Belleville washers 5.1C 22

Recommended lubrication 4.3 13

Top works styles-Gate 6.4A 36

•
Top works styles-Globe 7.4A 42
Torque values 5.3A 31

6
•
INTRODUCTION

• 1.1 GENERALINTRODUCTION

his manual has been prepared by Velan

T engineerS, designerS and maintenance

personnel to assist yOU in obtaining many
years of satisfactory service from your cast steel

valves.
It will also assist you in restoring your valve to the
best working condition with a minimum of time
and expense.
Velan valves are designed and manufactured based

•
on many years of research and product development
and are constantly being improved. Before beginning
any major work, we recommend that you read this
booklet carefully at least once to understand the
valve's physical condition.
Please note that if you do not understand the reason
for the service problem, we Suggest that you get in
touch with your local Velan representative or call the
Customer Service Manager for technical assistance.

Before beginning any major work, we recommend

that you carefully check the nameplate on the valve
and record the figure number to identify the type and
size of valve. See the "Essential Features of Velan
Valves" form on the following page for an explanation
of Velan "Figure Numbers".

7
INTRODUCTION

1.2 ESSENTIAL FEATURES OF VELAN VALVES

Gate, Globe and Check Valves
e-
Type of Connection Size of connection Pressure- Rating Type Body/Bonnet Style Body Material Trim Material

D
A

F
II III
1
.
B

• •• •• •• ••
C

0 0
0

6 4
E

C
F G

F10-0064C-02TY(valve size is part of figure number)

EXAMPLES:
3" F-0064C-02TY(valve size is shown separately) t
01- X" 05- 1· 09- 2W 13- 5" 18- 12" 22- 20· 28- 28" 36- 36"
02- %" 06- 1X" 10- 3" 14-6" 19- 14" 23- 22" 30- 30· 42- 42"
03- ~" 07- 1W 11- 3W 15-8" 20-16" 24- 24" 32- 32" 48- 48"
04- *" 08-'2" 12- 4" 16- 10" 21- 18" 26- 26" 34- 34" 99-Special

(11 Base material is either the same as the body or solid at manufacturer's option.
(21 NA, NB, and NC trims are for NACE service and are supplied with bolting with maximum hardness of RC 22.
NS code is used for special NACE trim (details must be specified on order}.
{3} Teflon insert may be in seat or wedge at manufacturer's option.

8
•
RECEIVING AND PREPARATION FOR INSTALLATION II

• 2.1 RECEVING INSPECTION

All valves must be examined for signs of damage
that may have occurred during transportation. Any
damage should by analyzed and a report should
be issued. Serious damage should be reported to
your local Velan representative or to the Customer
2.5 INSTRUCTIONS FOR GATE VALVES
The flow through gate valves can be from either
end. There may be exceptions to this if bypass
piping is welded to the valve body. Check your
piping layout drawing to ensure correct position
and direction of flow. Gate valves should be
Service Manager so that a suitable arrangement installed and welded into the pipeline with the
for repairs can be made without delay. wedge or disc in the fully closed position. If the
valve is left open or partially open, it could distort
and leak during operation. Also, leaving the valve
2.2 QUALITY CONTROL INFORMATION in a fully closed position helps prevent weld spatter
from falling directly onto the mating faces of
For valves purchased with Quality Control (QC) the seats.
_ certification, check the package of documents to
., see that the Quality Control certificates are The preferred orientation of a gate valve is upright.
complete as per the purchase order. The valve may be installed in other orientations,
but any deviation from vertical is a compromise.
Installation upside down is not recommended
2.3 STORAGE because of possible dirt buildup in the bonnet.

Valves should be stored in a suitably sheltered

place to prevent contamination by weather, dirt or 2.6 INSTRUCTIONS FORGLOBEVALVES
dampness. The valve is shipped with end
protectors on the inlet and outlet which should Globe valves are usually installed with the inlet

•
stay on the valve until it is ready for installation. below the valve seat. This must be checked careful-
NOTE: If actuators are involved, please refer ly to prevent incorrect installation. If throttling ser-
to the applicable manufacturer's instructions vice is particularly severe, Velan recommends that
the valve be installed so that the flow enters over
for storage.
the top of the seat and goes down through it. This
maintains the valve in a more stable condition,
2.4 HANDLING AND PREPARATION minimizes wear and reduces external noise. Valve
operation also becomes easier because less torque
_ On large valves, a hoist is needed to assist installa- is required to close the valve .
., tion. A sling should be placed under the valve
body so that the unit can be lifted vertically to its Globe type valves should be installed and welded
final destination. End protectors must be removed with the disc in a fully closed position to prevent
from all types of valves and connections must be damage to the valve during installation. Leaving
checked for cleanliness. Any visible foreign matter the disc in a fully closed position also prevents
must be removed from end connections on weld- weld spatter from falling directly onto the mating
end valves. The weld-end preparation must be faces of the seat and disc.
cleaned properly with a suitable solvent such as
acetone or alcohol. Do not use solvents containing
chloride or fluoride.
PRECAUTION: Allow time for welding to
cool before trying the valve for the first
time in the pipeline.

9
II RECEIVING AND PREPARATION FOR INSTALLATION

2.7 INSTRUCTIONS FOR CHECK VALVES

Check type valves must be installed with the arrow
in the direction of the normal flow. This must be
checked carefully before installing the valve.
Placing a check valve in the opposite direction to
the flow will prevent the disc from operating in the
2.8 RECHECK FOR BOLT TIGHTNESS
Bring up the line pressure as close as possible to
normal operating pressure and temperature.
Recheck and retighten the bolts as necessary to
the values given as follows:
•
intended manner. Gasket bolts: Use Table4.5A on page 15.
Packing bolts: Use Table5.1A (for gate) on
page 20 and Table 5.18 (for globe) on page 21.
CAUTION: Velan piston check and stop
check valves without springs should be
The tightness of the joint bolt tension should be
installed with the bonnet up, and the angle checked at approximately one year intervals.
of incline of the line should be no more
than 45° from horizontal. Also, the roll
angle of the valve bonnet should be no
more than 45° from side to side.

Figure 2.7 Check valve: Angle of incline and roll angle

10
•
WARNING AND SAFETY III

• FOR SAFETY REASONS,

it is important to take these precautions
before removing a valve from a line.

(""Personnel makinganyadjustmentsonthe valvesshouldwear safetyequipment

normallyusedto work with fluid inthe linewherethe valveis installed.

(.... Before removingthe yoke bushingunder pressure,the valve shouldbe in fully open posi-
tion in order to prevent injuries.

( Before removinga valvefrom a line, line pressuremust be relievedwith no exception.

( Velanvalvescan be equippedwith a variety of manualgear,electric motor,hydraulicor

pneumaticactuators.Generally,all pressuremustbe relievedfrom both sidesof the valve
beforethe actuatoris removed.

C.... A valve in the fully open position(backseated),shouldnot be jammed-tight(overtorqued),

to avoidthermal binding. It is our recommendationthat the valve be removed1/4turn of
the handwheelfrom the fully open position. Thiswill also ensurethat packingtightness is
verifiable. In gear-operatedvalves,becauseof the backlash,it is difficult sometimesto
ensurethis position.

(.... Valvestandards,such asAPI and MSS, cautionusersthat successfulcompletionof a

backseattest shouldnot be construedas a recommendationbythe manufacturer
that a valvemaybe repackedwhile it is underpressure.

(.... Thebackseatmaybeusedas a meansof stoppingor reducing

packingleakageuntilthe packingcan be replacedunder
no pressure.Removalof packingwith the valve
underpressureis atthe owner'srisk.

1. Warning on Over-Pressurization Relief 2. Warning on NACE Conversions

Under certain conditions, double-seated valves It is extremely important to ensure that valves,
which have the intergate cavity filled with fluid and when converted to NACE trims in the field are done
is subjected to increase in temperature can result in by Velan authorized service shops. Unauthorized
excessive buildup of pressure in the center cavity, conversions can result in failure to carry out post-
leading to pressure boundary failure. weld heat treatment and result in severe stress
cracks in non-stress relieved areas.
Such situations occur when liquid from condensa-
tion, testing fluid, leakage from upstream side, etc.
3. Warning on Conversion to Globe Stop Check
accumulates in the center cavity. If this fluid is not
relieved by some means, over-pressurization may Velan globe valves cannot be automatically con-
occur. It is the responsibility of the purchaser to verted to glove stop check valves, without verifying
ensure that adequate precautions are taken design parameters in detail with Velan Engineering.
against such an eventuality.

•
Any unauthorized conversions may result in the
jamming of the disc in the valve .

For further details on the above subjects, please

contact the Customer Service Manager.

11
11--
IV GENERAL MAINTENANCE

4.1 TROUBLE SHOOTING CHART

GENERAL PROBLEMS

• Packing compression
PROCEDURE FOR REPAIR

• Packing chamber leakage

•
PACKING • Gland bushing binding Gate: Section 5.2. 1
Globe: Section 5.2.1
CHAMBER
LEAKAGE • Packing worn • Repacking procedure
• Stem, packing chamber Gate: Section 5.1.3
damaged Globe: Section 5.1.3

• Gasket damaged • Replacement of gasket

• Body or bonnet damaged Gate: Section 6.3
Globe: Section 7.3
BODy-BONNET
Swing check: Section 8.3
JOINT LEAKAGE
• lightness of bolting • Body-bonnet stud torquing
Gate: Section 4.5
Globe: Section 4.5
Swing check: Section 4.5

SEAT
• Lack of seating torque

• Damaged seat faces

• Closing torque
Gate: Section 5.2.5
Globe: Section 5.2.5

• Seat repair
•
LEAKAGE (optional information

• Disc movement restricted

available upon request)

• Disassembly and reassembly

Swing check valves
•
• Lubrication
• Lubrication Gate: Section 4.3
Globe: Section 4.3
Swing check: Section 4.3

• Packing torque
OPERATIONAL • Packing compression Gate: Section 5.1.5
SMOOTHNESS Globe: Section 5.1.5

• Stem thread • Disassembly and reassembly

• Yoke nut thread Gate: Sections, 6.3, 6.4, 6.5

12
Globe: Sections, 7.3, 7.4, 7.

•
GENERAL MAINTENANCE IV

• 4.2 OPERATION

4.2.1 General
All valves require examination before being put
into operation. Additionally, valves should be
4.4 GENERAL ASSEMBLY INFORMATION
1. The most important fact to be considered is
the cleanliness of all parts. All rust and dirt
should be removed from all parts with a wire
brush or emery cloth. Oil and grease should
be removed with suitable solvents.
inspected regularly during operation and should
2. All threaded parts (capscrews, nuts and studs)
receive prompt attention when trouble arises.
must be well relubricated. The stem and yoke
As a general rule, valves should be subjected to
nut threads should be cleaned of all old grease
scheduled maintenance.
before new grease is applied to the threads.
All recommended lubricants can be found in
4.2.2 Smoothness of Operation Section 4.3. Use correct lubricant for each indi-
vidual part.
Stem threads, gearing and other working compo- 3. Repaired or replacement parts must be
nents outside the fluid area should be lubricated checked to see if all repair procedures have
frequently and at least once every six months. been done and that all replacement parts (e.g.
Specific lubricants and frequency of application packing rings, gasket, etc.) have been checked
are shown in the recommended lubrication Table for size so that they will fit into the valve you
of Section 4.3. Valves that are not operated are servicing.
frequently and which may remain open or closed
for long periods of time should be worked (even if 4. All orientation marks assigned during disas-
only partially) about once a month. sembly must be observed so that correct
orientation is maintained. Where applicable,
IMPORTANT: Excessive handwheel effort can orientation marks should be made on parts

•
indicate the following: near the body serial number (e.g., wedge, disc,
seat etc.)
a) Improperly lubricated or damaged valve stem.
b) Valve packing compression too tight
(check Torque table in Section 5.7.5).
c) Faulty or damaged valve parts.

e 4.3 RECOMMENDED LUBRICATION

Table 4.3 Recommended lubrication

Lubrication Application Frequency

Stem Exxon: Nebula EPI Directly to When threads

threads Lubriplate No. 930-AA threads appear dry
Shell: Darina EPI or
equivalent EPI designation

Stem nut and Exxon: Nebula EPI Inject through Concurrently

bearings Lubriplate No. 930-AA grease fitting with stem
Shell: Darina EPI or at hub of yoke thread lubrication
equivalent EPI designation

All threaded parts except Anti-seize compound Thin coat on On valve

stem and stem nut Felpro type C5A or threads assembly only
equivalent EPI designation

Recommended lubricant subject to change without notice.

13
IV GENERAL MAINTENANCE

4.5 BODY/BONNET (OR COVER) TORQUING

PROCEDURE

4.5.1 General
1. Clean all studs and nuts. Visually inspect
4.5.2 Application of Torque
When applying the torque to the bolts, each bolt
should be torqued in steps of approximately 20%
of the final torque.
•
all threads to ensure removal of all foreign
matter, rust, corrosion, burrs and previous
lubricants. PRECAUTIONS:
2. Liberally cover the stud threads and the 1. Iftightening sequence is not followed, it
surface under the nut head with FELPRO is possible that the gasket will not be com-
type CSAHi-Temp Antiseize compound or pressed evenly, causing the joint to leak.
approved equivalent. Also, lubricate the 2. Over-torquing can cause deformation of

•
female threads of the nuts and wipe off any the body or bonnet flange and can also
excess lubricant that may adhere to any of causejoint leakage.
the stainless steel parts with recommended 3. Do not use impacting devices to tighten
solvents. up the bolting on the body/bonnet (cover).
Recommended solvents for this work are: Use suitable mechanical devices for
a) unused or redistilled acetone tightening.
b) alcohol 4. Usetorque wrenches. If torque wrenches
3. After tightening bolts by hand, follow the bolt are not suitable, use standard wrenches
tightening sequence shown in Fig. 4.SA.This and the following guidelines will apply:
sequence depends on the quantity of bolts ~" Bolts S" wrench
used. The drawing illustrates the tightening ~" Bolts 6" wrench

•
sequence of different size and class. The bolts ~6" Bolts 9" wrench
should be torqued to the values in accordance %" Bolts 12" wrench
with the table material for stud threads (see ){" Bolts 18" wrench
Table 4.5A). ~" Bolts 24" wrench
1" Bolts 30" wrench
1~" Bolts 36" wrench
On sizesof bolts larger than 1%", special

•
torque multipliers with ratio 1:7or 1:6
should be used for torquing.

14
•
GENERAL MAINTENANCE IV

• Table4.5A Body/bonnet bolting torque ft.lb (Nm).

%-16 UNC 15 (20) 20 (27) 20 (27) 20 (27) 15 (20) 20 (27)

~.-14UNC 25 (34) 30 (41) 25 (34) 35 (47) 25 (34) 25 (34)

~-13 UNC 40 (54) 50 (68) 40 (54) 55 (75) 35 (47) 45 (61)

e %.-12

%-11 UNC
UNC 55

75
(75)

(102)
70

100
(95)

(136)
60

80
(81)

(108)
80

100
(108)

(136)
55

70
(75)

(95)
65 (88)

85 (115)

0/.-10 UNC 135 (183) 170 (231) 150 (203) 200 (271) 125 (170) 150 (203)

~-9 UNC 200 (271) 270 (366) 250 (339) 300 (407) 200 (271) 200 (271)

1-8 UNC 350 (475) 400 (542) 350 (475) 450 (610) 300 (407) 350 (475)

•
1~-8 UN 500 (678) 600 (814) 500 (678) 650 (881) 450 (610) 450 (610)

lX-8 UN 675 (915) 850 (1153) 700 (949) 950 (1288) 650 (881) 650 (881)

1%-8UN 900 (1220) 1200 (1627) 1000 (1356) 1300 (1763) 900 (1220) 900(1220)

1~-8 UN 1200 (1627) 1500 (2034) 1300 (1763) 1700 (2305) 1200 (1627) 1200(1627)

(t 1%-8 UN 1600 (2170) 2000 (2712) 1700 (2305) 2200 (2983) 1500 (2034)

10/.-8 UN 2000 (2712) 2500 (3390) 2100 (2848) 2800 (3797) 1900 (2576)

1~-8 UN 2500 (3390) 3100 (4204) 2600 (3526) 3500 (4746) 2300 (3119)

2-8 UN 3000 (4068) 3800 (5153) 3200 (4339) 4200 (5695) 2800 (3797)

2111-8 UN 3600 (4882) 4500 (6102) 3800 (5153) 5000 (6780) 3400 (4610)

2X-8 UN 4400 (5966) 5400 (7322) 4600 (6238) 6100 (8272) 4100 (5560)

2~-8 UN 6000 (8136) 7500(10170) 6400 (8678) 8500 (11526) 5700 (7729)

Note:
(1) Torque tolerance ±10%
((t (2) Maximum temperature for 630 is 650°F
(3) For temperatures above 750°F(400°C)use 75% of the torque values

15
1b
IV GENERAL MAINTENANCE

•
4 8

•
8 16 10

10 24 12
•

12 16
Figure 4.5A Bolt tightening sequence

16
•
INFORMATION PERTINENT TO GATE AND GLOBE VALVES V

• NOTE: All Cast Steel Valves having 135X as

the last four digits of the figure number (see
p.8) come standard with teflon packings and
gasket. These valves may, as an option, come
with graphite packings and gasket but this
must be requested at time of order, in such a
case an orange tag stating graphite packing
and gasket will be attached to the valve.
Figure 5.1A Graphite ribbon packing
5.1 PACKING

5.1.1 Number of packing rings required

Number of packing rings (Figs 5.1Aand 5.18)

required without a leak off connection:
(1) For cast gate valves up to 12·,
5-6 packings are required.
(2) For cast gate valves 14" and up, Figure 5.1 B Braided graphite packing ring
6-7 packings are required.
(3) For all sizes of cast globe valves,
6-7 packings are required (Fig.5.10.
Braided
5.12 Packing Ring Replacement on Line packing

• Follow warning instructions in Section1/1 before

replacing packing rings on line.
1.
2.
Remove the packing flange nuts.
Lift packing flange and gland bushing as high
as possible and secure.
Graphite
ribbon
packings

Braided
3. Remove old packings using special flexible packing
removal tools. The removal tools have special
hooks which screw into the packing ring.
Removal of the packing rings is a difficult and
time consuming operation. Care has to be Figure 5.1C Seven packings shown
taken not to scratch the stem or the walls of
the packing chamber during the removal of t'\ ~Braided
Graphite packing
the packing rings. ribbon ____.
packing
?~~
I>~~~~ ~~. ?~~~
~Braided
4. If the valve is equipped with a leak-off pipe,
packing
there is a lantern ring after the third packing
ring. To remove the lantern ring, insert two
hooks into the holes at the top of the lantern
ring or insert screw-in extracting wires where
cb
tapped holes are provided.
~Braided
5. After the lantern ring is lifted, the last four packing
packing rings can be removed using the Graphite
ribbon ____.
I~~~~?~~~
~??????
procedure described in Step 3. packing ~?$$$~$
>~~~~~~?
~Braided
*For all cast gate and globe valves equipped packing
with a leak off connection 7 packings - 4 below
the lantern ring and 3 above-are required.
Figure 5.10 Lantern ring configuration

17
V INFORMATION PERTINENT TO GATE AND GLOBE VALVES

5.1.3 Repacking with Graphite Packing Rings for 7. Cycle valve at least five times from fully closed
valves without leak off connection to fully open position, under line pressure
whenever possible. When cycling is complet-
1. Before repacking, check the stem and the ed, retighten packing flange nuts to the
packing chamber wall for damage. Scratches required torque (Table 5.1A/B).
no deeper than .010" (O.25 mm) can be
removed by polishing the surfaces with a fine
emery cloth or by special lapping or machining.
2. Insert the first packing ring (braided graphite
type, end ring) manually and place as deep 2X"-600 2"-150/300/600
into the packing chamber as possible followed 3" and up 2X"-150/300
by 1 graphite ribbon (intermediate packing 150/300/ 600
ring). Refer to Fig. 5.1E.
3. Insert the split packing adaptor. Push the
packing rings to the bottom of the chamber,
making sure that the lap joint is not reversed
during the operation.
4. Place the gland bushing and packing flange
into position and compress the bottom
packing by tightening the nuts to 130% of
the torque value shown in Table5.1A/B.
NOTE: Ensure gland bolts/nuts are welliubri-
cated with anti-seize compound.
S. Remove the nuts and split packing adaptors
(Fig. 5.1F), insert the next graphite ribbon
packing and repeat the procedure above until
all intermediate graphite ribbon packings have
been torqued. (For correct number of packings
required see Section5.1.1). Figure 5.1E Insertion of first packing ring
NOTE: The split lap joints of each consecutive
ring must be staggered at 1200 so that
the fourth ring installed has its lap back at the
staring point (Fig. 5.1G). Subsequent packing 2X"-600 2"-150/300/600
rings should be repacked in the same manner 3" and up 150/300/600
until the special packing adaptors are no 2X"- 150/300
longer required and the standard gland
bushing can be used.
6. Remove the nuts and split packing adaptor
and insert the last end ring (braided graphite
type). Lower gland bushing and check for
bushing positive engagement with packing
chamber.
NOTE: As a rule of thumb X" min. engage-
ment is required (Fig. 5.1G). Lower the gland
flange, relubricate the gland studs/nuts using
anti-seize compound and torque to values
shown in Table 5.1A/B and/or project drawing.

Figure 5.1F Split packing adaptor

18 fJ~
INFORMATION PERTINENT TO GATE AND GLOBE VALVES V

• 5.1.4 Repacking with graphite rings for valves with

1.
leak off connection (Lantern Ring) Refer to
Fig.5.1H
Follow the same procedure as described in
steps one through four of the previous
section-Section 5.1.3, Repacking with
Step 3:
Tighten the packing flange nuts a little at a
time on each side, then torque in accordance
with valve type, size, pressure class and pack-
ing type as shown in Table 5.1A (for gate) and
Table 5.1B (for globe).
Graphite Packing Rings for valves without leak NOTE: Values in Table 5.1A and 5.1B are
off connection. approximate for standard Velan valves.
Whenever possible, refer to project
2. Insert next intermediate graphite ribbon
engineering drawings for individual valves
packing ring and repeat the procedure above.
and their required torques.
3. Insert (1) braided graphite packing ring.
Lower the lantern ring and repeat the
procedure above.
4. Place (1) braided and (1) graphite ribbon
packing ring above the lantern ring and
2~"-600 2"-150/300/600
precompress to 130% oftorque value of 3" and up 2 W'-150/300
Table 5.1A/B. 150/300/600
NOTE: In case valves are equipped with live-
loading (Belleville spring washers) remove
spring washers during precompression of MIN ~"
packing rings, and reinstall at final torque.
5. Insert (1) last end ring braided graphite type
lower gland bushing and check for positive

•
engagement. As a rule of thumb X" engage-
~
ment is required. Carefully align the gland
bushing and packing flange. Relubricate gland
bolts/nuts and torque down to values shown
in Table 5. 1A/B and/or project drawing.
6. Cycle the valves at least 3 to 5 times from fully
closed to fully opened position. When cycling
is completed, retighten packing flange nuts to
required final torque (Table 5.1A/B).
Figure 5.1G Six packings installed
5.1.5 Packing Torques
Step 1:
2~"-600 2"-150/300/600
Clean all studs and nuts. Visually inspect all 3" and up 2 ~"-150/300
threads to ensure removal of all foreign 150/300/600
matter, rust, corrosion, burrs and previous
lubricants.
Step 2:
Liberally cover the stud threads and female
threads of the nuts with an anti-seize com-
pound such as Felpro type CSA Hi-Temp or
approved equivalent.

Figure 5.1 H Leak off connection

gO
19
V INFORMATION PERTINENT TO GATE AND GLOBE VALVES

Table 5.1A Packing flange stud/nut torques in ft.lb (Nm) for Graphite and Teflon packings-Gate

*Note:
(1) The torque table is based on a packing compression (PC) of 3500 psi.
For other PC simply multiply the above torque values by: PC new (psi)/3500
(2) The torque values listed are for standard Velan valve designs.
For other valve sizes and/or stud diameters contact the Velan Customer Service Manager.
(3) Torque tolerances ± 10%
(4) If the packings are installed individually and pre-compressed, use the torque values as in the table.
(5) If the packings are installed as a set without individual pre-compression, use 130%of the torque
values in the table, cycle the valve 5 times and ensure that after each cycle the gland bolts are torqued
to the 130% value.

20 III
INFORMATION PERTINENT TO GATE AND GLOBE VALVES V

• Table 5.18 Packing Flange Stud/Nut torques in tt.lb (Nm) for Graphite and Teflon Packings-Globe

• *Note:
74 100 74 100

(1) The torque table is based on a packing compression (PC) of 3500 psi.
For other PC simply multiply the above torque values by: PC new (psi)/3500
(2) The torque values listed are for standard Velan valve designs.
For other valve sizes and/or stud diameters contact the Velan Customer Service Manager.
(3) Torque tolerances ± 10%

21
V INFORMATION PERTINENT TO GATE AND GLOBE VALVES

5.1.6 Live-Loading Pac kings

The basic parts necessary for achieving the live-
loading on packings consist of longer gland studs, Gland nut
Belleville washers and flat washers (see Fig. 5.1/). Flat
washer
Assembly Procedure:
1. On each gland stud, place a flat washer on the
packing flange, a stack of Belleville washers
(as indicated in Table 5.1e and Fig.5.1J) and a
gland nut.
2. Tighten the gland nuts a little at a time on
each side up to the torque values indicated
in Table5.1A/B.
NOTE: Make sure that the Belleville washers
(
do not slide laterally while tightening.

Table5.1C
Quantity of Belleville washers required
QUANTITY ARRANGEMENT
PERSTUD TYPE*
Figure 5.11 Live-loading
2"-150/300/600
2 W'-150/300 6 1
10"-600

3"-150
4"-150 4 1

2W'-600
3"-300
4"-300/600 8
6"-150
8" -300
10"-150

3"- 600 12
Arrangement Arrangement
2"-600 No.1 No.2
6"-600
10"-300 5 2
12"-150/300 Figure 5.1J Live-loading arrangement type

6"-300
8"-150 9 2
12"-600

*Refer to Fig. 5.1J

22
INFORMATION PERTINENT TO GATE AND GLOBE VALVES V

• 5.2 DETAILED MAINTENANCE

5.2.1 Packing Chamber Leakage

If moisture or dripping occurs around the stem or

the packing chamber, the following points must be
5.2.3 GASKET BOLTS RETORQUING .
PROCEDURE

The following procedure should be used when

retightening gasket bolting with or without line
pressure.
investigated before removing the packing: 1. Remove one nut at a time, lubricate stud and
nut thoroughly with an approved anti-seize
1. Check if the packing flange nuts are torqued
compound and torque to recommended
down to the correct torque as shown in
values shown in Table 4.5A.
Table5.1A1B. If leakage persists, then continue
to the next step. 2. Remove opposite nut and repeat procedure
until all nuts have been retorqued.
2. The next step would be to loosen the gland
nuts and cycle the valve three to five times 3. Recheck bolt torque by going once around
and retighten the nuts to original torque value. clockwise.
If leakage persists then continue to the next NOTE: If gasket must be replaced, follow
step. Section 4.5, Body/bonnet (or cover) Torquing
3. The third step would be to verify stem for pos- Procedure
sible scratches. First open the valve fully then
remove gland nuts and washers (if applicable) 5.2.4 Seat Leakage
and simultaneously lift gland bushing and
packing flange in order to examine stem for 5.2.4.1 General
scratches. If scratch is visible, it may be
caused by foreign particles caught between An indication of a valve leak is a pressure loss in
the stem and other parts. Shop air may be a the high pressure line side after a valve has been
way to blow particles away from stem and properly closed. In the case of hot water or steam
local components. Stem would also require lines, note whether the downstream pipe remains
polishing for small scratches or replacement if hot beyond the usual length of time. This type of
scratch is too deep. leak may be the result of a distorted seat caused
by improper welding of the valve into the pipeline,
If above steps do not stop leakage, proceed with
or by stress relieving temperatures that may have
the removal and replacement of the packing rings
been used during installation.
as explained in Packing Ring Replacement on Line
Section 5.1.2.
Leaks can also develop from failure to close the
valve tightly, resulting in high-velocity flow
5.2.2 BODY/BONNET (GASKET) LEAKAGE through a small opening. The hardfacing material
(e.g., Stellite 6) is corrosion and erosion-resistant,
To maintain the tightness of a factory-tested but grooves, pit marks or other surface irregulari-
bolted bonnet valve, it is essential to apply ties may still form on the mating surfaces. Valves
sufficient bolt tension at all times by having the which leak should be repaired as quickly as possi-
proper torque on the nuts or cap screws. The ble to prevent greater damage caused by high
original torque might be lost due to vibration, velocity.
relaxation of material caused by frequent tempera-
ture and pressure fluctuations, or by creep in high
temperature applications. Gasket bolt tension
should be checked at approximately one-year
intervals (see gasket bolts retorquing procedure).
NOTE: Standard gasket material is corrugated
steel with graphite in the channels or spiral
wound gasket. For alternate gasket materials
contact our service department.

23
V INFORMATION PERTINENT TO GATE AND GLOBE VALVES

5.2.4.2 Wedge And Disc Repairs- Gate and Globe

1. Disassemble valve as described in Section 6.4. 1
for gate valves and Section 7.4. 1for globe
valves, and inspect the wedge or disc for
scratches or damage.
2. If seating faces are scratched, the wedge or
disc must be lapped. Slight pitting, grooving or
indentations no deeper than .005" (0.1 mm) can
be removed by lapping. If defects cannot be
corrected by lapping, wedge or disc should be
ground. Velan recommends that a maximum of f
.015" (0.4mm) on each side be removed from a
10degree seated wedge and .010" (0.25mm)
on each side for a 7 degree seated wedge.
3. For the lapping, a flat plate, preferably cast
iron, should be used and an abrasive lapping
compound mixed with olive oil should be even-
Figure 5.2A Lapping of wedge
ly distributed over the plate as shown in Fig.
5.2A. Only light, even pressure should be
applied to the plate, lifting the wedge or disc as
often as possible to prevent accumulation of
particles in one area and to allow for proper
distribution of the lapping compound.
The lapping plate should be turned slightly
1 !
every few strokes to maintain a flat surface
(Fig. 5.28). The part should be lapped until
seating faces are smooth. Velan recommends
the use of Clover Compound (silicone carbide)
Grade D or C, or an approved equivalent.
4. Thoroughly clean off the lapping compound
with a suitable cleaning fluid such as acetone
or alcohol. Do not use solvents containing
chloride or fluoride.

PRECAUTION: Lapping may be slow due

to the erosion-resistant surface, but too
much lapping must be avoided.
Figure 5.28 Lapping of disc

24
INFORMATION PERTINENT TO GATE AND GLOBE VALVES V

..~
• 5.2.4.3 Seat Repairs

Gate Valves
1. Automatic grinding and lapping of seat faces
can be done by specialized equipment which
is readily available at Velan authorized repair
Globe, Needle, Stop and Piston Check Valves
1.

2.
Disassemble the valve as described in
Section 7.4.1.Inspect the disc and the seat for
scratches, pitting marks or other damage.
If there are indentations or pitting marks no
deeper than .005" (0.1 mm), a cast iron

i 2.
facilities. For further details on such opera-
tions, contact our Customer Service Manager.
In those cases where the automatic grinding
and lapping machine is not employed, seat
lapping disc (5.20) with the proper seat angle
must be used with a suitable lapping com-
pound to roughen the surface first. If you use a
new or pre-finished original disc (Fig 5.2E),
faces must be repaired using a lapping plate. you can use a finer lapping compound to fin-
The plate should be made of cast iron if possi- ish lapping the disc and seat together.
ble and should be large enough to cover the IMPORTANT: A guiding plate for the stem is
face of the seat (Fig.5.2C). required to maintain alignment during the lap-
Apply lapping compound mixed with olive oil ping operation. Refer to Fig 5.2E. It should be
and distribute evenly over the plate. Lap seat made of wood or any other suitable material
by moving lapping plate in a circular motion to the same gasket dimensions as the bonnet.
on seat face, Lift the plate as often as possible The section of the plate where the stem
to prevent accumulation of particles in one extends through should be made x." (0.4 mm)
area and to allow for proper distribution of the larger than the outside diameter of the stem.
lapping compound. Lap until both seats have 3. Place a small quantity of lapping compound
smooth faces and then clean off the lapping mixed with olive oil and evenly distribute on
compound very thoroughly with a suitable the two mating surfaces.
cleaning fluid such as acetone or alcohol. 4. It is important to apply slight pressure when
lapping seats and to rotate it reciprocally. For
1(0 best results, use an air or electric hand tool
with adjustable speed and reciprocal move-
ment. The lap should be lifted frequently and
turned to a new starting position so that the
lapping will be rotated over a new area.
5. In order to ensure that the pressure is applied
evenly, it is necessary, on some valves, to
suspend the disc and stem assembly from a
coil spring as shown in Fig. 5.20.
6. Automatic grinding and lapping of seat faces
can be done by specialized equipment which
is readily available at Velan authorized repair
facilities. For further details on such opera-
tions, contact our Customer Service Manager.

Figure 5.2C Lapping plate

25
gb
V INFORMATION PERTINENT TO GATE AND GLOBE VALVES

5.2.4.4 Fitting Of Repair-ed Parts

Gate Valves Original stem-disc

assembly
1. After the seating faces of the wedge or seats
have been relapped and cleaned, a blueing
test is recommended before reassembly.
A blueing ink should be distributed smoothly
and equally over the full circumferential
surface of both sides of the wedge (Fig. 5.2F).
Placethe side of the wedge possessing the
body serial number together with the side of
the seat also possessing the body serial num-
ber. These sides should have been marked-up
during valve disassembly in accordance with
Section4.4, GeneralAssembly Information.
(
Slowly lower the part into the body and find
the correct mating point of the faces.

Figure 5.2E Original stem-disc assembly

Figure 5.2F Blueing test

Figure 5.20 Cast iron lapping disc

26
INFORMATION PERTINENT TO GATE AND GLOBE VALVES V

• 2. If a part cannot be repaired, new parts must be

fitted and installed. All spare part wedges are
supplied slightly oversized. In order to fit, they
must be ground or machined followed by a
blueing test to confirm 100% seating contact,
and then finally lapped. Refer to Fig'.5.2G.
NOTE: If the outside diameter of hardface and
top and bottom face-to-face dimensions of the
old wedge are given to Velan, it is possible
that there will be very little or no fitting
required at the site when replacing the part.
3. In some cases the seat angle may be lost
when the seat is ground in the body. Therefore
the wedge must be shimmed while the seat is
being ground or machined. Shim only as
much as required to obtain a full fit over the
full circumference of the seating faces.
Determine new wedge dimensions per
Fig. 5.2G_ Figure 5.2H illustrates a wedge with
a full seating circumference, which is essential Figure5.2H Full seating circumference
whenever fitting a wedge.
4. When fitting a wedge, it is also important that
the clearance between the wedge and the
wedge guide slots be checked with a filler
gauge at four locations, as shown in Fig, 5.21.

(0 TOP WEDGE DIMENSION Ideally, the clearance on both sides should be

the same, however, a minimum clearance of
.01" at any position along the length of the
guide must be maintained.

t = (T- B) x d + B
D

Bottom wedge dimension

, Serial numberof body

Note:
Seat dimensionB
should betransferred
to wedge dimension
b ± .005" (0,1 mm)
NOTE: Numbers refer to four locations to be checked bV filler gauge,

Figure 5.2G Wedge dimensions Figure 5.21 Clearance verification

27
V INFORMATION PERTINENT TO GATE AND GLOBE VALVES
.~

Globe, Stop Check and Piston Check Valves

NOTE: Velan globe valves have, in the past,
• ~i~
been designed with a flat style disc. In a
continuous effort to improve valve design,
Velan has more recently adopted a tapered
disc as its standard.
1. After the seating faces of the disc and seat
have been relapped and cleanedwith a suit-
able cleaning fluid such as acetone or alcohol,
it is essential that the results be verified using
a blueing test check for full circumferential
contact. A blueing ink should be distributed
smoothly and equally over the seating diame-
ter of the disc. Slowly lower the part into the
body and find the correct mating point of the
Figure 5.2J Tapered disc-Full seating
(
faces. Fig. 5.2J illustrates a disc with a full
circumference
seating circumference, which is essential
whenever fitting a disc.
2. When fitting the disc, it is also important that
the body inside diameter be checked for suffi-
cient clearance to allow the disc to move freely
up and down. We recommend a visual exami-
nation of the body wall. Any grooves or
. scratches should be polished with a fine
emery cloth.
3. Verification of contact between the valve disc
and the stem is made by a radius on the end
of the valve stem and is designed to give
center loading for the disc as closely as
possible. A hard thrust pad (Fig. 5.2K and
5.2L), which can be found in some designs,
will help prevent galling. On valves without a
thrust pad, the bearing surface in the disc has Figure 5.2K Tapered disc- Thrust pad
a hardface deposit on it (Fig. 5.2M).
If particles get caught between the end of the
valve stem and the disc, the center of the stem
could be destroyed and the disc will not seat
tightly. The contact surfaces of the stem and
the disc must be checked first in leaky valves
in order to ensure that the disc-stem contact is
in proper condition.

Hardface deposit

Figure 5.2L Figure5.2M

Flat style disc Tapereddisc-
Hardface deposit

28
I
,
52.5 Seat Tightness-Closing Torques
INFORMATION PERTINENT TO GATE AND GLOBE VALVES V

«f Evenwith a brand new valve, seattightness will

CAUTION: The use of wheel wrenches,
cheater bars, etc., is quite common.
only be achievedwhen sufficient load has been However, it must be emphasized that these
applied to the wedge or disc.This load varies with devices should be used with discretion, and
the pressuredifferential againstwhich the valve has
then only to achieve approximately the
to be closed or opened.
torque as calculated from Diagram 5.2A.
As a guideline, Diagram 5.2A can be usedto esti-
matethe torque required to open or close a valve
againsta given differential pressure.The torque cal-
culated is that torque which hasto be applied
directly to the valve stem and does not take into
accountany mechanicaladvantagesuch as that
achievedwith a gear actuator,etc.

Diagram 5.2A Closing torques

(0 K18.0
7.0
6.0
5.0
4.0 IL
3.0
V
2.0 V EXAMPLE:
/'

/
V Torque = (Pressure x Kt) + K2
1.0
0.9
0.8 Type = Gate
0.7
0.6
0.5 / / Size = 10"
'11

g~1
0.4 f--
Pressure = 1125 psi
0.3 - -~~ K1 = 0.41
0.2 -(
~t/
-
00
K2 =
26
~~ ~
0.1 00 Torque = (1125x0.41)+26
0.09
0.08
0.07
18
70 = 487 ft.lb.
0.06 60
0.05 II
60
0.04
II V 40
0.0 3 »: 30 Note: For API 603 valve use 50%
/' of value calculated
/'
0.0 2 20
Y
0.0 1
V
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Valve size

29
'10
V INFORMATION PERTINENT TO GATE AND GLOBE VALVES

52.6 Backseat Repairs

1. The following valves are equipped with an
integral or screwed-in backseat in the bonnet
(Fig.5.2N).
a) Screwed-in: All API 600 gate, globe, and
stop check valves
b) Integral: All API 603 gate, globe, and stop

~,
check valves
The above valves have a stem with a backseat 'j'
.~)
Screwed in API 600
shoulder. This should sit perfectly against
the bonnet backseat to make a perfect seal.
It is possible that this seal may leak due to
scratches, pitting or other reasons. Therefore
this seal must be repaired by relapping the
mating faces.
(
2. Dismantle the valve in accordance with
Section 6.4.1 for gate, and Section 7.4. 1 for
globe valves. Integral API 603
3. Place the bonnet and stem upside down as
shown in Fig. 5.20 and insert two or three
packing rings in the packing chamber to serve
Figure 5.2N Types of backseats
as a guide for the centralizing of the stem to
the backseat.
Add a fine mixture of lapping compound
between the two mating faces. Gently rotate
the stem back and forth and occasionally lift
t /'
the stem slightly and rotate around backseat
so that lapping will be distributed over a new
area.
NOTE: On larger valves, the stem must be
supported so that the weight of the stem does
not cause a groove or galling on the backseat.
4. When the lapping procedure is finished, all
lapping compound must be removed with a
suitable cleaning fluid such as acetone or
alcohol.
5. Velan recommends that the lapping procedure
be verified for full contact by blueing one of
the two faces. After verification, the surfaces
must be cleaned again.

Figure 5.20 Backseat repair

30
ql
INFORMATION PERTINENT TO GATE AND GLOBE VALVES V

5.3 TORQUE VALUES - ACTUATOR, YOKE/BONNET BOLTING

The torque values shown in Table 5.3A are for all bolting other than bonnet retaining
bolting or packing flange studs.

Table5.3A Torque Values

'I
%-16UNC 30 41 10 14

Y,s
-14 UNC 45 61 15 20

~-13UNC 75 102 25 34

o/,s-12UNC 105 142 35 48

%-11 UNC 145 197 50 68

*-10UNC 255 346 85 115

o ~-9UNC
1- 8 UNC
405
615
549
834
135
205
183
278

1).{j-8
UN 900 1221 300 407

1X -8 UN 1270 1723 425 576

f,J4 1-------+--------1-------1-------+-------1
1% -8 UN 1725 2340 575 780

1~-8 UN 2280 3092 760 1031

1% - 8 UN 2935 3981 980 1329

1* - 8 UN 3715 5039 1240 1682

1~ -8 UN 4615 6259 1540 2089

2-8 UN 5650 7663 1880 2550

Note:
(1) Torque tolerance ± 10%
(2) For temperatures above 750°F (400°C) use 75% of the values.
(3) Maximum temperature for 630 is 650°F (345°C)

31
VI GATE VALVES

6.1 TYPES OF GATE VALVES

f' rG
'i

PARTS DESCRIPTION
1 Body 19 Gasket
2 Bonnet 26 Key
4 Stem 27 Yoke bushing
5 Wedge 29A Bearing
9 Seat 29B Thrust race
11 Packing flange 30 Handwheel nut
12 Gland bushing 33 Handwheel
13A Braided packing ring 34 Grease fitting
13B Graphite packing ring 39 Groove pin
15A Gland stud 55 Bushing
(
15B Body/Bonnet stud 57 Washer
16A Gland nut 61 Spring pint
16B Body/Bonnet nut 66A Nameplate
18 Backseat 67 Rivet
88 Stem nut

Figure 6.1A Gate valve API 600 cast bolted bonnet 2-12". Illustration shows classes 300 and 600. f ~
/"

PARTS DESCRIPTION

1 Body 16B Body/bonnet nuts

(
2 Bonnet 18 Backseat
3 Yoke 19 Gasket
4 Stem 26 Key
5 Wedge 27 Yoke bushing
9 Seat 29 Bearings
11 Packing flange 30 Nuts
12 Gland bushing 33 Handwheel
13A Packing ring (braided) 38 Gland eyebolt
138 Packing ring (graphite) 39 Eyebolt pin
15 Stud 63 Spacer ring
16A Gland nuts 88 Yoke nut

Figure 6.18 Gate valve API 600 cast bolted bonnet 14- 24". Illustration shows class 150.

32
GATE VALVES VI

r. 6.1 TYPES OF GATE VALVES (CONT'D)

PARTS DESCRIPTION

Body 15B Body/bonnet stud

2 Bonnet 15C Yoke/actuator stud
3 Yoke 16A Gland nut
4 Stem 16B Body/bonnet nut
5 Wedge 16C Yoke/actuator nut
9 Seat 17 HSH CapScrew

(' 11
12
13A
Packing flange
Gland bushing
Packing ring (braided)
18
19
32
Backseat
Gasket
Gear operator
Name plate
13B Packing ring (graphite) 66
15A Gland stud

,~

Figure 6.1C Gate valve API 600 cast bolted bonnet 26-28". Illustration shows class 150.

Ii.
PARTS DESCRIPTION

1 Body 15B Body/bonnet stud

2 Bonnet 16A Gland nut
4 Stem 16B Body/bonnet nut
5 Wedge 19 Gasket
11 Packing flange 27 Yoke bushing
12 Gland bushing 33 Handwheel
13A Packing rings 34 Grease fitting
13B Packing rings 39 Eye groove pin
15A Gland stud 61 Spring pin
66A Nameplate

Figure 6.1D Gate valve API 603 stainless steel bolted bonnet,
!6-20" CL. 150, !6-12" CL. 300 Integral seats., N/A IN CL 600/900.
Illustration shows classes 300, 600 and 900.
1",&"
'\'fI
Note: API 600 cast bolted bonnet gate valves, 30" and up- are also equipped with gear operators.

33
9t
VI GATE VALVES

6.2 GATE VALVE: EXPLODED VIEW

PARTS DESCRIPTION

1 Body
2 Bonnet
4 Stem
5 Wedge
9 Seat
11 Packing flange
12 Gland bushing
13A Packing ring braided (
13B Packing ring graphite
15A Gland stud
15B Body/Bonnet stud
16A Gland nut
16B Body/Bonnet nut
18 Backseat
19 Gasket
26 Key
27 Yoke bushing
30 Handwheel nut
33 Handwheel
34 Grease fitting
39 Groove pin
55 Bushing
57 Washer (
61 Spring pin
66A Nameplate
67 Rivet
88 Stem nut

34
GATEVALVES VI

,.. 6.3 PARTIAL DISASSEMBLY - CAUTION: Do not tighten the body/bonnet

\I GASKET REPLACEMENT nuts when the wedge is in the fully
Follow warning instructions in Section 1/1 before closed position.
beginning disassembly. If valve is equipped with
gear or motor actuator, see appendix for disas-
sembly of actuators. 10. Mount packing flange nuts and torque down in
accordance with Table 5.1A.
NOTE: Numbers between brackets refer to
item numbers in exploded view. 11. Verify operation by cycling at least three times
from fully opened to fully closed position.
1. Valve should be in partially open position.
2. If the valve is equipped with a leakoff pipe,
disconnect it first. Leakoff pipes should be cut 6.4 TOTAL DISASSEMBLY
, approximately six inches from the bonnet .
• 3. Remove body/bonnet nuts (16B). 6.4.1 Disassembly of Body/Bonnet and Wedge/Stem
NOTE: If a valve has been in high temperature
service for extensive periods of time, the nuts Follow warning instructions in Section III before
may be seized to the studs (15B). Tight nut beginning disassembly. If valve is equipped with
threads can sometimes be loosened by gear or motor actuator, see Appendix for disassem-
JIIIIIiIII.. applying penetrating oil or applying heat to bly of actuators.
, 1 the nut and working it free. As a last resort, NOTE: Numbers between brackets refer to
a hacksaw, a cutting torch or cold chisel can item numbers in exploded view.
be used to cut the nut away from the stud.
1. Valve should be in partially open position.
4. Once all the nuts are removed, the entire

o bonnet assembly can be lifted from the valve

body. When lifting the bonnet assembly, care
should be taken to prevent the internal parts
2. If the valve is equipped with a leakoff pipe, dis-
connect it first. Leakoff pipes should be cut
approximately six inches from the bonnet.
from disengaging from the stem. It is very 3. Remove body/bonnet nuts (16B).
important to match-mark the body/bonnet and NOTE: If a valve has been in high temperature
the wedge (5) in order to maintain proper service for extensive periods of time, the nuts
orientation of these parts at reassembly. may be seized to the studs (15B). Tight nut
5. Remove used gasket (19). threads can sometimes be loosened by apply-
ing penetrating oil or applying heat to the nut
• 6. During inspection check the body/bonnet
and working it free. As a last resort, a hacksaw,
studs for damage. Studs may have been
a cutting torch, or cold chisel can be used to
damaged when removing seized nuts. If studs
cut the nut away from the stud.
are damaged, replace them.
4. Once all the nuts are removed, the entire bon-
7. Install new gasket. For corrugated steel with
net assembly can be lifted from the valve body.
graphite strips gasket and spiral wound
When lifting the bonnet assembly, care should
gasket, body and bonnet flange surface must
be taken to prevent the internal parts from dis-
be completely cleaned and free of oil and
engaging from the stem. It is very important to
grease. (Refer to Table 4.3, Recommended
match-mark the body/bonnet and the wedge
Lubrication).
(5) in order to maintain proper orientation of
8. Line up the bonnet assembly with the body these parts at reassembly.
and lower onto the body.
5. Remove used gasket (19).
9. Apply recommended lubricant (Table 4.3) to
6. During inspection check the body/bonnet studs
the body/bonnet studs (15B) and then install
for damage. Studs may have been damaged
body/bonnet nuts (16B). Tighten nuts in strict
when removing seized nuts. If studs are dam-
accordance with the body/bonnet torquing
aged, replace them.
procedure.

35
VI GATE VALVES

7. Loosen gland nuts (16A) and then carefully 2. Remove the handwheel (33) and the hand-
pull stem out of the bottom of the bonnet. wheel key (26).
8. Unscrew gland nuts from gland studs (15A). 3. After the tack weld is removed, unscrew the
9. Remove packing flange (11) from gland studs. yoke bushing (27) from the bonnet (2).
For Style 2 and Style 3, remove the top set
10. Only if required, remove groove pins (39) in
of bearings.
order to remove gland studs.
4. Unscrew the stem nut (88) from the stem (4).
11. Unscrew the backseat (18).
For Style 2, remove bottom set of bearings.
12. Carefully remove old packing rings (13A,13B).
Care should be taken not to scratch the walls
of the packing chamber during the removal of Table 6.4A Top Works Styles-Gate
the packing rings.
STYLE CLASS API 600 API 603
6.4.2 Disassemblv of Top Works
150 2 to 12" ~to 12"
There are four basic styles of valve top works for 300 2 to 8" ~to 12" (
Velan valves. Style 1(no bearings), Style 2 1 600 2 to 4" N/A
(top and bottom sets of bearings) and Style 3 900 2to 4" N/A
(top set of bearings) apply to gate valves, 1500 2 to 4" N/A
(Fig. 6.4A). They are available for various sizes of
150 14 to 24". 14 to 20"
gate valves as indicated in Table 6.4A.
300 14to 16" 14to 16"
The disassembly procedure for each of these
2 600 6 to 12" . N/A
styles is described below. 900 6 to 8" N/A
1500 6" N/A
1. Remove the small spring pin (61) in the
handwheel nut (30) and then unscrew the 150 10 to 12" N/A
handwheel nut.
3
300 10 to 12" N/A (~ 4

Style 1

ITEM QUANTITY PART NAME

4 Stem
26 Key
27 Yoke bushing
29 A Bearing
29 B Thrust race
30 Handwheel nut
33 Handwheel
34 Grease fitting
61 Spring pin
88 Stem nut

Figure 6.4A Top works styles-Gate

36
q1
GATEVALVES VI

• 6.5 ASSEMBLY
NOTE: Where *appears refer to lubrication
table in Section 4.3.

6.5.1 Top works assembly

1.*Apply new grease to threaded portion of
6.5.2 BONNET I BODY ASSEMBLY
1.*lnstall new gasket (19). For corrugated steel
with graphite strips gasket and spiral wound
gasket, body and bonnet flange surface must be
completely cleaned and free of oil and grease.
2. Line up the bonnet assembly with the body and
lower onto the body.
stem (4).
3.* Apply recommended lubricant to the body/bon-
2.*For Style 2, grease and place bottom set of net studs (158) and then install body bonnet
bearings. nuts (168). Tighten nuts in strict accordance
3.*Apply new grease to internal thread in stem nut with the body/bonnet torquing procedure.
(88).
4. Place stem nut. CAUTION: Do not tighten the body/bonnet
• 5.*For Style 2 and Style 3 grease and install top nuts when the wedge is in the fully
set of bearings. closed position.
6. Screw in the yoke bushing (27). The yoke bush-
ing must be tack-welded to the bonnet (2).
4. Mount packing flange nuts and torque down in
7. Insert the handwheel key (26) in the stem nut
accordance with Table 5.1A.
and mount the handwheel (33).
5. Verify operation by cycling at least three times
8. Tighten handwheel nut (30) onto the stem nut.
from fully open to fully closed position.
Use a spring pin (61) to lock the handwheel nut
in place.
9.* Inject more new grease into the top works
through the grease fitting (34) on the side of the
bonnet.
10. Verify operation by cycling at least once from
fully open to fully closed position.

37
VII GLOBE VALVES

7.1 TYPES OF GLOBE VALVES

NOTE: Velan globe valves have in the past been designed with a flat disc configuration. In a continuous
effort to improve valve design, Velan has more recently adopted a tapered disc as its standard.

PARTS DESCRIPTION

Body 16A Gland nuts

2 Bonnet 16B Stem nut
4 Stem 18 Backseat
6 Disc 19 Gasket
9 Seat 27 Yoke bushing
11 Packing flange 33 Handwheel
12 Gland bushing 38 Gland eyebolt
13A Packing ring (braided) 39 Groove pins
13B Packing ring (graphite) 40 Disc union
15 Body/bonnet stud 57 Washer
16 Body/bonnet nuts 63 Spacer ring

Figure 7.1A Globe valve API 600 cast bolted bonnet 2-12". Illustration shows 600 class. tie

Figure 7.18 Globe valve API 600 cast bolted bonnet 14-16". Illustration shows 600 class.

38
GLOBE VALVES VII

PARTS DESCRIPTION

Body 16B Body/bonnet nut

2 Bonnet 18 Backseat
3 Yoke 19 Gasket
4 Stem 27 Yoke bushing

• 6
9
11
12
13B
Disc
Seat
Packing flange
Gland bushing
Packing ring
30
33
39
40
42
Handwheel nut
Handwheel
Groove pins
Disc union
Disc thrust pad
15B Body/bonnet stud 46 Spring
15A Gland stud 57 Washer
16A Gland nut

) o Figure 7.1C Stop check valve API 600 cast bolted bonnet 2-14".
The hardfaced seat is seal welded .

• 1 Body
PARTS DESCRIPTION

16
16A
lock nut
Gland nut
2 Bonnet
4 Stem '16B Nut
6 Disc 19 Gasket
11 Packing flange 27 Yoke bushing
12 Gland bushing 33 Handwheel
13A Packing ring 35 Set screw
15A Gland stud 40 Disc union
15B Body/bonnet stud 66A Nameplate

fa) Figure 7.1D Globe valve API 603 stainless bolted bonnet *-12". Integral seats.

39
VII GLOBE VALVES

7.2 GLOBE VALVE: EXPLODED VIEW

J ·t
~~ @
®.t @
PARTS DESCRIPTION 33

Body I

@.
T
2 Bonnet
4 Stem
@
.~
6 Disc
9 Seat
~ ~9
11 Packing flange {pj~ ~9
12 Gland bushing
13 Packing ring
15 Body I bonnet
19
16 Nut
18 Backseat
19 Gasket
@
(I
-
I

30 Handwheel nut
33 Handwheel ~
38 Gland stud
40 Disc union
55 Yoke bushing
57 Flat washer
(
4

6 15

40
lot
GLOBE VALVES VII

A", 7.3 PARTIAL DISASSEMBLY- 10. Mount packing flange nuts and torque down in
., GASKET REPLACEMENT accordance with Table 5.18.
11. Verify operation by cycling at least three times
Follow warning instructions in Section III before from fully opened to fully closed position.
beginning disassembly. If valve is equipped with
gear or motor actuator, see appendix for disassem-
bly of actuators. 7.4 TOTAL DISASSEMBLY
1. Valve should be in partially open position.
7.4.1 Disassembly of Body/Bonnet and
2. If the valve is equipped with a leakoff pipe,
disconnect it first. Leakoff pipes should be Disc/Stem/Union
unscrewed or cut approximately six inches
Follow warning instructions in Section III before
from the bonnet.
beginning disassembly. If valve is equipped with
3. Remove body/bonnet nuts (16). gear or motor actuator, see appendix for

• NOTE: If a valve has been in high temperature

service for extensive periods of time, the nuts
may be seized to the studs (15). Tight nut
threads can sometimes be loosened by
applying penetrating oil or applying heat to the
disassembly of actuators .

1.
NOTE: Numbers between brackets refer to item
numbers in exploded view.
Valve should be in partially open position.
nut and working it free. As a last resort, 2. If the valve is equipped with a leakoff pipe,
a hacksaw, a cutting torch or cold chisel can be disconnect it first. Leakoff pipes should be cut
used to cut the nut away from the stud. approximately six inches from the bonnet.
4. Once all the nuts are removed, the entire 3. Remove body/bonnet nuts (16).
bonnet assembly can be lifted from the valve NOTE: If a valve has been in high temperature
body. When lifting the bonnet assembly, care service for extensive periods oftime, the nuts
should be taken to prevent the internal parts may be seized to the studs (15). Tight nut
from disengaging from the stem. It is very threads can sometimes be loosened by
important to match-mark the body/bonnet and applying penetrating oil or applying heat to
the disc (6) in order to maintain proper orienta- the nut and working it free. As a last resort, a
tion of these parts at reassembly. hacksaw, a cutting torch or cold chisel can be
5. Remove used gasket (19). used to cut the nut away from the stud.
6. During inspection check the body/bonnet studs 4. Once all the nuts are removed, the entire
for damage. Studs may have been damaged bonnet assembly can be lifted from the valve
when removing seized nuts. If studs are dam- body. When lifting the bonnet assembly, care
aged, replace them. should be taken to prevent the internal parts
7. Install new gasket. For corrugated steel with from disengaging from the stem. It is very
graphite strips gasket and spiral wound gasket, important to match-mark the body/bonnet and
body and bonnet flange surface must be com- the disc (6) in order to maintain proper
pletely cleaned and free of oil and grease. orientation of these parts at reassembly.
8. Line up the bonnet assembly with the body and 5. Remove used gasket (19).
lower onto the body. 6. During inspection check the body/bonnet studs
9. Apply recommended lubricant (Table 4.3) to for damage. Studs may have been damaged
the body/bonnet studs (15) and then install when removing seized nuts. If studs are
body bonnet nuts (16). Tighten nuts in strict damaged, replace them.
accordance with the body/bonnet torquing pro- 7. On the globe and needle disc valves the stem
cedure of Section 4.5. and disc will come out in one piece with the
bonnet assembly. As for the stop-check valve,
CAUTION: Do not tighten the body/bonnet the disc must be removed only after the bonnet
nuts when the disc is in the fully closed assembly has been removed from the body.
position. 8. The connection between the stem and the disc
is made by the use of a disc union. To remove
this connection, break the tack welds by using a
saw or a chisel.

41
I 0 l--
VII GLOBE VALVES

9. For the globe and needle disc valves, after the

tack welds are removed, unscrew the disc
union (40) from the disc. Check inside the disc
for possible damages.
10. Loosen gland nuts (16) and then carefully pull
stem out of the bottom of the bonnet.
11. Unscrew gland nuts from gland studs (38).
12. Remove packing flange (11) from gland studs.
13. Only if required, remove groove pins (39) in
order to remove gland studs.
14. Unscrew the backseat (18).
15. Carefully remove old packing rings (13). Care
should be taken not to scratch the walls of the
packing chamber during the removal of the
packing rings.

7.4.2 Disassembly of Top Works

There are four basic styles of valve top works for

Velan valves. Style 2 (top and bottom sets of
bearings) and Style 4 (no bearings) shown in
Fig.7.4A, apply to globe valves. They are available
for various sizes of globe valves as indicated in Style 4
Table 7.4A.

The disassembly procedure for each of these

ITEM QUANTITY I PART NAME
styles is described below. 4 1 Stem
26 1 Key
27 1 Yoke bushing
Disassemblv Procedure: 29A 1 Bearing
298 1 Thrust race
Style 2 30 1 Handwheel nut
1. Remove the small spring pin (61) in the 33 1 Handwheel
handwheel nut (30) and then unscrew the 34 1 Grease fitting
57 1 Flat washer
~
handwheel nut.
61 1 Spring pin
2. Remove the handwheel (33) and the
88 1 Stem nut
handwheel key (26).
3. After the tack weld is removed, unscrew the Figure 7.4A Top works styles-Globe
yoke bushing (27) from the bonnet. Remove
the top set of bearings.
4. Unscrew the stem nut (88) from the stem (4).
Table 7.4A Top works styles-Globe
Remove bottom set of bearings. API 600
STYLE CLASS API 603
Style 4 150 12 to 14" N/A
300 8 to 14" N/A
1. Remove the handwheel nut (30) and hand- 2 600 6 to 8" N/A
wheel (33).
900 2 to 4" N/A
2. After the tack weld is removed, unscrew the 1500 2 to 4" N/A
yoke bushing (27) from the bonnet. 150 2 to 10" ~ to 6"
300 2 to 6" ~ to 6"
4 600 2 to 4" N/A
900 2 to 4" N/A
1500 2 to 4" N/A

42
GLOBE VALVES VII

.. 7.5 ASSEMBLY 7.5.2 Disc and Bonnet/Body Assembly

" NOTE: Where *appears refer to lubrication 1. Insert disc into valve body. Insert spring into
table in Section 4.3. disc if so equipped.
2. Install small thrust pad into disc. Install stem in
7.5.1 Top Work Assembly disc and tighten down with disc union. Check if
disc can be rotated. If disc can be rocked, it is
1.* Apply new grease to threaded portion of
correctly installed on stem. The rocking will
stem (4). '.
allow the disc to self-align itself to the seat.
2. * For Style 2, grease and place bottom set of
3. Tack weld disc union to disc in three or four
bearings.
places. Check again to see if the disc can rock

I,
3. * Apply new grease to internal thread iii stem after tack welding has cooled.
nut (88).
4.* Install new gasket. For corrugated steel with
4. Place stem nut. graphite strips gasket and spiral wound gasket,
i .,. * ~or Style 2 grease and install top set of bear- body and bonnet flange surface must be com-
t mgs. .... pletely cleaned and free of oil and grease.
6. Screw in the yoke bushing (27). The yoke 5. Line up the bonnet assembly with the body and
bushing must be tack-welded to the bon- lower onto the body.
net (2). 6.* Apply recommended lubricant to the
7. Insert the handwheel key (26) in the stem nut body!bonnet studs (15) and then install
and mount the handwheel (33). body/bonnet nuts (16). Tighten nuts in strict
8. Tighten handwheel nut (30) onto the stem nut. accordance with the body/bonnet torquing
Use a spring pin (61) to lock the handwheel procedure.
nut in place.
A 9.* Inject more new grease into the top works CAUTION: Do not tighten the body/bonnet
., through the grease fitting (34) on the side of nuts when the disc is in the fully closed
the bonnet. position.
10. Verify operation by cycling at least once from
fully open to fully closed position. 7. Mount packing flange nuts and torque down in
accordance with Table 5.18.
8. Verify operation by cycling at least three times
from fully open to fully closed position.

43
VIII SWING CHECK VALVES

~8._1_n_p_ES_O_F_SW_I_N_G_CH_E~CK_V_A_~_ES ~ ~(] ,~

PARTS DESCRIPTION

Body
8 Disc Manufacturer's option
9 Seat
15 Stud
16 Nuts
16A Disc nut
19 Gasket
50 Cover
51 Hanger arm
54 Hinge pin
56 Hex hd cap screw
57 Washer
57B Hinge pin washer
58 Cotter pin
60 Tab washer

Figure S.1A Velan swing check valve API 600 cast bolted cover 2-24".
The hardfaced seat is seal welded.

PARTS DESCRIPTION
t
Body
8 Disc
9
15
Seat
Stud
.
16 Nuts !
16A Disc nut
19 Gasket
50 Cover
51 Hanger arm
54 Hinge pin
56 Hex hd cap scr
57 Washer
57B Hinge pin washer
58 Cotter pin

L-
60 Tab washer
-L ~ 4t. ~
Figure 8.18 Velan swing check valve API 603 stainless bolted cover 2-24" integral seats.

44
SWING CHECK VALVES VIII

t 8.2 SWING CHECK VALVE: EXPLODED VIEW

PARTS DESCRIPTION

Body
8 Disc
9 Seat
15 Body/bonnet stud
16 Body/bonnet nut
16A Disc nut
19 Gasket
50 Cover
51 Hanger arm
54 Hinge pin
56 Hex hd cap screw
57 Flat washer

I I

(,.~

45
(ob
VIII SWING CHECK VALVES

8.3 PARTIAL DISASSEMBLY-

GASKET REPLACEMENT
Follow warning instructions in Section 11/ before
beginning disassembly.
NOTE: Numbers between brackets refer to
•
item numbers in exploded view.
1. Remove body-cover nuts (16).
2. Once all the nuts are removed, the cover (50)
and gasket (19) can be lifted from the valve
body.
3. Install new gasket. On soft iron gaskets, apply

'/
lubrication (a light coat of oil).
4. Line up the cover with the body (1) and lower
onto the body.
5. Apply the recommended lubricant to the
body-cover studs and then install the
body-cover nuts. Tighten in strict accordance
with Section 4.5, Body/Cover Torquing
Procedure.

• 0/
f.•
•
l
•

s
.~

-,
I
I
1

46
•
SWING CHECK VALVES VIII

t 8.4 TOTAL DISASSEMBLY

Follow warning instructions in Section 11/ before
beginning disassembly.

Further to steps 1 and 2 in SectionB.3 Partial

Disassembly, the following steps illustrate total
disassembly of the swing check valve.
1. The valve is now ready for inspection. At this
point in the disassembly procedure, inspect
the rotation of the disc (8) on the hanger arm
(51) and the alignment between the disc and
the seat (9). Ensure that the hanger arm has

'. free movement, is not seized and cannot be

restricted by any internal part.
2. After inspecting all points mentioned above,
remove all internal parts by unfolding the tab
washers (60) around the hex hd bolt (56) in
body.
3. After hex HD bolts have been removed, the
internal assembly can be removed from the
body. Figure B.4A shows internal assembly.
4. Velan has two major styles of cast swing Style A

I,'
checks, (Fig.B.48).
STYLE "A" 2 to 24" 150 to 600 CIS cast valves.
STYLE liB" ~ to 24" 150 to 300 SIS cast valves.

Style 8
8-Disc
16A-Disc nut
19-Gasket
51-Hanger arm
54-Hinge pin
56-Hex HD cap screw
57-Washer
58-Cotter pin
60- Tab washer
64-Plug

\:(t Figure 8.4A Disc unit Figure 8.48 Swing check styles

47
VIII SWING CHECK VALVES

8.5 DETAILED MAINTENANCE

8.5.1 Body/Cover (Gasket) Leakage

To maintain the tightness of a factory-tested

bolted bonnet valve, it is essential to apply
8.5.2 Seat Leakage

8.5.2.1 Disc Repairs

1. Disassemble the valve as described in
Section 8.4, and inspect the disc and seat for
scratches, pitting marks or other damage.
•
sufficient bolt tension at all times by having the
proper torque on the nuts or cap screws. The 2. If the seating face of the disc is scratched, it
original torque might be lost due to vibration, must be lapped. Slight pitting, grooving, or
relaxation of material caused by frequent tempera- indentations no deeper than .005" (0.1 mm)
ture and pressure fluctuations, or by creep in high can be removed by lapping. If defects cannot
temperature applications. Gasket bolt tension be corrected by lapping, the disc can be
should be checked at approximately one-year ground and/or machined. Velan recommends
that no more than .031" (0.80 mm) be removed.
intervals (see Section 5.2.3 Gasket bolts retorquing
procedure). After grinding is completed, lap the disc. I
3. For the lapping, a flat plate (preferably made )
NOTE: Standard gasket material is corrugated of cast iron) should be used. An abrasive lap-
steel with graphite in the channels or spiral
ping compound should be mixed together
wound gasket. with olive oil and evenly distributed over the
For alternate gasket materials contact our service plate as shown in Fig. 8.SA. Only light, even
pressure should be applied and the disc
department.
should be moved in a circular motion on the
plate. Lift the disc as often as possible to pre-
vent accumulation of particles in one area and
to allow for proper distribution of the lapping
compound. The lapping plate should be
turned slightly every few strokes to maintain a
flat surface. The part should be lapped until
seating faces are smooth.
4. Thoroughly clean off the lapping compound
with a suitable cleaning fluid such as acetone
or alcohol. Do not use solvents containing
chloride or fluoride.

48
•
SWING CHECK VALVES VIII

• 8.5.2.2 Seat Repairs 8.5.2.3 Bearing Blue or Developer Test

(Removal of disc is required)
If repairs are required on the seat of a swing check
valve, the procedure is the same as described in To perform a bearing blue or developer test the
Section 5.2.4.3, Seat Repairs - Gate. The only disc unit must be preassembled as described in
difference between these seats is the angle of the Section 8.6 Disc Assembly Fit-Up. First, smear or
seat face. They can be repaired with an automatic spray a light coating of bearing blue or dye devel-
grinding or lapping machine or by the manual oper over the disc seating circumference. With one
method. hand, hold the disc at its post-disc nut area. With
the other hand, hold the hanger block in place.
Lower the whole disc unit into the valve body and
place the hanger block so that it matches the dowel
pin location holes (only if original hanger block
is used).

If the hanger block is new, dowel pins are not

required. To align the disc manually, lower the disc
unit, release the disc gently against the seat, insert
the hanger block bolts and tighten finger-tight.
Back off bolts X turn, press disc lightly against seat
and retighten bolts finger-tight. With light pressure
against disc, rotate disc slightly back and forth.
Take hold of disc post/disc nut area and pull away
from body seat. Undo hanger block bolts and
remove disc unit from valve body.

'(l Figure 8.5A Lapping of disc

o
49
lib
VIII SWING CHECK VALVES

Examine disc seating area for contact

I-\inge •.
a) If there is seating contact throughout the ~---Pln
whole seating circumference (360°), the disc is /lHanger
well aligned with sufficient disc freedom. This
also indicates that the seating surfaces are
well mated and free of any damage. Disc
~ nut
b) If there is contact at the three or nine o'clock
position, the disc does not have sufficient free- Cotter
pin
dom of movement in the disc hanger arm
bore. The disc should be held, but not con-
strained, by the hanger arm. The disc should
Disc
be free to find its own seat. This freedom
comes from the clearance between the disc
post 00 and the hanger arm bore 10,and the
gap between the hanger arm and the disc nut
washer. Confirm that the clearances are ade-
quate (Fig.8.58).
c) If there is contact at the 12 o'clock position
(see Fig.8.5C), the disc needs to be lifted by Figure B.5e Twelve o'clock contact
machining. Material must be removed from
the top of the disc post and base of the post,
as shown in Fig.8.50.
NOTE: This condition is rare for a valve with l

its original parts. It sometimes occurs when

new seating surfaces have been added, when
a new disc has been installed, or if a hanger
arm has been replaced or bent (if bent, the
I,i
hanger arm should be replaced). J
t
"C" L
---~~~~~~-r- Area to be t
r-
+- machined i
Both heights
must be equal
L__

Figure 8.58 Disc assembly clearances Figure 8.5D Material removal from disc post •

50
SWING CHECK VALVES VIII

If there is contact at six o'clock (seeFig. 8.SE), 8.5.2.4 Paper Or Light Test
the disc is too high in the hanger arm, or the (Removal of disc is not required)
seats are too low. This sometimes happens
after extensive lapping. To correct the prob-
Paper Test
lem, the disc must be lowered. The top of the
hanger arm should be machined and a washer
With the disc unit assembled, clean, dry and
of equal thickness "C" must be added to the
installed in the valve, conduct a paper test
base of the disc post, as shown in Fig. 8.SF.
(similar to the bearing blue and developer test).
This will lower or "drop" the disc.
The paper should be .001 to .002" (0.025 to
.050 mm) thick, 1" (25 mm) wide and about 8"
(200 mm) long. Lift the disc off the seat enough to
put the paper between the two seats and gently
lower the disc. Pull the paper out with just enough
Hinqe force so that the paper does not rip. Do this test
S pin around the disc, taking special note atthe top
(120'clock) position, at the bottom (6 o'clock) posi-
tion, and at both sides (3 and 9 o'clock). Make a
record of where the paper holds and where the
paper pulls without ripping.
a) If paper pulls at three o'clock or nine o'clock
Cotter
pin position, the disc cannot move enough in the
disc hanger arm bore. The disc should be free
to find its own seat. This freedom comes from
the clearance between the disc post 00 and
the hanger arm 10, and the gap between the
hanger arm and the disc nut washer. Confirm
that the clearances are adequate (Fig. 8.58).
b) If the paper pulls at the 12 o'clock position
(contact at 6 o'clock) (see Fig. 8.58, the disc is
too high in the hanger arm, or the seats are
too low. This sometimes happens with exten-
sive lapping. To correct the problem, the disc
I(eFigure B.5E Six o'clock contact
must be lowered. The top of the hanger arm
should be machined and a washer of equal
thickness "C" must be added to the base of
the disc post, as shown in Fig. 8.SF. This will
lower or "drop" the disc.
c) If the paper pulls at the six o'clock position
Area to be machined (contact at 12 o'clock) (see Fig. 8.5Q, the disc
needs to be lifted by machining. Material must
be removed from the top of the disc post and
base of the post, as shown in Fig. 8.50.
NOTE: If paper cannot be used, the same test
Jle"
can be done using shim stock material.
I? 2 2 212 2 2 21=:::;:*=
Wa~her t

()L...-___ _
Figure B.5F Machining of hanger arm

51
VIII SWING CHECK VALVES

Light Test

Use a small flash light and position it on the up

stream side with the light facing the disc. Observe
any light indication when disc is closed. Reco~d
the position of light (gap) and then proceed with
8.6 ASSEMBLY

8.6.1 Disc assembly fit-up

This procedure is to be used when replacement of

disc assembly parts or rework is required. Use it
•
repairs as for paper test above. after you have made sure that the body and disc
seats are clean, smooth, flat and free of any
8.5.2.5 Fitting of New Disc seating surface damage.
1. Preassemble disc unit (Fig. B.4A), making sure
When damage to the disc seating face cannot be
that there is sufficient clearance between disc
removed by grinding or lapping, the disc must be
washer and hanger arm, disc post and hanger
replaced. All new discs coming from the factory
arm bore (Fig. B.68). Also ensure that hanger
are already ground and should be lapped before
arm rotates freely around hinge pin. The
installation. See installation procedures in
hinge pin should fit comfortably into hanger
Section B.6, Assembly.
arm bore and body recess/spacer washers. A
gap up to .065" is acceptable. A gap exceeding
.065" may be cause for rejection. To determine
actual gap, follow these steps (see Fig. B.6e):
a) Measure both hinge pin and hanger arm
pin and record gap.
b) Insert a screwdriver between body recess
and spacer washer, push everything to one

•
side, and measure the gap with a feeler
gauge.
NOTE: Minimum gap required is .005" .If the
gap exceeds .065", a thicker spacer washer
should be added.

52
•
SWING CHECK VALVES VIII

8.6.2 Internal and Mid-Section Assembly

• 1. Mount disc on hanger arm, tighten disc nut
and lock in place with cotter pin. Check that
disc can rotate freely on hanger arm.
2. Place entire assembly carefully back into the
body making sure that the hinge pin can move
freely in an axial direction.
3. Insert tab washers and tighten down with hex
bolts. Lock the bolts by turning up the ears on
the tab washers.
4. After installation is finished, check the rotation
of the disc on the hanger arm and the align-
ment between the disc and seat.
"5. Install new gasket. On soft iron gaskets, apply
lubrication (a light coat of oil). .
6. Line up the cover with the body and lower
onto the body.
7. Apply the recommended lubricant to the
body-cover studs and then install the
body-cover nuts. Tighten in strict accordance Figure 8.68 Disc assembly clearances
with Section 4.5, Body/Cover Torquing
Procedure.

StyieA
Hinge pin

Hanger arm

___. ._
Gap to be measured

Figure 8.6e Body recess-spacer washer gap

53
114
IX APPENDIX

9.1 PROCEDURE FOR REMOVING MANUAL

GEAR ACTUATOR
Velan valves can be equipped with a variety of
manual gear actuators. Actuators of this type
come in two main styles: one for applications
9.1.1 Style I (Fig. 9.1AJ
1.

2.
3.
Valves with Style 1 manual gear actuators are
equipped with a self-contained thrust unit. This
actuator can be removed under line pressure.
Remove housing actuator bolting (178).
Using a hoist, raise the actuator (32) above the
•
where only rotary torque is required, and one
for applications requiring both rotary torque and stem (4) and stem nut (88).
linear thrust. 4. To repair the actuator, refer to the manufacturer's
instruction manual. If there is further work to do
Generally, all pressure must be relieved from both on this valve, refer to the appropriate section
sides of the valve before removal of the manual of this manual.
gear actuator. Exceptions to this rule include 5. The disassembly of the self-contained thrust
valves which have a self-contained unit. unit follows the same procedure as described
IMPORTANT: Determine the actuator style in Disassembly Valve Top Works. _,
that is mounted on the valve you are servic-
ing.lf it is not possible to determine the style
of actuator, refer to the actuator manufactur-
er's maintenance and instruction manual or
contact your local Velan representative for
more technical assistance.

•
3 - Yoke
4 - Stem
17A - Yoke/housing cap screw
28 - Yoke/housing cover
29A - Bearing
32 - Gear actuator
34 - Grease fitting
88 - Stem nut
113 - Stem nut gear driver
178 - Housing/actuator
cap screw

Figure 9.1A Manual gear actuator-Style 1

54
•
APPENDIX IX

9.1.2 Style 2 (Fig. 9.18)

Assembly
• 1. Valves with a Style2 manual gear actuator are
equipped with a self-contained thrust unit
which will be removed with the actuator.
Therefore the actuator cannot be removed
under line pressure. The pressure must be ---\------
relieved.
2. The valve should be in a partially open position.
3. Make sure that the packing flange nuts are tight.
4. Remove the yoke-actuator bolting (178).
5. Turn the actuator handwheel to close the valve.
This will cause the actuator (32) to rise and
unthread from the valve stem. As this takes
place, the weight of the actuator should be sup-
ported by a hoist to prevent damage to the
stem thread or any internal part of the valve.
6. To repair the actuator, refer to the manufactur-
er's instruction manual. If there is further work
to be done on the valve, refer to the appropriate
" section of this manual.
Exploded view
CAUTION: When reinstalling actuator, the

...
~
valve should be in a slightly off-seated
position (main seat or backseat) for
centering purposes .
-.~-.--
!

3 - Yoke
4- Stem
17B - Yoke/actuator cap screw
32 - Gear actuator

NOTE: Applications where both rotary torque

•
and linear thrust are required .

Figure 9.18 Manual gear actuator-Style 2

55
IX APPENDIX

9.2 PROCEDURE FOR REMOVING

MOTOR ACTUATOR
Velan valves can be equipped with a variety of
electrical motor actuators. Motor actuators are
mounted through two different methods. Some
units are attached directly to the yoke (Fig. 9.2A),
and some are attached to an adaptor plate and
then to the valve yoke (Fig. 9.28). Both methods
have the same removal procedure.
IMPORTANT: The torque switch of the motor-
actuated valve is set during factory assembly to
close the valve against the specified differential
pressure and requires the same special
attention for resetting. Figure 9.2A Motor actuator-
WARNING: Should it become necessary to Direct attachment
change the torque switch setting for any
reason, contact your VelanCustomerService
Managerto obtain a correct new setting from
the factory.

CAUTION:
'1 ~
~

.1
1. Ifthe valve packing material is changed
for any reason, the torque switch setting
must be changed.
2. Upon reassembly of a valve equipped
with an electro-mechanical actuator, the 1
I
open and close limit switches must be
reset. Please refer to the maintenance
and instruction manual provided by the
actuator manufacturer for appropriate
instructions.
3. When checking for proper rotation of the Figure 9.28 Motor actuator-
Adaptor plate attachment
electrical actuator, make sure that the
(Assembly)
valve is in mid-stroke position. If the three-
phase wiring connection is incorrect, the
valve will close when the open button is
pressed and the close torque switch will
not function, which could damage the
valve. If the valve does not travel in the
correct direction, then simply interchange
any two of the three power connections.
4. When checking for full stroke of the valve
without pressure in the line, the closing
torque switch should be set to its mini-
mum value which will close the valve
until all testing is finished. The torque

•
switch should then be reset to its
recommended value.

56
APPENDIX IX

Refer to Fig. 9.2C

• 1. All pressure must be relieved from both
sides of the valve before removing the
motor actuator.
2. The valve should be in a partially open
position.
3. Disconnect the electrical wiring from the actuator.
4. Tighten the packing flange nuts.
5. Remove all actuator bolting (17C) from the
underside of the yoke flange.
6. All electrical actuators have an automatic
handwheel declutching arrangement. In most
cases, move the lever from the motor operation
position to the hand operation position.
NOTE: Do not try to force declutch lever into
an operation position.
7. Turn the actuator handwheel to close the valve. ~~
This will cause the actuator to rise and 3 - Yoke
unthread itself from the valve stem. As this 4 - Stem
takes place, the weight of the actuator should 15- Adaptor/actuatorstud
be supported by a hoist to prevent damage to 16- Adaptor/actuatornut
the stem or to the internal parts of the valve. 17C- Yoke/adaptorcapscrew
32- Motoractuator
8. If further disassembly of the actuator is
37- Adaptorplate
1"\.' required, refer to the maintenance manual
.., provided by the actuator manufacturer.
9. If there is further work to be performed on the
Figure 9.2C Motor actuator-Adaptor plate
valve, refer to the proper valve disassembly attachment (Exploded view)
and maintenance section in this manual.

CAUTION: When reinstalling actuator, the

valve should be in the slightly off-seated
position (main seat or backseat) for
centering purposes.

NOTE: After reinstalling the actuator it will be

necessary to readjust the actuator's open/close

I" limit switches.

Velan recommends the following:
The" open" limit switch should be adjusted,
as a rule of thumb, 1/4" off the backseat.
The "close" limit switch should be adjusted at
95% of close valve travel and if necessary, it can
be further increased to 90% of closed travel.

,I~ 57
IX APPENDIX
j
9.3 PROCEDURE FOR MOTOR
HYDRAULIC OR PNEUMATIC
ACTUATORS (Refer to Fig. 9.3A)
The following instructions will give you a general
guide for removal and reinstallation of a hydraulic
or pneumatic actuator.AII hydraulic or pneumatic
actuators have a connection between the valve
stem and the stem of the actuator. All these
connections are formed by some type of coupling.
Fig. 9.3A illustrates some examples of coupling used
on Velan valves. As a rule, examine this connection
first to understand how the coupling works.

Removal of Actuators (Refer to Fig. 9.38)

1. All pressure must be relieved from both sides 16- Jam nut
4 - Stem
of the valve before removal of actuator. 97 - Coupling
48 - Actuator stem
2. All air pressure must be relieved from actuator
before disassembly. Figure 9.3A Examples of coupling
3. Remove yoke-actuator bolting (178).
4. Loosen coupling (97).
Precaution: Examine coupling (97) for set

•
screw (35) or any locking device before
loosening it.
NOTE: On some actuators, it is necessary
to rotate the actuator stem to remove this
connection.
5. When the stem threads are disengaged, lift
the actuator (32) clear of the yoke and place it
down on a clean area. If further disassembly on
the actuator is required, refer to the manufac-
turer's maintenance and instruction manual.
6. If there is further work to be performed on the
valve, refer to the proper valve disassembly
section in this manual.

CAUTION: When reinstalling actuator, the

valve should be slightly off seated position
(main seat or backseat) for centering
purposes.

3 - Yoke 32 - Actuator
4 - Stem 35 - Coupling set screw
16 - Jam nut 97 - Coupling
L-1_7_B_-_Y_O_k_e/_a_ct_u_at_o_r_c_ap_s_c_re_w ~~

Figure 9.38 Removal of actuators

58
II ~
APPENDIX IX

•. 4 SPARE PARTS
All parts on any valve can be ordered, but Velan
does not recommend changing all parts in the
field (e.g. integral seat, integral backseat, wedge
guides, etc.).

Changing these parts may require special fitting.

In these cases, it is best to get in touch with your
local Velan representative who will help you deter-
mine the way to restore your valve with a mini-
mum of time and expense.

When ordering spare parts, correctly determine

Avhich parts are required. After this is done, pre-
~ent Velan with some of the following information:
1. Velan order number
2. Velan item number (if more than one item)
3. Velan figure number, model number and/or
manufacturing order number as well as drawing
number, if available, from the nameplate.
OR
1. Customer order number
2. Customer item number
• 3. Valve size, type, pressure class and drawing
number.

59
TERMS AND CONDITIONS OF SALE
CONTRACT: Orders are subject to acceptance by the Velan Companies here- discharge of Seller's maximum liability herewith, refunding all monies paid by
inafter referred to as the seller. No terms or conditions of Purchaser's order Purchaser to Seller for the Product and, at discretion of Seller, having the
contrary to the Seller's terms and condition shall be binding upon the Seller product removed and returned to Seller at Purchaser's expense. All transportae
unless specifically agreed to by the Seller in writing. tion charges relative to corrective work, defective parts or replacement parts
MINIMUM ORDER CHARGE: $500.00 net. shall be borne by Purchaser. Purchaser shall give Seller immediate notice upon
PRICES: All quoted prices are subject to change by the seller without prior discovery of any defect. The undertaking of repairs or replacements by
notice and, unless otherwise stipulated by Seller, are understood to be F.O.B. Purchaser or its agents without Seller's written consent shall relieve seller of
Seller's plant. with delivery to carrier constituting delivery to purchaser. Right to all responsibility herewith.
possession of the material to secure the payment of the purchase price shall Finished materials and accessories purchased from other manufacturers are
remain in Seller until all payments therefore shall have been fully made. For the warranted only to the extent of the manufacturer's warranty to Seller.
protection of the Purchaser and the Seller, verbal customer orders must be Any alteration in material or design of Seller's product or component parts
confirmed by a formal written purchase order. If a written purchase order is not thereof by Purchaser or others without written authorization by Seller voids all
received within ten days of a verbal order, product descriptions, quantities, obligations of Seller regarding the product and any associated warranty herein
specifications, etc., as set forth in Seller's acknowledgement and invoice shall stated or implied.
be conclusive and binding on both parties. Any order that is shipped before Seller's sale liability shall be exclusively as set forth herein, and Seller shall not
receipt of confirmation which might have been entered incorrectly and would be liable for any incidental or consequential damages due to its breach of any
require remedial action would be for the Purchaser's account. warranty herein contained, or otherwise. Without limitation to the foregoing, in
TAXES: All prices are exclusive of taxes. Sales, use and other taxes, by no event shall Seller be liable for the loss of use of the product or of any other
whomsoever levied, are to be paid by the Purchaser, and unless invoiced, are to product. process, plant. equipment. or facilities of the Purchaser or end-user
be paid by the Purchaser directly to the appropriate governmental agency. whether partially or wholly due to defects in material androrworkmanship
DELIVERY: Delivery or shipment specified is Seller's best estimate and Seller andror design of Seller's product. and in no event shall Seller be liable for ..
shall not be liable for delay in deliveries resulting from any cause whatsoever. removal of appurtenances or incidentals such as connections, pipe work and.
Failure to ship on or near the estimated date shall not entitle Purchaser to similar items of obstruction or for any cost brought about by the necessity of
cancel his order without charge. removing the product from its point of installation.
RETURN OF MATERIALS: Materials may be returned only with prior written Seller makes no warranty of any kind whatsoever, expressed or implied, other
agreement of Seller. then is specifically stated herein; and there are no warranties of merchantabili-
CANCELLATION: Cancellation of orders may be made only with the Seller's ty and/or fitness for a particular purpose which exceed the obligations and
written consent and Purchaser shall be subject to cancellation charges. warranties specifically stated herein.
PRODUCT WARRANTY: Seller warrants the equipment of its own manufac- Parts furnished without charge as replacements for original parts under
ture to be free of defects in material and workmanship, under normal use and warranty are warranted for that period of time during which the original parts '-"
proper operation for a period of one year from the date of shipment from Seller's warranty is effective.
plant. Seller's obligation under warranty shall be strictly limited, at Seller's All SHIPMENTS WILL BE F.O.B. PLANT lOCATION. SHIPMENTS Will BE
option, to: (i) furnishing replacement parts for or repairing without charge to MADE VIA MOST ECONOMICAL CARRIERS UNLESS OTHERWISE REQUEST-
Purchaser, F.O.B. Seller's plant or (ii) issuing written authorization for Purchaser ED.TERMS: NET 30 DAYS FROM DATE OF INVOICE: lX% PER MONTH OFAll
or others to replace or repair without charge to Purchaser, at costs comparable OVERDUEACCOUNTS, All TAXES EXTRA. PRICESSUBJECTTO CHANGE
to Seller's normal manufacturing costs those parts proven defective, or (iii) in WITHOUT NOTICE.

U.S.A.
Bill Hannon! Don Bowers Tony Boland David Brodnax John Smith Room4003of No. 13 VELANVALVE
18Avenue C 45W. Franklin Street 503ComancheTrail VELAN ENGINEERING Xiao-Ying Road CORPORATION 2125Ward Avenue
Griswold Industrial Park Bellbrook, OH45305 West Monroe, lA CO.LTO. Chao Yang District 18Avenue C Montreal, ac H4M IT6
Williston, VT 05495-9798 Tel: (937)848-2011 71291 Cambridge Rd., Beijing 100101 Griswold Industrial Park Tel: (514)748·7743
Tel: 86-10-64968995 Williston, VT Fax:(514)748-8635
Tel: (802)864-3350
Fax:(802)865-3030
RonaldJ. Harrington
Fax:(937)848-2144
Charles Pogue/
B. lawson / T. Harlield
Tel.: (318)396-7517
Fax:(318)396-4994
Frank Keegan
Whetstone
leicester lE86lH
England
Tel: 0116275-0206
Fax:86-10-64968997
SINGAPORE
05495-9798
Tel: (802)863-2562
Fax:(802)862-4014
VELAN INC.
550McArthur Ave.
It
43Wyckoff Avenue 730N. Post Oak Road Unit 14, Pierre Cohen Montreal, ac H4T 1 "
Fax:0116 275-0224 Tel: (514)748-7743
Waldwick, NJ Suite 311 9007Highland Road 17Hyde Park Gate FRANCE
Houston,TX 77024 Gordon Hogben Seletar Base Fax:(514)341-3032
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Tel: (201)670-0995 Tel: (713)682-1084 70810 10ReynoldsWay Singapore 799546 90,rue ChallemelLacour VELANINC.
Fax:(201)670-6810 Fax:(713)682-6071 Tel: (504)767-7965 Croydon, CRO5JW Tel: (65)484-1734 69367lyon Cedex7 1010Cowie Street
Christopher G.Hiett Fax:(504)767-8160 England Fax:(65)484·1735 Tel: (33)78 616700 Granby, ac J2J 1E7
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19804-3316 CA 92646 Rein Maasik I Paul Dion Jacques Chanois Sergio Pensoni VELAN V.4LVULAS TAIWAN
Tel: (302)994-1176 GECAisthom-Velan
Fax:(302)994-6156
Tel: (714)965-6277
Fax:(714)965-6737
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VELAN VALVECORP.
730N. Post OakRoad
Industriais, lda.
Av. Ary dos Santos
VELAN-VALVAC
P.O.Box 2020
'-'
Tel: (514)748-7743 94134Fontenay Suite 311 Lisbon-26750divelas Taichung, Taiwan,
Jim Cate Peter Kindersley
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P.O.Box 430 Woody Bowler
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larry A. Woodworth
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•
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NOTE: Although every attempt has been made to ensure that the information contained in this manual is correct. Velan reserves the right to change designs or,
materials or specifications without notice. Please get in touch with your local Velan representative for more information.

PRINTED IN CANADA VEL-CSVM-97

I}-I
VOLUME-12 PIPING, VALVES AND ACCESSORIES Chapter-3

3.2 FORGED STEEL BONNETLESS

BLOW DOWN VALVES

~
'-6ontents 10137
(

FORGED STEEL BONNETLESS

BLOWDOWN VALVES
MAINTENANCE MANUAL
1f2 - 2" (15-50mm)
(

VEL-BDVM-98
TABLE OF CONTENTS PAGE
INTRODUCTION 1
1.1 General Introduction 1 (
1.2 Essential Featuresof Velan Valves 2
II RECEIVING & PREPARATION FOR INSTALLATION 2
2.1 Receiving Inspection 2
2.2 Quality Control Documentation 2
2.3 Storage 2
2.4 Handling and Preparation 2
2.5 Special Instructions 3
III WARNINGS 3
IV GENERAL MAINTENANCE 4
4.1 Blowdown Valve Design and Parts Description 4
4.2 Tools 5
6
4.3 Operation
4.3.1 General
4.3.2 Smoothness of Operation
6
6
6
c
4.4 Recommended Lubrication
4.5 General Assembly Information 6
4.6 Seat tightness - Closing Torques 6
V INFORMATIONPERTINENT TO SLOWDOWN VALVES 7
5.1 Packing Chamber Leakage 7
5.1.1 General 7
5.1.2 Packing Ring Removal and BackseatUsage 7
5.1.3 Removal With Special Tools 7
5.1.4 Repacking 7
5.1.5 PackingTorques 7
5.2 Disassembly 8
5.2.1 General 8
5.3 Seat and Disc Repairs 8
5.3.1 Seat Leakage 8
5.3.2 Seat Refinishing 8
5.3.3 Disc Refinishing 9
5.3.4 Seat -Disc Lapping 9
5.4 Reassembly 10
5.4.1 General 10 (

INTRODUCTION

1.1 GENERALINTRODUCTION
This manual has been prepared by Velan engineers, designers and maintenancepersonnel to assist you in obtaining many
yearsof satisfactory service from your continuous blowdown valves.It will also assist you in restoring your valves to the
best working condition with a minimum of time and expense.
Velan valves are designed and manufactured based on many years of research and product development and are con-
stantly being improved. Before beginning any major work, we recommend that you read this booklet carefully at least
once to understand the valve's physical condition. Pleasenote that if you do not understand the reason for the service
problem, we suggest that you get in touch with your local Velan representative or call the Customer Service Manager for
technical assistance.
This valve is designed for continuous blow-down but can be used for sampling, boiler feed pump bypass relief where
high pressure drop service is associated with wire drawing, erosion and cavitation which destroy conventional globe
valves. It incorporates a hardfaced Stellite 6 disc and seat and a venturi diffuser made from stainless steel type 316.
Orifice range: Vs"',3/16"', 1¥76"', 3/S"', Y2"',3fo"', and 1'" depending on the capacity required.
Srellite 6 provides the best possible protection against damage to seat and disc. The valve, however, is not absolutely i
safe from damage. If, for example, a particle of hard foreign matter is trapped between the seat and the disc and then \
pressed into the seat in valve service, damage might occur.
Before beginning any major work, we recommend that you carefully check the nameplate on the valve and record the
figure number to identify the type and size of valve. See the "'Essential Features of Velan Valves'" form on the following
page for an explanation of Velan "'Figure Numbers"'.

1
INTRODUCTION

( 1.2 ESSENTIAL FEATURES OF VELAN VALVES

The figure numbers shown on this key are designed to cover essential features of Velan valves. Please use figure numbers to ensure
prompt and accurate processing of your order. A detailed description must accompany any special orders.

Blowdown Valves
Type 01Connection Size of connection Class Type Body/Bonnet Style Body Material Trim Material

•• •• •• ••
A B C 0 E F G
Ii±] 0 0 III
W 0 5 3 1 0 5 V 0 2 T S
e.g.: is a 1" (25 mm) socket weld A 105continuous blowdown valve with TS trim.

(
RECEIVING & PREPARATION FOR INSTALLATION II

2.1 RECEIVING INSPECTION 2.3 STORAGE

All valves must be examined for signs of damage Valves should be stored in a suitably sheltered
that may have occurred during transportation. Any place to prevent contamination by weather, dirt or
damage should by analyzed and a report should be dampness. The valve is shipped with end protec-
issued. Serious damage should be reported to tors on the inlet and outlet which should stay on
your local Velan representative or to the Customer the valve until it is ready for installation.
Service Manager so that a suitable arrangement for NOTE: If actuators are involved, please refer
repairs can be made without delay.
to the applicable manufacturer's instructions
for storage.
2.2 QUALITY CONTROL DOCUMENTATION
2.4 HANDLING AND PREPARATION
For valves purchased with Quality Control (QC)cer-
( tification, check the package of documents to see End protectors must be removed from all types
that the Quality Control certificates are complete as of valves and connections must be checked for
per the purchase order. cleanliness. Any visible foreign matter must be

2
removed from end connections on weld-end 25 SPECIAL INSTRUCTIONS
valves. The weld-end preparation must be
cleaned properly with a suitable solvent such as Valves should be installed and welded into the
acetone or alcohol. Do not use solvents contain-
ing chloride or fluoride. Ensure that the tapered
pipeline with the disc in a fully closed position to
prevent damage to the valve during installation.
(
area between the packing flange and stem is clear Leaving the disc in a fully closed position also pre-
and free of foreign debris. vents weld spatter from falling directly onto the
mating faces of the seat and disc.

PRECAUTION: Allow time for welding to

cool before trying the valve for the first
time in the pipeline.

WARNING III

(
FOR SAFETY REASONS,
it is important to take these precautions

(.. Personnelmaking any adjustments on the valves should wear

safety equipment normally used to work with fluid in the line
where the valve is installed.
(.. Before removing the yoke nut under pressure, the valve should be in fully open (
position in order to prevent injuries.
(.. Before removing a valve from a line, line pressure must be relieved
with no exception.
(.. Velanvalvescan be equipped with a variety of manual gear, electric motor,
hydraulic or pneumatic actuators. Generally,all pressure must be relieved from (
both sides of the valve before the actuator is removed.
(.. A valve in the fully open position (backseated),should not be jammed-tight
(over-torqued), to avoid thermal binding. It is our recommendation that the
valve be removed 1/4 turn of the handwheel from the fully open position.
This will also ensure that packing tightness is verifiable. In gear-operated
valves, becauseof the backlash, it is difficult sometimes to ensure this position.
(.. Valvestandards,such as API and MSS, caution users that successful
completion of a backseattest should not be construed as a
recommendation by the manufacturer that a valve may be repacked
while it is under pressure. The backseatmay be used as a means
of stopping or reducing packing leakageuntil the packing
can be replaced under no pressure. Removal of packing
with the valve under pressure is at the owner's risk.

\ -,

3
GENERAL MAINTENANCE IV

( 4.1 SLOWDOWN VALVE DESIGN & PARTS DESCRIPTION

PARTS DESCRIPTION

1 -Body
4 -Stem
6 -Disc
( 9 - Seat and Venturi
11 - Packing flange
12 - Split gland bushing
13A - Packing ring, braided
13A - Packing ring, graphite
15 - Gland stud
16A - Gland nut
. 16B - Handwheel nut
18 - Backseat
27 - Yoke bushing
33 - Handwheel
( 35 - Set screw
56 - Cap screw
57A -Washer
57B - Packing washer
57C -Washer
66 - Nameplate
84A -Indicator dial
84B -Indicator
101 - Backseat retainer
106 - Holder

(__

4
IV GENERAL MAINTENANCE

4.2 TOOLS Tool kit numbers as well as item numbers for

Y-pattern bonnetless globe valve tool kits are
individual tools as shown in Table A, are for (
standard bonnetless globe valves.
available for all valve types and sizes. However,
for bonnetless continuous blowdown globe
needle valves similar tools can be provided
upon request.

TsbleA Y-Patterntool kits and tool part numbers TK976& TK576all sizes and all Classes(2680,4500)

Other tools and materials you should have ready before beginning repairs on these valves:
(
• large screwdriver • hammer or mallet • torque wrench • set of Allen keys • acetone or equivalent
• air motor or set of ratchet with socket wrenches • coarse and fine lapping compound • lathe

SEAT REFINISHING TOOL

WITH INTERCHANGEABLE HEADS
(

CUTTING STEM REMOVAL TOOL

HEAD
FOR ~-*.
VALVES

STEM
HOLDER HOLLOW
CAP SCREW

CROWNED
TOROUE WRENCH END TUBE WRENCH/PACKING REMOVER
.. ADA:;'

5
GENERAL MAINTENANCE IV

( 4.5 GENERAL ASSEMBLY INFORMATION

4.3 OPERATION
(
1. The most important fact to be considered is the
( 4.3.1 General cleanliness of all parts. All rust and dirt should
be removed from all parts with a wire brush or
All valves require examination before being put emery cloth. Oil and grease should be
into operation. Additionally, valves should be removed with suitable solvents.
inspected regularly during operation and should 2. All threaded parts (cap screws, nuts, studs)
receive prompt attention when trouble arises. must be well relubricated. The stem and yoke
As a general rule, valves should be subjected to bushing threads should be clean of old grease
scheduled maintenance. before a new application of grease is applied.
Recommended lubricants can be found in
Table 8, Section 4.4. Use correct lubricant for
4.3.2 Smoothness of Operation each individual part.
11( 3. Repaired or replacement parts must be
Stem threads, yoke bushing and other working
components outside the fluid area should be checkedto see that all repair procedures have
lubricated frequently and at least once every six been done and that all replacement parts
(e.g., packing rings, gaskets,etc.) have been
months. Specific lubricants and frequency of
checkedfor size so that they will fit into the
application are shown in the recommended valve being serviced.
lubrication Table 8 of Section 4.4. Valves that are
not operated frequently and which may remain 4. All orientation marks assigned during
open or closed for long periods of time should be disassembly must be observed so that correct
worked (even if only partially) about once a month. orientation is maintained. Where applicable,
orientation marks should be made on parts
near the body serial number (e.g. wedge, disc,
IMPORTANT: Excessive handwheel effort
seat, etc.).
can indicate the following:
1. Improperly lubricated or damaged
valve stem. 4.6 SEAT TIGHTNESS - CLOSING TORQUES
2. Valve packing compression too tight
(check torques in Table C). Even a new valve with seating faces lapped to
3. Faulty or damaged valve parts. perfection and a full seat-disc contact will be pres-
4. Foreign debris on threads and/or sure-tight only if sufficient stem load is applied.
packing area. The minimum stem load for each size of valve
varies with operating pressure, but should be
known by the operating personnel in order to seat
the valve properly. Over-torquing up to 25% will
not damage the valve.

4.4 RECOMMENDED LUBRICATION

TableS Recommended lubricant subject to change without notice.
PART LUBRICATION APPLICATION FREQUENCY

Stem threads Exxon Ronex MP, Castrol MP Directly to When threads

Lubriplate No. 93Q-AAor 930-AAA threads appear dry
Exxon Ronex MP, Castrol MP Inject through Concurrently
( Yoke bushing Lubriplate No. 930-AA grease fitting with stem
(C or 930-AAA at hub of yoke thread lubrication
( All threaded parts Hi-temp anti-seize compound Thin coat on On valve
except stem and yoke nut FEL-PROC5-A threads assembly only

6
V INFORMATION PERTINENT TO SLOWDOWN VALVES

(
5.1 PACKING CHAMBER LEAKAGE emery cloth, by lapping, or by machining.
NOTE: Velan uses combination graphite
5.1.1 General packings rings consisting of two braided
graphite end rings (first and last) and four
If moisture or dripping occurs around the stem or intermediate graphite ribbon (flexible
the 1.0. packing chamber, the following points graphite type).
should be investigated before removing the 2. Insert the first packing ring, (braided graphite)
packing. squeeze the ring manually and place as deeply
into the chamber as possible followed by sec-
CAUTION: For safety reasons, the valve ond, third, fourth and fifth intermediate rings.
The sixth and last packing ring should be
must be depressurized before removing
braided graphite.
packing or dismantling gland nuts.
NOTE: The packing rings should be
staggered approximately 1200 apart. (
1. Check if the packing flange is torqued down to
the correct torque as shown in Table C. Make 3. Place the gland bushing and packing flange
sure the gland is not binding against the in position. Make sure gland bush enters
packing chamber wall or stem. If so, open packing chamber for approximately
valve to backseat position and firmly tighten 1/8" (3 mm)
up on backseat. Loosen the packing flange 4. Lubricate the gland studs and nut flats with an
and re-align the gland bushing. Tighten up the anti-seize compound. Compress the packing
packing flange a little at a time on each side, by tightening the gland nuts in sequence and
then torque down to the correct torque as increments of 20% of the final torque value
shown in Table C. shown in Table C.
2. After retightening, cycle the valve for the
length of the packing chamber, first open then 5.1.5 Packing torque (
close and retorque to original torque value
shown in Table C. Do this until there is no 1. Clean all studs and nuts. Visually inspect all
more packing consolidation (no torque loss, threads to ensure removal of all foreign matter,
approximately 3 to 5 times). If steps 1 and 2 rust, corrosion, burrs and previous lubrlcant.
do not stop leakage, proceed with the removal 2. Liberally cover the stud threads and the
and replacement of packing rings. female threads of the nuts with Hi-Temp.
anti-seize compound.
5.1.2 Packing Ring Removal and Backseat Usage 3. With nuts hand-tight, tighten up the packing
(
flange nuts a little at a time on each side, then
For safety reasons, the valve should be depressur-
torque down to the correct torque in
ized. All valves have a backseat and safe use of
accordance with the valve size and pressure
this feature is the responsibility of the user. To
class, as shown in Table C.
backseat a valve, it is necessary to open the valve
fully and to tighten the stem against the backseat
firmly. Table C Packing flange nut torques
VALVE SIZE TORQUE
5.1.3 Removal with special tools in mm I Ibf·ft N·m
Remove old packing rings using special tube ~-1 15-25 23 31
wrench/packing remover shown on page 5 in
Section 4.2, Tools. This tool is available through 1~ 40 55 75
Velan. Next follow disassembly procedures in 2 50 76 103
Section 5.2.1, General steps 1-7.

5.1.4 Repacking
1. Before inserting the packing, check the stem
and the packing chamber wall to make sure
there is no damage. Scratches no deeper than
.001" to .003" (0.025 to 0.076 mm) can be
removed by polishing the surface with a fine

7
INFORMATION PERTINENT TO BLOWDOWN VALVES V

I( 5.3 SEAT AND DISC REPAIRS

5.2 DISASSEMBLY
5~1 Seatleakage
5~1 GENERAL
Leakscan also develop from failure to close the
CAUTION: For safety reasons, make sure valve tightly, resulting in high-velocity flow through
all pressure has been relieved from both a small opening. The hardfacing material (e.g.,
sides of the valve before beginning any Stellite 6) is corrosion and erosion-resistant, but
disassembly work. grooves, pit marks or other surface irregularities
may still form on the mating surfaces.Valves which
leak should be repaired as quickly as possible to
1. Removehandwheel nut and handwheel. prevent greater damage caused by high velocity.
2. Remove gland nuts and studs, loosening both
I( sides equally. If valve is fitted with live-loading, 5.3.2 Seat Refinishing
remove guide bushing and spring washers 1. Disassemblevalve (see Section 5.2). Select
(Belleville washers). Raisepackingflange and the proper head for the seat refinishing tool.
remove split gland bushing. Consult Velan Customer Service Department
~ for seat diameters. Minor damage can be
3. Grind off tack weld between yoke bushing and
yoke. repaired with the lapping head, but use the
cutting head first if there is severe damage.
4. Loosen hex socketset screw (35) and remove Removethe screw on the end of the tool with
the indicator dial. a small Allen key, position the cutting or
5. Make sure the valve is almost closed, but not lapping head and tighten the screw.
tight on the seat.Usea crescentwrench to NOTE: If valve is not in an upright position,
( unscrew the yoke bushing counterclockwise.
Should the yoke bushing bind, put handwheel
usethe yoke bushingto hold the tool in place.

on stem and close the valve a little. Continue

to unscrew the yoke bushing counterclockwise.
Remove handwheel and yoke bushing.
6. Placetube wrench/packingremover with the
I
cutting edge first over stem and into the packing
( chamber. Placeguide bushing into top of valve.
Placethe torque wrench adapteronto the
\ crowned end of the tube wrench/packing
remover and securewith set screw. Using the
hex drive on the torque wrench adapter,turn in
~ a clockwise direction while pushing down. This
will pick up the packingswithin the spiral flutes
of the tube wrench/packingremover. Pull up the
tool and remove packingswithin the spiral flutes. Figure 5A Using the seat refinishing tool
Re-inserttool to remove any remaining packings.
After complete removal of packing,remove guide 2. Use an air or electric motor for cutting and
bushing,torque wrench adapterand tube lapping if you have one. Placethe air motor
wrench/packing remover. Using two packing adapter on the end of the tool. If you don't
washer hooks, insert them into the packing have an air or electric motor, you can use a
washer holes and pull it up over the stem. ratchet and socket wrench, but the repair will
7. Insert the crowned end of the tube wrench/ take longer.
.. packing remover in valve body. Use a metal bar a) Hyou are using the cutting head .
I (- through the top holes of the tube wrench/ Insert the seat refinishing tool into the valve
packing remover to unscrewthe backseat bore. Rotatethe tool using either a socket
1 retainer counterclockwise. Removestem/disc wrench or an air motor while applying pres- .
assembly. The valve is now ready for servicing. sure on the tool. Removethe tool and inspect
the seat area. Repeatif necessary.

I ~0 8
V INFORMATION PERTINENT TO BLOWDOWN VALVES

(
b) If you are using the lapping head
Lightly coat the lapping tool head with medium
coarse lapping compound. Insert the seat refin-
ishing tool into the valve bore. Rotate the tool
using either a ratchet, electric or air motor
while applying pressure on the tool. Remove
the tool and inspect the seat area. Repeat if
necessary. When all visible damage is
removed, clean off all coarse compound grit
and finish lapping the seat with fine lapping
compound.
3. Use a portable vacuum cleaner to remove
loose chips. The valve is now ready for Figure 58 Using a rachet for seat-disc lapping
(
seat-disc lapping. holder over the stem and down into the body,
threaded end down. Screw the stem holder
into the body using the crowned end of the
5.3.3 Disc Refinishing tube wrench/packing remover. Put a metal bar
Minor damage can be repaired by machining the through the holes in the upper end of the tube
disc. Clean the surface, then chuck the stem-disc wrench/packing remover and screw down the
assembly in a lathe and center the disc on the stem holder lightly until it bottoms.
circular guides. Seethe diagrams below for disc
refinishing angles. Do not remove more than the 4. Rotatethe stem with an air or electric motor or
amounts shown in Table D, below. The disc is now rachet, applying light pressureto the stem.
ready for final lapping with seat. Remove stem and check periodically. When
the seating faces are perfectly smooth, clean
NOTE: If the disc is severely damaged, it them with acetone or equivalent. The valve is (
should be replaced. now ready for reassembly.

5.3.4 Seat - Disc Lapping TableD Disc and seat refinishing removal
allowances
After seat refinishing or when a new or recondi-
tioned disc is used, the disc and the seat should be VALVE SIZE ALLOWANCES
in mm in mm
lapped together to create a perfect sealing contact.
Seat-disc lapping can also be usedto eliminate Y..-X 8-20 0.010 0.25
(
minor seat and/or disc damage. 1-1~ 25-40 0.015 0.38
Use an air or electric motor for lapping if you have 2 50 0.015 0.38
one. Placethe air motor adapter on the end of the
tool. If you don't have an air motor, you can use a
ratchet and socket, but the repair will take longer.
1. The valve should be completely disassembled
including the packing rings, backseatand
backseatretainer.
NOTE: slip an O-ring over the end of the
stem and into the groove between the disc
and the stem to prevent the disc from
rotating during lapping.
2. Apply a small amount of lapping compound to
the disc seating surface. Insert the stem with
disc in the body.
3. Usethe stem holder to center the stem for the
Standard globe disc and (
flow control needle disc
lapping operation. Usethe stem, without any
backseator other parts on it. Slip the stem
Figure 5C Angle for disc refinishing

9
INFORMATION PERTINENT TO BLOWDOWN VALVES V

( For live-loaded valves reinstall the disc springs

5.4 REASSEMBLY
and guide bushings onto the studs tightening
both sides equally (hand-tight).
5.4.1 General
NOTE: The gland bushing should engage
1. Slip backseatonto stem, chamfered edge intothe bodyby ltI" (3 mm) min.
down. Lubricate backseat retainer threads
(see Table B). Then slide backseat retainer 7. Screw on yoke bushing clockwise, using a
onto stem, crowned end up. large crescent wrench. Should the yoke
bushing bind, it's becausethe stem has
2. Placepacking flange under yoke, flat side up. bottomed on the seat. Correct this by backing
Insert stem assembly through packing flange off the handwheelslightly. Secureyoke bushing
and into body. to yoke with tack weld.
3. Thread in backseat retainer, use the crowned S. Continue tightening packing nuts or guide
( end of the tube wrench/packing remover to bushing for live-loaded valves with a crescent
tighten the backseat retainer clockwise against wrench. Install the crescent key on the torque
the backseat. wrench and finish tightening the nuts to the
~ 4. Then place torque wrench adapter into the torques shown in Table C.
tube wrench/packing remover. Align holes to 9. Install position indicator if so equipped, then
insert a round bar through both parts. Use a handwheel and handwheel nut. Ensure the
torque wrench and continue to tighten until stem threads are well lubricated (see Table B).
torque value shown in Table E is obtained. Cyclethe valve approximately the length of
NOTE: Velan recommends the use of the packing chamber. First open then close and
tool kits listed on page 5 for the best retorque to the torque value in Table C. Do
maintenance results. this until the packings are fully consolidated,
( 5. Insert packing washer, chamfered edge down. showing no more torque loss (approximately
Then insert the set of precompressed packing 3 to 5 times).
rings one at a time, beginning and ending with
the braided rings. Use the crowned end of the Tab/eE Recommended backseat retainer
tube wrench/packing remover to tap the rings torques
into place.
VALVE SIZE TORQUES
NOTE: If uncompressed packing is used, in mm I CLASS Ibf·ft N·m
(

.,
the die-formed rings must be precom-
1500
pressed individually. x-% 15-20
2500
60 80
6. Slip split gland bushing under packing flange,
1500 120 160
one half at a time, chamfered edge up. 1 25 2500
Lubricate gland studs with anti-seize com-
pound, passthem through packing flange and lX-1X 32-40 1500 150 200
thread on the gland nuts, tightening both sides 2500
equally (hand-tight). 1500
2 50 180 245
2500

(
.~
I

10
TERMS AND CONDITIONS OF SALE
CONTRACT: Orders are subject to acceptance by the Velan Companiea repair without charge to Purchaser. at costs comparable to Seller's nor-
hereinafter referred to as the aeller. No terms or conditions of Purchase- mal manufacturing costs those parts proven defective. or (iii) in dis-
er's order contrary to the Seller's terms and condition shall be binding charge of Seiler'S maximum liability herewith, refunding all monies paid
upon the Seller unless specifically agreed to by the Seller in writing.
MINIMUM ORDER CHARGE: $500.00 net
by Purchaser to Seller for the Product and, at discretion of Seiler. having
the product removed and returned to Seller at Purchaser's expense. All
(
transportation charges relative to corrective work. defective parts or
PRICES: All quoted prices are subject to change by the seller without replacement parts shall be borne by Purchaser. Purchaser shall give
prior notice and. unless otherwise stipulated by Seiler. are understood Seller immediate notice upon discovery of any defect The under-taking
to be F.O.B. SeIler's plant. with delivery to carrier constituting delivery of repairs or replacements by Purchaser or its agents without Seiler's
to purchaser. Right to possesslon of the material to secure the payment written consent shall relieve seller of all responsibility herewith.
of the purchaae price shall remain in Seller until all payments therefore
shall have been fully mede. For the protection of the Purchaser and the Finished materials and accessories purchased from other manufacturers
Seiler. verbal customer orders must be confirmed by a formal written are warranted only to the extent of the manufacturer'S warranty to Seller.
purchase order. If a written purchase order is not received within ten Any alteration in material or design of Seller's product or component
days of a verbal order. product descriptions, quantities, specifications. parts thereof by Purchaser or others without written authorization by
etc., as set forth in Seller's acknowledgement and invoice shall be con- Seller voids all obligations of Seller regarding the product and any asso-
clusive and binding on both parties. Any order that is shipped before ciated warranty herein stated or implied.
receipt of confirmation which might have been entered incorrectly and
would require remedial action would be for the Purchaser'S account Seller's sole liability shall be exclusively as set forth herein. and Seller
TAXES: All prices are exclusive of taxes. Sales. use and other taxes. by shall not be liable for any incidental or consequential damages due to its
whomsoever levied. are to be paid by the Purchaser. and unless breach of any warranty herein contained. or otherwise. Without limita-
invoiced. are to be paid by the Purchaser directly to the appropriate tion to the foregoing. in no event shall Seller be Hable for the loss of use
governmental agency. of the product or of any other product. process. plant. equipment. or
facilities of the Purchaser or end-user whether partially or wholly due to
DElIVERY: Delivery or shipment specified is Seiler's best estimate and defects in material and/or workmanship and/or design of Seiler's prod-
Seller shall not be liable for delay in deliveries resulting from any cause
whatsoever. Failure to ship on or near the estimated date shall not enti-
uct. and in no event shall Seller be liable for removal of appurtenances (
or incidentals such as connections. pipe work and similar items of
tle Purchaser to cencel his order without charge. obstruction or for any cost brought about by the necessity of removing
RETURN OF MATERIAlS: Materials may be returned only with prior the product from its point of installation.
written agreement of Seiler. Seller makes no warranty of any kind whatsoever. expressed or implied.
CANCEUATION: Cancellation of orders may be made only with the other then is specifically stated herein; and there are no warranties of
Seller's written consent and Purchaser shall be subject to cancellation merchantability and/or fitness for a particular purpose which exceed the
charges. obligations and warranties specifically stated herein.
PRODUCT WARRANTY: Seller warrants the equipment of its own man- Parts furnished without charge as replacements for original parts under
ufacture to be free of defects in material and workmanship. under nor- warranty are warranted for that period of time during which the original
mal use and propar operation for a period of one year from the date of parts warranty is effective.
shipment from Seller's plant Seller's obligation under warranty shall ALL SHIPMENTS WILL BE F.O.B. PLANT LDCA nON. SHIPMENTS WILL
be strictly limited. at Seller's option. to: (i} furnishing replacement pa~ BE MADE VIA MOST ECONOMICAL CARRIERS UNLESS OTHERWISE
for or repairing without charge to Purchaser. F.O.B. Seller's plant or (II} REQUESTED. TERMS: NET 30 llA YS FROM llA TE OF INVOICE: 1:1% PER
issuing written authorization for Purchaser or others to replace or MONTH OF ALL OVERDUE ACCOUNTS. ALL TAXES EXTRA. PRICES
SUBJECT TO CHANGE WI1HOUT NonCE.
(
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fax: 1403)213-8547 specifications without notice. Please get in touch with your local Velan representative
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VEL-BDVM-98 In
PRINTEDIN CANADA
VOLUME-12 PIPING, VALVES AND ACCESSORIES Chapter-3

3.3 FORGED Y-PATTERN BONNETLESS

GLOBE VALVES

Contents 11/37
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-------------
FORGED Y-PATTERN BONNETLESS
GLOBE VALVES
MAINTENANCE MANUAL
%-4" (8-100 mm)

VEl-FBGM-2000
TABLE OF CONTENTS

(
GENERAL INFORMATION PAGE
INTRODUCTION 4
1.1 General Introduction 4
1.2 Essential Features of Velan Valves 5
II RECEIVING & PREPARATIONFOR INSTALLATION 6
2.1 Receiving Inspection 6
2.2 Storage 6
2.3 Special Instructions 6
III WARNINGS 7
IV GENERAL MAINTENANCE 8
4.1 Operation 8
4.1.1 General 8
4.1.2' Smoothness of Operation 8
4.1.3 Seat Tightness and Closing Torques 8
4.2 Recommended Lubrication 8
4.3 Packing Chamber Leakage 9
4.4 Disc Refinishing 9
4.4.1 Angle for Disc Refinishing 9
4.5 Seat Refinishing 10
4.6 Seat-Disc Lapping 10
4.7 Tools 11
4.7.1 Other Tools 12 .
(
"'

. .:

Y-PATTERN BONNETLESS GLOBE VALVE

V V-PATTERN BONNETLESS GLOBE VALVE 13

5.1 Z Type Y-Pattern Bonnetless Globe Valve 13
. 5.2 Y Type Y-Pattern Bonnetless Globe Valve 14
5.3 Disassembly of Z Type 15
5.4 Reassembly of Z Type 16
5.5 Disassembly of Y Type : 17
5.6 Reassembly of Y Type 18
TERMS AND CONDITIONS OF SALE 19

2
LIST OF FIGURES AND TABLES

(
FIGURES NUMBER PAGE

Seat refinishing tool with interchangeable heads . 4.7A 12

Standard globe disc and flow control needle disc . 4.48 9
Stem holder . 4.7C 12
Stem removal tool for 1/4 - 3/4" valves . 4.78 12
Stop check disc . 4.4A 9

Torque wrench adapter . 4.70 12

c Tube wrench / packing remover . 4.7E 12

Using the seat refinishing tool . 4.5 10

Using a socket wrench for seat-disc lapping . 4.6 11

TABLES NUMBER PAGE

Disc refinishing removal allowances . 4.4 10

(
Recommended gland nut torques for graphite packing . 4.1.2 8
Recommended lubrication . 4.2 8
Recommended spline bushing or backseat retainer torques . 5.3 16

Y-Pattern tool kits and tool part numbers TK976 & TK576
( all sizes and all classes (2680, 4500) . 4.7 12

/
3
INTRODUCTION

(
1.1 GENERAL INTRODUCTION

his maintenance manual has been prepared

to help yOU obtain many more years of

T satisfactory service from your y-pattern

bonnetless globe valves. It will also help yOU
restore your valves to the best working condition
with a minimum of time and expense.
Velan valves are designed and manufactured based
on many years of research and are constantly being
improved. Before beginning any major work, we
recommend that yOUcarefully read this booklet at c_
least once to understand the valve's physical
construction. If yOUdo not understand the reason
for the service problem, we Suggest that you get in
touch with your local Velan representative, or call
the Velan Service Department at the Head Office
for technical assistance.
(
Velan y_pattern bonnetless globe valves are
one-piece forged steel valves designed for high
pressure-temperature service. The valves have
guided Stellite 6 discs. Stellite, a cobalt, chromium
and tungsten alloy, has an average Brinell hardness
of 400, and is generallY accepted by the valve industry
as an ideal hardfacing material. However, the seat
and disc are not absolutely safe from damage. If, for
example, a particle of hard foreign matter becomes
trapped between the seat and the disc and is then
pressed into the seat in service, damage could occur.

4
INTRODUCTION

1.2 ESSENTIAL FEATURES OF VELAN VALVES

V-Pattern Globe Valves

Typeof Connection Size of connection Class Type Body/BonnetStyle BodyMaterial Trim Material

• •• •• •• ••
A B C 0 E F G
0 0 D
W 0 5 8 0 7 6 Z 0 2 T S
e.g. is a 1" socket weld A 105 bonnetless stop globe valve Z type 1690 class with TS trim as described

F- Flanged s- Threaded W - Socketweld

Customers have the choice of specifying valve size as part of the valve figure number ("8") using the numbers below,
or indicating valve size separately.
EXAMPLES: F08-20748-13MS (valve size is part of figure number)
2" F-20748-13MS (valve size is shown separately)
01- Yo" (8 mm) 02- %" (10mm) 03- X" (15mm) 04- r.' (20mm) 05- 1" (25mm) 06-1x"(32mm)
01- lX" (40mm) 08- 2"(50mm) 09- 2X"(65mm) 10- 3' (75mm) 11- 3X" (90 mm) 12- 4" (100mm)

3- 1500 4- 2500 5- 4500 1- 900 8- 1690 9- 2680

(
01 - Stop globe 08 - Stop check 09- Needle

6W - Y PatternWelded Bonnet 6Y- Y Pattern Bonnetless 6Z- Y Pattern(Non-RotatingStem)

( (RotatingStem) 7Z- Y Pattern45q (Two-Piece
Non-RotatingStem)

02- Al05 06 - Chrome moly, F22 13- Stainlesssteel, F316

SS 3168

5
II RECEIVING AND PREPARATION FOR INSTALLATION

(
2.1 RECEIVING INSPECTION 2.3 SPECIAL INSTRUCTIONS
Valves must be examined to establish that no Globe valves are usually installed with the inlet
damage occurred during transportation. If any below the valve seat. For particularly severe
damage is found, make sure that it does not throttling service, we recommend that the valve
impair the operation of the valve. Serious be installed so that the flow enters through the
damage should be reported to your local Velan top of the seat and goes down through it. This
representative or to the Velan Service Department maintains the valve in a more stable position,
at the Head Office so that arrangement for repairs minimizes wear and reduces the potential noise
can be made. level. Valve operation is also easier because less
torque is required to close the valve.
2.2 STORAGE Globe valves should be installed and welded into
the pipeline with the disc in the fully closed
C
..
Valves can be stored at any temperature in a
position to prevent damage to the valve during
sheltered area but must be protected from
installation. Also, leaving the disc in the fully '-'
contamination by dirt or the elements. The valve
closed position helps prevent weld spatter from
is shipped with end protectors on the inlet and
falling directly onto the mating faces of the seat
outlet which should stay in place until the valve
and disc.
is ready to be installed. Before installation,
remove the end protectors and check the
connections for cleanliness. Visible foreign
matter must be removed from end connections
of weld-end valves. The weld ends must be
cleaned with a suitable solvent, such as acetone
or alcohol. Do not use solvents containing
(
fluoride or chloride.

6
WARNINGS III

FOR SAFETY REASONS,

it is important to take these precautions

C" Personnel making any adjustments on the valves should wear

safety equipment normally used to work with fluid in the line
where the valve is installed.
C" Before removing the yoke nut under pressure, the valve should be in fully open
position in order to prevent injuries (backseat position).
C" B~fore removin_g a valve from a line, line pressure must be relieved
with no exception.
C.. Velan valves can be equipped with a variety of manual gear, electric motor,
hydraulic or pneumatic actuators. Generally, all pressure must be relieved from
c C..
both sides of the valve before the actuator is removed.
A valve in the fully open position (backseated), should not be jammed-tight
(over-torqued), to avoid thermal binding. It is our recommendation that the
valve be removed 1/4 turn of the handwheel from the fully open position. This
will also ensure that packing tightness is verifiable. In gear-operated valves,
because of the backlash, it is difficult sometimes to ensure this position.
C.. Valve standards, such as API and MSS, caution users that successful
completion of a backseat test should not be construed as a
recommendation by the manufacturer that a valve may be repacked
while it is under pressure. The backseat may be used as a means
of stopping or reducing packing leakage until the packing
can be replaced under no pressure. Removal of packing
with the valve under pressure is at the owner's risk.

((

14-0 7
IV GENERAL MAINTENANCE

(
4.1 OPERATION Table 4.1.2
Recommended gland nut torques
for graphite packing
4.1.1 General
SIZE CLASS TORQUE
All valves should be checked before being put in (mm) Ibf·ft (N'm)
into operation and inspected regularly during }{-% (S-20) 26S0 14 (19)
operation. Problems should receive prompt
}{-~ (S-15) 4500 17 (23)
attention. As a general rule, valves should be
subjected to scheduled maintenance. 1 (25) 26S0 25 (34)
%-1 (20-25) 4500 25 (34)
4.1.2 Smoothnessof Operation l}{-lX (32-40) 26S0 59 (SO)
Stem threads, stem nuts and other working 1}{ (32) 4500 30 (40) ('
components outside the fluid area should be 2-4 (50-100) 26S0 S2 (111)
lubricated frequently (at least once every six
months). Specific lubricants and frequency of 1~-2 (40-50) 4500 59 (SO)
application are shown in Table 4.2. Valves should 2~-4 (65-100) 4500 S2 (111)
be opened and closed at least once a month.
Note: For other packing materials and/or valve
IMPORTANT: Excessive handwheel effort can sizes, contact the Velan Service Department
indicate the following: at the Head Office.
a) Improperly lubricated or damaged valve
stem. 4.1.3 SeatTightnessand ClosingTorques
b) Valve packing compression too tight (see
Table 4.1.2 for torque values). Even a new valve with seating faces lapped to (
perfection and a full seat-disc contact will be
c) Faulty or damaged valve parts.
pressure-tight only if sufficient stem load is
applied. The minimum stem load for each size of
valve varies with operating pressure, but should
be known by the operating personnel in order to
seat the valve properly. Over-torquing up to 25%
will not damage the valve. (
4.2 RECOMMENDED LUBRICATION
Table 4.2 Recommended lubrication
ApPLICATION FREQUENCY

Stem Exxon: Ronex MP, Castrol MP Directly to When threads

threads or equivalent MP group (up to 6500F) threads appear dry
Ronex Extra duty 2 (above 650oF)

Yoke nut Exxon: Ronex MP, Castrol MP Inject through Concurrently

or equivalent MP group (up to 6500F) grease fitting with stem
Ronex Extra duty 2 (above 650oF) at hub of yoke thread lubrication

Spline Sure Turn Directly to At valve

bushing No. 1548016 threads assembly

All threaded parts - Anti-seize compound No. 425-A Thin coat on On valve
except (Crane) or equivalent threads assembly only
stem and yoke nut - Nickel Anti-Seize to MIL-A-90TE
or MOLYKOTE P37

Recommended lubricant subject to change without notice.

8
GENERAL MAINTENANCE IV

( 4.3 PACKING CHAMBER LEAKAGE 4.4 DISC REFINISHING

If the valve is leaking around the stem and/or Minor damage can be repaired by machining
around the outside diameter of the split gland the disc.
bushing in the back seated position, the valve
Clean the surface, then chuck the stem-disc
needs to be disassembled and the stem and/or
assembly in a lathe and center the disc on the
stellite backseat must be refinished or replaced.
circular guides. See the diagrams at right for disc
refinishing angles. Do not remove more than the
If the valve is leaking around the stem and/or
amounts shown in Table4.4.
around the outside diameter of the split gland
bushing in the partially open position, tighten the The disc is now ready for final lapping with seat
gland bolting. If this does not stop the leakage, (see page 10 &11).
proceed with Steps 1 through 5, as follows:
Ii"',
'"1;'
STEP 1 -
NOTE: If the disc is severely damaged, it
should be replaced.

Release line pressure and remove handwheel

assembly, packing flange. See Disassembly 4.4.1 Angle for Disc Refinishing
procedure on page 15 &17 according to valve type.

STEP 2
Examine valve stem and packing chamber bore
for grooves and scratches. Clean and smooth
surfaces. Polish stems that may have scratches up
to .005" (0.13 mm) deep with extrafine emery
cloth. Otherwise replace stem.

STEP 3
Reinstall stem/disc assembly. Follow reassembly
procedures on pages 16 &18 according to valve
type to complete repacking and to complete
reassembly.

NOTE: Velan recommends use of

precompressed packing.
Figure 4.4A Stop check disc

Figure 4.48 Standard globe disc and

flow control needle disc

9
IV GENERAL MAINTENANCE

Disc refinishing 3. Use a portable vacuum cleaner to remove

(
Table 4.4
removal allowances loose chips. The valve is now ready for
seat-disc lapping
VALVE SIZE
in (mm)
(8-20) .020 (0.5)
1-4 (25-100) .030 (0.75)

4.5 SEAT REFINISHING

1. Disassemble valve (see page 15 & 17). Select
the proper head for the seat refinishing tool.
Minor damage can be repaired with the (
lapping head, but use the cutting head first
if there is severe damage. Remove the screw
on the end of the tool with a small Allen key,
position the cutting or lapping head and
tighten the screw.
NOTES:
a) If valve is not in an upright position, use the
yoke bushing to hold the tool in place. Figure 4.5 Using the seat refinishing tool
b) Total angle for seat (stop check disc)
refinishing 60°
c) Total angle for seat (standard globe and (
needle disc) refinishing 30° 4.6 SEAT-DISC LAPPING
2. Use an air motor for cutting and lapping if you
have one. Place the air motor adapter on the After seat refinishing or when a new or
reconditioned disc is used, the disc and the seat
end of the tool. If you don't have an air motor,
should be lapped together to create a perfect
you can use a ratchet and socket wrench, but sealing contact. Seat-disc lapping can also be
the repair will take longer. used to eliminate minor seat and/or disc damage.
(
If You are Using the Cutting Head Use an air motor for lapping if you have one.
Placethe air motor adapter on the end of the tool.
Insert the seat refinishing tool into the valve
If you don't have an air motor, you can use a
bore. Rotate the tool using either a socket ratchet and socket wrench, but the repair will take
wrench or an air motor while applying longer.
pressure on the tool. Remove the tool and
1. The valve should be completely disassembled
inspect the seat area. Repeat if necessary.
including the packing rings, backseat and
spline bushing.
If you are using the lapping head
NOTE: For Y type valves only, slip an O-ring
Lightly coat the lapping tool head with over the end of the stem and into the groove
medium coarse lapping compound. Insert the between the disc and the stem to prevent the
seat refinishing tool into the valve bore. disc from rotating during lapping.
Rotate the tool using either a socket wrench or
an air motor while applying pressure on the 2. Apply a small amount of lapping compound
tool. Remove the tool and inspect the seat to the disc contact face. Insert the stem in
area. Repeat if necessary. When all visible the body.
damage is removed, clean off all coarse 3. Use the stem holder to center the stem for the
compound grit and finish lapping the seat with lapping operation. Use the stem, without any (
fine lapping compound. backseat or other parts on it. Slip the stem
holder over the stem and down into the body,

(4-J
10
GENERAL MAINTENANCE IV

threaded end down. Screw the stem holder

into the body using the crowned end of the
tube wrench/packing remover. Put a metal bar
through the holes in the upper end of the tube
wrench/packing remover and screw down the
stem holder lightly until it bottoms.
4. Rotate the stem with an air motor or socket
wrench, applying pressure to the stem.
Remove stem and check periodically. When
the seating faces are perfectly smooth, clean
them with acetone or equivalent. The valve is
now ready for reassembly.

Figure 4.6 Using a socket wrench

for seat-disc lapping

4.7 TOOLS
v Y-pattern bonnetless globe valve tool kits are
available for all valve types and sizes.
Tool kit numbers as well as item numbers for
individual tools are shown in Table 4.7.

Table 4.7 Y-Pattern tool kits and tool part numbers TK976 & TK576
all sizes and all classes (2680, 4500)

1(,(.

11
IV GENERAL MAINTENANCE

(
Cutting --..-,
head

LapPing~
head .....,

Figure 4.7A Seat refinishing tool with interchangeable heads (

Hollow
cap screw
.~---
Ij!. ... j

Figure 4.70
Torque wrench
Figure 4.7C Stem holder adapter
(
Figure 4.78
Stem removal tool
for ~ -% "valves

Crowned end (

~"'-cuttingend

Figure 4.7E: Tube wrench / packing remover

4.7.1 Other Tools

Other tools and materials you should have ready - acetone or equivalent
before beginning repairs on these valves:
- air motor or set of ratchet with socket wrenches
- large screwdriver
- coarse and fine lapping compound
- hammer or mallet
- lathe
- torque wrench
- set of Allen keys

f4S
12
V-PATTERN BONNETLESS GLOBE VALVES V

(( 5.1 Z TYPE Y-PATTERN BONNETLESS GLOBE VALVE

AP RING

INDICATOR

DUST COVER

SNAP RING

NAME PLATE

THRUST BEARI

NOTE: Live-loading
available, see page 14.
STEM
PACKING
FLANGE

SPLIT GLAND
BUSHING OUiCK & EASY DISASSEMBLY
NO WElDS TO REMOVE

PACKING RING

GLAND NUT

BACKSEAT

HOLDER

SEAT

BODY

13
V Y-PATTERN BONNETLESS GLOBE VALVES

5.2 Y TYPE Y-PATTERN BONNETLESS GLOBE VALVE (

HANDWHEEL

TACK WELD

YOKE BUSHING (

I NOTE: Live-loading available. I

PACKING FLANGE
GUIDE BUSHING (
SPLIT GLAND
HING DISC SPRING
"BELLEVILLE
WASHERS"

PACKING RING

WASHER
(

BACKSEAT RETAINER

BACKSEAT

HOLDER

SEAT

BODY

14
Y-PATTERN BONNETLESS GLOBE VALVES V

5.3 DISASSEMBLY - Z TYPE

IMPORTANT: Release line pressure. (if unable to
unscrew the
1. Remove packing gland nuts and studs,
stem this way,
loosening both sides equally. If valve is fitted
see Emergency
with live-loading, remove guide bushing and
Procedure).
spring washers (Belleville washers). Raise
packing flange and remove split For V4- 3/4" valves:
gland bushing. Screw stem removal tool
on the end of the stem
2. With the tip of a screwdriver,
until it bottoms, then back
bend the square end of the
off two turns. Use an
tab washer up and the
adjustable wrench to
curved end down to free
tighten the hollow cap
the yoke bushing.
screw against the stem.
Continue the same
procedure as for
1- 4" valves. Figure 5.3C
WARNING: Do not apply
the full force of a wrench,
on stem square.

c 3.
Figure5.3A
Make sure the valve is almost closed, but not
tight on the seat. Use a crescent wrench to
unscrew the yoke bushing counterclockwise
EMERGENCYPROCEDURE:
If the stem absolutely refuses to unscrew
(with the handwheel still attached). Should the using the torques specified, proceed as
yoke bushing bind, close the valve a little. follows:
Continue to unscrew the yoke bushing 1. Use the cutting end of the tube
counterclockwise. wrench/packing remover to remove
4. Remove handwheel assembly and yoke packing.
bushing.
5. Grip stem protector (or position indicator) and 2. Use the packing washerhooks to fish
push it up to force the thrust bearings and out the packing washer under the
stem protector up and out of the body. packing.
6. For 1- 4" valves: 3. Insert the crowned end of the tube
While holding stem in the backseat wrench/packing remover in valve body.
position, apply an adjustable Use a metal bar through the top holes
wrench to the square end of the of the tube wrench/packing remover to
stem. Turncounter clockwise
unscrew the spline bushing counter
until spline bushing (and the
clockwise.
packing above it)
is completely free. NOTE: Velan recommends the use of
Do not exceed 150% tool kits listed on page 11 & 12 for the
of torques shown best maintenance results.
in Table 5.3 (page 16).
Pull out stem/disc
assembly
complete
with packings.

Figure 5.38

15
V Y-PATTERN BONNETLESS GLOBE VALVES

(
Table 5.3 Recommended spline bushing continue to tighten until torque value shown
or backseat retainer torques in Table 5.3 is obtained.
TORQUES NOTE: Velan recommends the use of the
lh-ft (N·m)
tool kits listed on page 11 and 12 for the best
X-% (8-20) 2680 maintenance results.
60 (80)
X-~ (8-15) 4500 5. Insert packing washer, chamfered edge down.
(25) 2680 Then insert the set of precompressed packing
120 (160) rings one at a time, beginning and ending
%-lX (20-32) 4500 with the braided rings.
lX-l~ (32-40) 2680 NOTE: Velan recommends the use of
150 (200)
1~-2 (40-50) 4500 precompressed packing rings.

2-4 (50-100) 2680

6. Slip split gland bushing under packing flange, (
180 (245) one half at a time, chamfered edge up.
2~-4 (65:-100) 4500 Lubricate gland studs with anti-seize
compound, pass them through packing flange
and thread on the gland nuts, tightening both
5.4 REASSEMBLY - Z TYPE sides equally
(hand-tight).
1. Slip backseat onto stem, chamfered edge
For live-loaded
down. Then slide spline bush-ing onto stem,
valves reinstall
crowned edge up.
the disc springs
2. Lubricate spline bushing threads (see and guide bushings
Table 4.2 for recommended lubricants).
Place packing flange under yoke, flat side up.
onto the studs
tightening both
(
Insert stem assembly through packing flange sides equally
and into body. (hand-tight).
3. Thread in spline bushing a few turns, then pull
up firmly on stem with one hand while using NOTE:
an adjustable wrench to continue tightening The gland
the spline bushing. bushing should
clockwise against the engage into Figure 5.48 (
backseat. If spline the body by
bushing does not W' (3 mm) min.
engage easily,
insert crowned end
of the tube wrench 7. Place stem protector (or position indicator)
/packing remover inside yoke and push down over stem with
to engage the crowned end of the tube wrench/packing
spline bushing remover. Drop in one set of thrust bearings
threads into (washer - bearing - washer).
the body.
If Handwheel, Stem Nut and Yoke Bushing
Figure5.4A are Disassembled:
Install upper thrust bearing (washer - bearing -
4. Insert the tube wrench/packing remover into washer) on stem nut. Lightly press yoke
the body over the stem, crowned end down. bushing over bearing (threaded side down
Insert a metal bar through the holes in the towards bearing). Install key and handwheel
tube wrench/packing remover and start to with nameplate. Secure with snap ring to
tighten the spline bushing. Then place torque
wrench adaptor into the tube wrench/packing
hold handwheel in stem nut. (
remover. Align holes to insert a round bar
through both parts. Use a torque wrench and

16
V-PATTERN BONNETLESS GLOBE VALVES V

5.5 DISASSEMBLY - Y TYPE

IMPORTANT: Release line pressure.
1. Remove handwheel nut and handwheel.
2. Remove packing gland nuts and studs,
loosening both sides equally. If valve is fitted
with live-loading, remove guide bushing and
spring washers (Belleville washers). Raise
packing flange and remove split gland bushing.
3. Grind off tack weld between yoke bushing
and yoke.
4. Make sure the valve is almost closed, but not
(~ tight on the seat. Use a crescent wrench to
unscrew the yoke bushing counterclockwise.
Should the yoke bushing bind, put handwheel
Figure 5.4C on stem and close the valve a little. Continue
to unscrew the yoke bushing counter
If Handwheel, Stem Nut and Yoke Bushing are clockwise. Remove handwheel and yoke
Assembled: bushing.
Set tab washer in place on yoke. Lubricate 5. Place tube wrench/packing remover with the
yoke and stem threads (refer to Table 4.2). cutting edge first over stem and into the
Screw counterclockwise the handwheel packing chamber. Place guide bushing into

c assembly onto stem about half-way. Then

begin tightening yoke bushing clockwise into
top of valve. Should the yoke bushing bind,
it's because the stem has pushed the disc
top of valve. Place the torque wrench adaptor
onto the crowned end of the tube wrench/
packing remover and secure with set screw.
Using the hex drive on the torque wrench
against the seat. Correct this by backing off the adaptor, turn in a clockwise direction while
handwheel slightly and continue tightening by pushing down. This will pick up the packings
hand. Finish tightening with a large crescent within the spiral flutes of the tube
wrench, holding tab washer in position against wrench/packing remover. Pull up the tool and
flat spot on yoke. Press square tab down with . remove packings within the spiral flutes. Re-
tip of screwdriver. On the opposite side, press insert tool to remove any remaining packings.
rounded edge up against yoke bushing. After complete removal of packing, remove
8. Continue tightening packing nuts or guide guide bushing, torque wrench adaptor and
bushing for live-loaded valves with a crescent tube wrench/packing remover. Using two
wrench. Install the crescent key on the torque packing washer hooks, insert them into the
wrench and finish tightening the nuts to the packing washer holes and pull it up over the
torques shown in Table 4.1.2. stem.
6. Insert the crowned end of the tube
wrench/packing remover in valve body. Use a
metal bar through the top holes of the tube
wrench/packing remover to unscrew the
backseat retainer counterclockwise. Remove
stem/disc assembly. the valve is now ready
for servicing.

17
V V-PATTERN BONNETLESS GLOBE VALVES

(
5.6 REASSEMBLY - Y TYPE
1. Slip backseat onto stem, chamfered edge 8. Continue tightening packing nuts or guide
down. Lubricate backseat retainer threads bushing for live-loaded valves with a crescent
(see Table 4.2). Then slide backseat retainer wrench. Install the crescent key on the torque
onto stem, crowned edge up. wrench and finish tightening the nuts to the
2. Place packing flange under yoke, flat side up. torques shown in Table 4.1.2.
Insert stem assembly through packing flange
and into body.
3. Thread in backseat retainer, then use the
crowned end of the tube wrench/packing
remover to tighten the backseat retainer
clockwise against the backseat. (
4. Then place torque wrench adaptor into the
tube wrench/packing remover. Align holes to
insert a round bar through both parts. Use a
torque wrench and continue to tighten until
torque value shown in Table 5.3 is obtained.
NOTE: Velan recommends the use of the tool
kits listed on page 11 and 12 for the best
maintenance results.
5. Insert packing washer, chamfered edge down.
Then insert the set of precompressed packing
rings one at a time, beginning and ending with (
the braided rings. Use the crowned end of the
tube wrench/packing remover to tap the rings
into place.
NOTE: If uncompressed packing is used,
the braided rings must be precompressed
individually.
6. Slip split gland bushing under packing flange,
(
one half at a time, chamfered edge up.
Lubricate gland studs with anti-seize
compound, pass them through packing flange
and thread on the gland nuts, tightening both
sides equally (hand-tight). For live-loaded
valves reinstall the disc springs and guide
bushings onto the studs tightening both sides
equally (hand-tight).
NOTE: The gland bushing should engage into
the body by Va" (3 mm) min.
7. Screw on yoke bushing clockwise, using a
large crescent wrench. Should the yoke
bushinq bind, it's because the stem has
bottomed on the seat. Correct this by backing
off the handwheel slightly. Secure yoke
bushing to yoke with tack weld.
(

18
TERMS AND CONDITIONS OF SALE

( CONTRACT: Orders are subject to acceptance by

the Velan Companies hereinafter referred to as the
costs comparable to Seller's normal
manufacturing costs those parts proven defective,
seller. No terms or conditions of Purchaser's order or (iii) in discharge of Seller's maximum liability
contrary to the Seller's terms and condition shall herewith, refunding all monies paid by Purchaser
be binding upon the Seller unless specifically to Seller for the Product and, at discretion of
agreed to by the Seller in writing. Seller, having the product removed and returned
MINIMUM ORDERCHARGE: $500.00 net. to Seller at Purchaser'S expense. All transportation
charges relative to corrective work, defective parts
PRICES: All quoted prices are subject to change by
or replacement parts shall be borne by Purchaser.
the seller without prior notice and, unless
Purchaser shall give Seller immediate notice upon
otherwise stipulated by Seller, are understood to
discovery of any defect. The undertaking of repairs
be F.O.B. Seller's plant, with delivery to carrier
or replacements by Purchaser or its agents
constituting delivery to purchaser. Right to
without Seller's written consent shall relieve seller
possession of the material to secure the payment
of the purchase price shall remain in Seller until all of all responsibility herewith.
payments therefore shall have been fully made. Finished materials and accessories purchased
For the protection of the Purchaser and the Seller, from other manufacturers are warranted only to
verbal customer orders must be confirmed by a the extent of the manufacturer's warranty to
formal written purchase order. If a written Seller.
purchase order is not received within ten days or a Any alteration in material or design of Seller'S
verbal order, product descriptions, quantities, product or component parts thereof by Purchaser
specifications, etc., as set forth in Seller's or others without written authorization by Seller
acknowledgement and invoice shall be conclusive voids all obligations of Seller regarding the product
and binding on both parties. Any order that is and any associated warranty herein stated or
shipped before receipt of confirmation which
implied.
might have been entered incorrectly and would
require remedial action would be for the Seller's sole liability shall be exclusively as set
forth herein, and Seller shall not be liable for any
( Purchaser'S account.
TAXES: All prices are exclusive of taxes. Sales,
incidental or consequential damages due to its
breach of any warranty herein contained, or
use and other taxes, by whomsoever levied, are to
otherwise. Without limitation to the foregoing, in
be paid by the Purchaser, and unless invoiced, are
no event shall Seller be liable for the loss of use of
to be paid by the Purchaser directly to the
the product or of any other product, process,
appropriate governmental agency.
plant, equipment, or facilities of the Purchaser or
DELIVERY: Delivery or shipment specified is end-user whether partially or wholly due to
Seller's best estimate and Seller shall not be liable defects in material and/or workmanship and/or
for delay in deliveries resulting from any cause design of Seller's product, and in no event shall
whatsoever. Failure to ship on or near the Seller be liable for removal of appurtenances or
estimated date shall not entitle Purchaser to cancel incidentals such as connections, pipe work and
his order without charge. similar items of obstruction or for any cost
RETURN OF MATERIALS: Materials may be brought about by the necessity of removing the
returned only with prior written agreement of product from its point of installation.
Seller. Seller makes no warranty of any kind whatsoever,
CANCELLATION: Cancellation of orders may be expressed or implied, other then is specifically
made only with the Seller's written consent and stated herein; and there are no warranties of
Purchaser shall be subject to cancellation charges. merchantability and/or fitness for a particular
PRODUCTWARRANTY: Seller warrants the purpose which exceed the obligations and
equipment of its own manufacture to be free of warranties specifically stated herein.
defects in material and workmanship, under Parts furnished without charge as replacements
normal use and proper operation for a period of for original parts under warranty are warranted for
one year from the date of shipment from Seller's that period of time during which the original parts
plant. Seller's obligation under warranty shall be warranty is effective.
strictly limited, at Seller's option, to: (i) furnishing
replacement parts for or repairing without charge ALL SHIPMENTS WILL BE F.O.B. PLANT LOCA TlON.
( to Purchaser, F.G.B. Seller's plant or (ii) issuing
written authorization for Purchaser or others to
SHIPMENTS WILL BE MADE VIA MOST
ECONOMICAL CARRIERS UNLESS OTHERWISE
replace or repair without charge to Purchaser, at REQUESTED.TERMS: NET 30 DA YS FROM DA TE OF
INVOICE: 1)-2% PER MONTH OF ALL OVERDUE
ACCOUNTS, ALL TAXES EXTRA. PRICESSUBJECT
TO CHANGE WITHOUT NOTICE.
19
(

2-60 50-1500 ASME 150-1500 API 600

X-24 15-600 ASME 150-300

2-24 50-600 ASME B16.34

x- 24 8-600 ASME 150-600

1000-2000 WOG
ASME B16.34

2-36 50-900 150 psi

(
15-300
15-300 ASME 150-2500 ASME B16.34

ASME 150-2500

SALES OFFICES MANUFACTURING PLANTS

U.S.A. CANADA EUROPE INDIA U.S.A. CANADA
BillHannonl Don Bowers Charles Pogue I Paul Dian I John Smithl Brian Hall S.Giridhar VELAN VALVE VELANINC.
94 Avenue C
Williston. VT 05495-9732
Tel: (802) 864-3350
B. Lawson I T. Harfield I
M. Tilley
730 N. Post Oak Road
Jacques Godboutl
Woody Bowler
7007 Cote de liesse
VELANENGINEERING
CO.LTD.
Cambridge Rd.,
Block A·l, Flat 604
Glaxo Apartments
Mayur Vihar-PH-l
CORPORATION
94 Avenue C
Williston, VT 05495-9732
7007 Cote de liesse
Montreal, oc H4T 1G2
Tel: (514) 748-7743
(
Fax: (802) 865-3030 Suite 311 Montreal, QC H4T 1G2 Whetstone Delhi-110091 Tel: (802)863-2562 Fax: (514) 748-8635
Houston, TX 77024 Tel: (514)748-7743 Leicester LE86LH TeVFax: 91-11-271-2196 Fax: (802) 862-4014
Ronald J. Harrington VELANINC.
Tel: (713) 682-1084 Fax: (514)748-8635 England Fax: 91-11-225-8799
43 Wyckoff Avenue
Tel: 44-6-275-0206
FRANCE 2125 Ward Avenue
Waldwick, NJ Fax: (713)682-6071 CHINA VELANS.A. Montreal, nc H4M IT6
George S. Lysakowski Fax: 44-6-275-0224
07463·1721 Christopher G. Hiett 871 Kowal Drive Room 4003 01 No. 13 90, rue Challemel Lacour Tel: (514) 748-7743
Tel: (201)670-0995 21931 Harborbreeze Lane Mississauga, ON Gordon Hogben Xiao-Ying Road F 69367 Lyon Cedex 7 Fax: (514) 748-8635
Fax: (201)670-6810 Huntington Beach, L5H3T3 10 Reynolds Way Chao Yang District Tel: (33) 4 78 616700 VELANINC.
CA 92646 Tel: (905)278-7522 Beijing 100101 Fax: (33) 4 78 721218
Paul R. Lee
208 lindbergh Avenue
Tel: (714)965-6277 Fax: (905)278-8155
Croydon, CRO5JW
England Tel: 86-10-64968995
ENGLAND
550 McArthur Ave.
Montreal, ac H4T lX8 (
Fax: (714)965-6737 Tel: 44-181-680-7409 Fax: 86-10-64968997 Tel: (514) 748-7743
Wilmington, DE Bill Patrick VELANENGINEERING
19804-3316
John Flynn 8825,51" Avenue Fax: 44-181-760-1968 JAPAN CO.LTO. Fax: (514) 341-3032
289 Antioch Road Edmonton, AB T6E5H1 Tak Sakamoto Cambridge Rd.,
Tel: (302)994-1176 J.M. Gatard VELANINC.
Lake Lure, NC 28746 Tel: (780)465-1122 4-31-3 Kamimeguro, Whetstone
Fax: (302)994-6156 VELANS.A. 1010 Cowie Street
Tel: (828)625-9441 Fax: (780)465-0403 Meguro-ku
90, rue Challemel Lacour Tokyo 153-0051
Leicester LE86LH Granby, nc J2J lE7
Michael Midgley Fax: (828)625-9437 Tel: 44-6-275-0206
Leo Shewchuk Tel: (450) 378-2305
F 69367 Lyon Cedex 7 Tel: 81.3-3792-1891
3160 Vera Valley Drive
Franklin, TN 37064
Joe Denny 80 Sienna HillsCourt France Fax: 81-3-3792-1891
Fax: 44-6-275-0224 Fax: (450) 378-6865 "-
Tel: (615)599-5910
1638 Estate Circle S.w. Tel: (33)4 78 616700 PORTUGAL PROQUIP
Naperville, IL60565 Calgary, AB T3H 2W3 Fax: (33)4 78 72 1218 VELANVALVULAS 835 Fourth line
Fax: (615)599-6949
Tel: (630) 579-1833 Tel: (403)232-6482
MIDDLEEAST
Cheril Demian INOUSTRIAIS,LOA. Oakville, ON L6L5B8
Larry A. Woodworth Fax: (630)579-1834 Fax: (403)686-6485 Wolfgang Maar Av. Ary dos Santos Tel: (905) 842-1721
Hadayik AI-Obour Bid 134
1343 Paddock Place David Brodnax VELANGmbH Salah Salem Road 1679-018Famoes Fax: (905) 849-0923
Bartlett.IL 60103 503 Comanche Trail MEXICO, Daimlerstrasse 8 Floor #16 Flat #3 lisbon
Tel: (630)736-9395 West Monroe, LA 71291 CENTRAL 0·47877 Willich Cairo, Egypt Tel: (351-21) 934-7800 KOREA
Fax: (630)736-9397 Germany Fax: (351-21) 934-7809 VELANLTD.
Tel.: (318)396-7517 & SOUTH Tel: 00 212-500-4040
B 608-7 Panwollnd.
Tel: (49) 2154/4938-0
Tony Boland
Fax: (318) 396-4995 AMERICA Fax: (49) 2154/4938-99
Fax: 00 202-402-9766 TAIWAN Estate
Frank Keegan Sergio Pensotti VELAN-VALVAC
45 W. Franklin Street P.O. Box 12
Bellbrook, OH 45305 Unit 14, VELAN VALVECORP. SINGAPORE P.O. Box 2020 Ansan City, Kyunggi-do
9007 Highland Road 730 N. Post Oak Road Gary Tan Taichung, Taiwan, R.O.C. Tel: (82) 345-491-2811
Tel: (937)848-2011
Fax: (937)848-2144 Baton Rouge, LA 70810 Suite 311 No.4 Pioneer Place Tel: (04) 2792649 Fax: (82) 345-491-2813
Tel: (225) 767-7965 Houston, TX 77024 Singapore 627 893 Fax: (886) 42750855
Fax: (225) 767-8160 Tel: (713) 682-1837 Tel: (65) 862-0572
Fax: (713) 682-6071 Fax: (65) 862-0573 GENERAL INFORMATION
Tel: (514)748-7743
(
Fax:(514)748-8635
Velan's valve distributors are located worldwide, Web: http://www.velan.com
PRINTED IN CANADA VEl-FBGM-2000
Ie:;)
· VOLUME-12 PIPING, VALVES AND ACCESSORIES Chapter-3

3.4 FORGED STEEL VALVES

@
Contents 12137
(

FORGED STEEL VALVES

MAINTENANCE MANUAL
Bolted Bonnet Gate, Globe, Piston, Ball & Swing Check Valves
Welded Bonnet Gate, Globe and Check Valves .
C ~-2" (8-50 mm)

(
VEL-SFVM -2000
TABLE OF CONTENTS

GENERAL INFORMATION PAGE (

INTRODUCTION 5
1.1 General Introduction 5
1.2 Essential Features of Velan Valves 6

II RECEIVING & PREPARATIONFOR INSTALLATION 7

2.1 Receiving Inspection 7
2.2 Storage 7
2.3 Special Instructions for Gate Valves 7
2.4 Special Instructions for Globe Valves 7
2.5 Special Instructions for Piston, Ball and Swing Check Valves 8

III WARNINGS 10 C
IV GENERAL MAINTENANCE 11
4.1 Operation 11 "'-
4.1.1 General 11
4.1.2 Smoothness of Operation 11
4.1.3 Seat Tightness and Closing Torques 11
4.2 Recommended Lubrication 11

12
V INFORMATION PERTINENTTO GATE, GLOBE AND CHECK VALVES
5.1 Packing Chamber Leakage 12
(
5.1.1 General 12
5.1.2 Packing Ring Removal on line- Use of Backseat.. 12
5.1.3 Repacking with Uncompressed Packings 12
5.1.4 Repacking with Graphite Packing Rings for Valves Without Leak-Off Connection 13
5.1.5 Packing torques 14
5.2 Body-Bonnet Joint Tightness 14 (
5.2.1 General 14
5.2.2 Body-Bonnet Bolt Torquing 14
5.2.3 Torque Procedure 15
5.2.4 Application of Torque 15
5.2.5 Replacement of Spiral Wound Gasket 15

GATE VALVES

VI GATE VALVES 16
6.1 Seat Leakage 16
6.1.1 General 16
6.1.2 Wedge Repairs: Gate Valves 16
6.1.3 Seat Repairs: Gate Valves 16
6.1.4 Fitting of Repaired Parts: Gate Valves 17
6.2 Disassembly of Gate Valves 18
6.2.1 General 18 (
6.2.2 Total Disassembly 18
6.3 Reassembly of Gate Valves 18
6.3.1 General 18

2
TABLE OF CONTENTS

• GLOBE VALVES

VII
7.1 Seat Leakage
7.1.1 General
PAGE

GLOBE VALVES ••••••••••••••••••••••••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••19

19
19
7.1.2 Seat Repairs: Globe Valves 19
7.1.3 Fitting of Repaired Parts: Globe Valves 19
7.2 Disassembly of Globe Valves 20
7.2.1 General 20
7.2.2 Total Disassembly 20
7.3 Reassembly of Globe Valves 20
7.3.1 General 20

CHECK VALVES

VIII CHECK VALVES ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••21

8.1 Seat Leakage 21
8.1.1 General 21
8.1.2 Seat Repairs: Piston and Ball Check Valves 21
8.1.3 Seat Repairs: Swing Check Valves 21
8.1.4 Fitting of Repaired Parts: Piston Check Valves 21
8.1.5 Supplementary Instructions for Soft-Seated Piston Check Valves 21
8.1.6 Fitting of Repaired Parts: Swing Check Valves 22
8.2 Disassembly of Check Valves 22
8.2.1 General 22
8.2.2 Disassembly of Small Bolted Cover Piston and Ball Check Valves 22
8.2.3 Disassembly of Swing Check Valves 24
8.3 Reassembly of Check Valves 24
8.3.1 General 24
8.3.2 Reassembly of Piston and Ball Check Valves 24
8.3.3 Reassembly of Swing Check Valves 24

WELDED BONNET VALVES

IX WELDED BONNET VALVES •••••••.••.•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••25

9.1 Welded Bonnet Gate, Globe and Check Valves 25
9.1.1 Disassembly 25
9.1.2 Reassembly 25

TERMS AND CONDITIONS OF SALE 27

3
LIST OF FIGURES AND TABLES

FIGURES NUMBER PAGE (

Bolt tightening sequence . 5.28 15
Bolted bonnet gate valve . 2.3 7
Bolted bonnet globe valve . 2.4 8
Bolted cover piston check valve . 2.5A 9
Bolted cover piston check valve exploded view . B.2A 23
Bolted cover swing check valve . 2.58 9
Bolted cover ball check valve exploded view . B.28 23
Braided graphite packing ring . 5.18 12
Check valve: angle of incline and roll angle . 2.5C 9
CTFE or PTFE disc-swaged seat . B.18 22
Gasket recess . 5.2A 14 (
Gate valve wedge . B.18 17
Graphite ribbon packing . 5.1A 12
Insert braided end ring, followed by intermediate ring . 5.1E 13
Lantern ring configuration . 5.10 12
Packings installed . 5.1G 13
Piston disc with replaceable CTFE or PTFE soft seat . B.1C 22
Piston disc with replaceable EPDM soft seat . B.1A 22
Repacking with split packing adaptor . 5.1F 13
(
Six packings shown . 5.1C 12
Stem disc contact area . 7.1A 19
Welded bonnet gate valve . 9.1C 26
Welded bonnet globe valve . 9.18 26
Welded cover piston check . 9.1A 25 (
Wedge seating face . B.1A 17

TABLES . NUMBER PAGE

Locking nut torques . B.1 22

Packing flange nut torques for gate or globe valves
(graphite ribbon or PTFE packing) . 4.1.2 11
Recommended lubrication . 4.2 11
Torque values (100%) for body-bonnet bolting . 5.2 15

4
INTRODUCTION

( 1.1 GENERAL INTRODUCTION

hiS manual has been prepared by Velan

T
engineerS, designerS and maintenance
personnel to assist you in obtaining many years
of satisfactory service from your forged steel valves,
It will also assist you in restoring your valve to the
best working condition with a minimum of time
and expense.
Velanvalves are designed and manufactured based
on many years of research and product development
c and are constantly being improved. Before beginning
any major work, we recommend that yOUread this
booklet carefully at least once to understand the
valve's physical condition.
Pleasenote that if you do not understand the reason
for the service problem, we Suggest that you get in
touch with your local Velan representative or call the
customer Service Manager for technical assistance.

Before beginning any major work, we recommend

that yOUcarefully check the nameplate on the valve
and record the figure number to identify the type and
size of valve. See the 'Essential Features of Velan
Valves' form on the following page for an explanation
of Velan "Figure Numbers".

5
INTRODUCTION

1.2 ESSENTIAL FEATURES OF VELAN VALVES

(
Gate, Globe and Check Valves
Typeof Connection Size of connection Class Type Body/Bonnet Style Body Material Trim Material

• • • • • ••
0 E F G

•• ••
A B C
D
F 0 8 2 0 7 4 B 1 3 M S

01 - Flow control 06 - Full port gate 10 - Continuous 15 - Instrument 21 - Boiler blowoff 34 - Tilting disc check
02- Ball check 07 - Stop globe blowdown 17 - IREBgate 22 - Pressure relief 99- Special
03 - Piston check 08 - Stop check 11 - Swing check 18 - Extended body gate 23- Double disc gate
05 - Conventional port gate 09 - Needle

A- Special R - Forged bolted T - Allwelded bellows seal

4- Vertical 7- Y-pattem
B - Bolted bonnet (forged) bonnet bellows seal W - Welded bonnet
5- Angle (45'inclinedtwo-piece)
8 - Elbowdown)
o- Diaphragm S - Y-pattern bellows seal Y - Bonnetless (rotating stem)
6 - Y-pattem(inclined E - Extended bonnet (cryogenic) (non-rotating stem) Z - Bonnetless (non-rotating stem)

01- Special 09 - Chr. moly, F9, C12 14 - Stainless steel, F316L, CF3M 20- Inconel 25- LCB 31- LCC 35- 254SMO
02- Al05,WCB 10 - Stainless steel, F316HJF316111 15 - Stainless steel, F347, CF8C 21 - Hastelloy 26 - LF2 32- Duplex 36- F321 H
04 -
05 -
Chr. moly, F5, C5
Chr. moly, Fl', WC6
11-
12 -
Stainless
Stainless
steel,
steel,
F304, CF8
F304L, CF3
16 -
18 -
Stainless
Stainless
steel,
steel,
F304H
F321
22 -
23-
Titanium
Alloy 20
27 -
28 -
LF3JLC3
F317
stainless
steel F51
37 - Incoloy
(
06 - Chr. moly, F22, WC9 13 - Stainless steel, F316111, CF8M 19- Monel 24- LFI 29- F317L 34- F91

If IMaterial Code ·,0· F316H/F316 has a minimum carbon content of 0.04 and is to be used if temperatures are over 1000'F 1538"CJ. Forged F316,
Material Code ·,3·,
is not suitable for temperatures above 1000'F 1538"CJas it is dual certified IF316/F316LJ.
(ZJ Base material may be same as body or same as trim at manufacturer's option.
(31 NA, NB and NC trims are for NACE service and are supplied with bolting with maximum hardness of Rc. ZZ. NS code is used for special NACE trim
and details must be specified on order.

Valve
Standard
Packed
Gate or globe Add a one-digit suffix to the figure number:
0- for live-loading, double packing and leak-off
Example: W05-3054B-{)2TY-0 is IN 1500 class
carbon steel bolted bonnet gate valve
(
Valves 2 - for live-loading only with TY trim, live-loading, double packing
3 - for double packing and leak-off and leak-off.

6
RECEIVING & PREPARATION FOR INSTALLATION II

( 2.1 RECEIVING INSPECTION

All valves must be examined for signs of damage
that may have occured during transportation. Any
damage should by analyzed and a report should be
issued. Serious damage should be reported to
your local Velan representative or to the Customer
Service Department so that a suitable arrangement
for repairs can be made without delay.

2.2 STORAGE
Valves can be stored at any temperature in a
sheltered area but must be protected from
contamination by dirt or the elements. The valve
is shipped with end protectors on the inlet and
outlet which should stay in place until the valve is h__---,05
ready to be installed. Before installation, the end
protectors must be removed and connections
@
must be checked for cleanliness. Visible foreign ~==~==~~6
matter must be removed from end connections of
weld-end valves. The weld end must be cleaned
with a suitable solvent, such as acetone or alcohol.
Do not use bearing solvents containing fluoride
(, or chloride.

2.3 SPECIAL INSTRUCTIONS FOR GATE

VALVES
PARTS DESCRIPTION
The flow through gate valves can be from either 01 - Body 16 - Glandnut
... end. The preferred orientation of a gate valve 02 - Bonnet 19 - Spiral wound gasket
04 -Stem 71 - Yokebushing
• is upright. The valve may be installed in other
05 -Wedge 30 - Handwheel nut
orientations, but any deviation from the vertical 09 - Seat 33 - Handwheel
is a compromise. Installation upside down is not 11 - Packingflange 56 - Capscrew or stud andnut
recommended because of possible dirt build-up 12 - Gland bushing 51 -Washer
in the bonnet. 13 - Packing ring 66 - Nameplate
15 - Gland stud 88 - Stem nut

2.4 SPECIAL INSTRUCTIONS FOR Figure 2.3 Bolted bonnet gate valve
GLOBE VALVES
Globe valves are usually installed with the inlet CAUTION: Gate valves should be
below the valve seat (Fig. 2.4). This should be installed and welded into the pipeline with
verified to prevent incorrect installation. For wedge in the fully closed position. If the
particularly severe throttling service, it is valve is left wholly or partially open, the
recommended that the valve be installed so valve could distort and leak during
that the flow enters over the top of the seat and operation. Also, leaving the valve in a fully
goes down through it. This maintains the valve closed position helps prevent weld spatter
in a more stable condition, minimizes wear and from falling directly onto the mating
reduces the potential noise level. Valve operation
surfaces of the seats.
is also easier because reduced torque is required
to close the valve.

!b 0 7
II RECEIVING & PREPARATION FOR INSTALLATION

2.5 SPECIAL INSTRUCTIONS FOR PISTON

(
CHECK, BALL & SWING CHECK VALVES
Piston, ball and swing checkvalves must be
installed with the inlet in the direction of the arrow,
as shown in Fig. 2.5A and 2.58. This should be
verified before installing the valve. Placing a
piston, ball and swing checkvalve inlet opposite
the direction of flow prevents the disc (ball) from
lifting and therefore prevents normal operation of
the valve.

All piston and ball check valves should be installed

in a horizontal pipe run with the cover up, and the
angle of incline of the line should be no more than
(
45' from horizontal. Also, the roll angle of the
valve cover should be no more than 45' from side
to side (Fig.2.5C). For vertical flow condition,
please consult the Velan Customer Service
Department. Swing check valves should be
installed in an horizontal, inclined or vertical
position. The roll angle of the valve cover should
be no more than 45' from side to side (Fig.2.5C).
NOTE: All check valves should be installed at
least ten pipe diameters away from upstream
pumps, elbows, fittings or equipment. If closer
(
installation is required, please consult the
Velan Customer Service Department.
WARNING: Soft-seated piston and swing
PARTS DESCRIPTION
check valves should not be welded into the
01 - Body 16 - Glandnut pipeline with the soft-seated disc in the valve.
02 - Bonnet 19 - Spiral wound gasket
04 - Stem 27 - Yokebushing
The disc must be removed and reinstalled after (
06 - Disc 30 - Handwheel nut the valve is welded into the pipeline. '
11 - Packing flange 33 - Handwheel
12 - Glandbushing 56 - Capscrew or stud and nut
13 - Packing ring 57 -Washer
15 - Glandstud 66 - Nameplate

Figure 2.4 Bolted bonnet globe valve

CAUTION: Globe valves should be installed

and welded into the pipeline with the disc in
a fully closed position to prevent damage to
the valve during installation. Also, leaving
the disc in a fully closed position helps
prevent weld spatter from falling directly
onto the mating faces of the seat and disc.
Globe valves with soft-seated disc must be
in the open position prior to welding into
the pipeline. Installation upside down is (
not recommended because of possible dirt
build-up in the bonnet.

8
RECEIVING & PREPARATION FOR INSTALLATION II

Swing Check
, 90° Max.

c
PARTS DESCRIPTION
, >~ / r-- .....
V Piston, Ball & Swing Check
45° Max.
01 - Body 50 - Cover
06 - Disc 5& - Capscrew or stud and nut
19 - Spiral wound gasket &6 - Nameplate
I /" V )
46 - Spring 67 - Rivet (or tack weld)

Figure 2.5A Bolted cover piston check valve

Figure 2.5C Check valve: angle of incline

and roll angle

PARTS DESCRIPTION
01 - Body 54 - Hingepin
08 - Disc 5& - Capscrew or stud and nut
09 - Seat 61 - Pin
19 - Gasket &6 - Nameplate
50 - Cover n -Seat insert
51 - Hanger 90 - Coverextension

Figure 2.58 Bolted cover swing check valve

III WARNINGS

FOR SAFETY REASONS,

it is important to take these precautions
C" Personnel making any adjustments on the valvesshould
wear safety equipment normally used to work with fluid in
(
the line where the valve is installed.

C" Before removing the yoke nut under pressure, the valve should be in fully open
position in order to prevent injuries.

C" Before removing a valve from a line, line pressure must be relieved with no exception.

C" Velanvalves can be equipped with a variety of manual gear, electric motor, hydraulic
or pneumatic actuators. Generally,all pressure must be relieved from both sides of
the valve before the actuator is removed.

C" A valve in the fully open position (backseated),should not be jammed-tight

(over-torqued), to avoid thermal binding. It is our recommendation that the valve
be removed 1/4 turn of the handwheel from the fully open position. This will also
ensure that packing tightness is verifiable. In gear-operated valves, becauseof
the backlash, it is difficult sometimes to ensure this position.

C.. Valvestandards, such asAPI and MSS, caution users that successfulcompletion
of a backseattest should not be construed as a recommendation by the
(
manufacturer that a valve may be repacked while it is under pressure.
The backseatmay be used as a means of stopping or
reducing packing leakageuntil the packing can be
replaced under no pressure. Removal of
packing with the valve under pressure is
at the owner's risk.

10
GENERAL MAINTENANCE IV

{ 4.1 OPERATION IMPORTANT: Excessive handwheel effort can

indicate the following:
4.1.1 General 1. Improperly lubricated or damaged valve stem.
2. Valve packing compression too tight
All valves should be checked before being put into (see Table 4.1.2 for torques).
operation and should be inspected regularly during 3. Faulty or damaged valve parts.
operation. Prompt attention should be paid when
trouble arises. As a general rule, valves should be 4.1.3 Seat Tightness and Closing Torques
subjected to scheduled maintenance.
Even a new valve with seating faces lapped to
4.1.2 Smoothness of Operation perfection and a full seat-wedge or disc contact
will be pressure-tight only if sufficient stem load
Stem threads, stem nuts and other working is applied. The minimum stem load for each size
components outside the fluid area should be of valve varies with operating pressure in order to
lubricated frequently (at least once every six seat the valve properly. Slight over-torquing will
months). Specific lubricants and frequency of not damage the valve.
application are shown in Table 4.2.
CAUTION: Do not use "cheaters" on the
handwheel.

Table 4.1.2 Packing flange nut torques for gate or globe valves (graphite ribbon or PTFE packing)

« Note:
150-800 85
For other sizes and packing materials, contact the manufacturer.
90

4.2 RECOMMENDED LUBRICATION

Table 4.2 Recommended lubrication
PART • • 4 ••
• • • •
Stem Exxon: Ronex MP, CastroI MP Directly to
threads When threads
or equivalent MP group (up to 650!!F) threads appear dry
Ronex Extra duty 2 (above 650!!F)
Yoke nut Exxon: Ronex MP, Castrol MP Inject through Concurrently
or equivalent MP group (up to 650!!F) grease fitting with stem
Ronex Extra duty 2 (above 650!!F) at hub of yoke thread lubrication
Spline Sure Turn Directly to At valve
bushing No. 1548016 threads .assembly
All threaded parts - Anti-seize compound No. 425-A Thin coat on On valve
except (Crane) or equivalent
((_ stem and yoke nut - Nickel Anti-Seize to MIL-A-90TE
or MOLYKOTEP37
threads assembly only

Recommended lubricant subject to change without notice.

11
V INFORMATION PERTINENT TO GATE, GLOBE AND CHECK VALVES

5.1 PACKING CHAMBER LEAKAGE 5.1.3 Repacking with Uncompressed Packings (

Velan generally uses two types of packings:
5.1.1 General (Fig. 2.3 and 2.4) pre-formed graphite ribbon continuous ring and
braided graphite, or PTFE. The packing procedure
If moisture or dripping occurs around the stem (04)
is basically the same for both types of packing.
or the gland bushing, the following points must be
investigated before removing the packing rings (13).
Before inserting the packing ring (13A), check the
stem (4) and the packing chamber wall to make
CAUTION: For safety reasons, the valve
sure there is no damage. Scratches up to 0.005 in
must be depressurized before removing
(0.13 mm) can be removed by polishing the surface
packing (13) or dismantling gland nuts (16).
with an extra fine emery cloth or by machining
skimcut.
1. Check if the packing flange bolting is torqued to
the correct torque as shown in Table 4.1.2. Graphite ribbon packing may be cut as shown in (
2. Make sure the gland bushing (12) is not binding Fig. 5.1A to facilitate insertion into bonnet chamber.
against the packing chamber wall or stem (04).
If so, open valve to backseat position and firmly
tighten up on backseat. Loosen the gland nuts
(16) and realign the gland bushing (12).
Retighten the packing flange (11) with the gland
nuts (16), a little at a time on each side, then
torque down to the correct torque as shown in
Table 4.1.2. Figure5.1A Figure 5.18
Graphite ribbon Braided graphite
3. After retightening, cycle the valve three to five
packing packing ring
times and retighten gland nuts (16) after each
cycle until fully consolidated to original torque (
value (Table 4.1.2). Slacken the gland nuts (16)
slightly if torque is too high. If steps 1 to 3 do
not stop leakage, proceed with the removal and
Braided__.",__~~~~~~~ x
packing----,..--~ x
replacement of packing rings (13). »»> » .»
~tit~~ite ~~>~>~>~>~~w~~
5.12 Packing Ring Removal on line packings [ >> >
- Use of Backseat »» » » (
Braided-.~~~m§§~~
packing ~
For safety reasons, follow warning instructions in
Section 11/ before replacing packing rings on line.
The valve must be depressurized. Figure 5.1C Six packings shown

1. Remove the top gland nuts (16).

2. Lift packing flange (11) and gland bushing (12)
up as high as possible and secure.
3. Remove old packing rings (13). Care must be
taken not to scratch the stem (4) or the wall of

4.
the packing chamber during removal of the
packing rings (13).
If the valve is equipped with a leak-off pipe,
o +-
Lantern
ring

there is a lantern ring below the top packing

rings. To remove the lantern ring, insert two
hooks into the holes at the top of the
lantern ring.
5. After the lantern ring is lifted, the last packing
(
rings can be removed using the procedure
described in Step 3. Figure 5.10 Lantern ring configuration

12
INFORMATION PERTINENTIO GATE, GLOBE AND CHECK VALVES V

«( 5.1.4 Repacking with Graphite Packing Rings for

Valves Without Leak-Off Connection
1. Insert the first packing ring (13A) (braided
graphite type end ring) manually and place
as deep into the packing chamber as possible
followed by 1 graphite ribbon (138) (inter-
mediate packing ring). Refer to Fig. 5. 1E.
2. Insert the split packing adaptor. Push the
packing rings to the bottom of the chamber,
making sure that the lap joint is not reversed
during the operation.
3. Place the gland bushing and packing flange into
position (Fig. 5. 1F) and compress the bottom
packing by tightening the nuts to 130% ofthe
torque_value shown in Table 4.1.2.
NOTE: Ensure gland bolts/nuts are well
lubricated with anti-seize compound.
4. Remove the nuts and split packing adaptors,
insert the next graphite ribbon packing and
PARTS DESCRIPTION
repeat the procedure above until all
02 - Bonnet 13A - Packing ring (braided)
intermediate graphite ribbon packings have 04 - Stem 138 - Packingring (die-formed)
been torqued. 11 - Packing flange 15 - Stud
12 - Gland bushing 16 - Nut
NOTE: For Packings with split joints
(1) The split lap joints of each consecutive ring
Figure 5.1F Repacking with split packing
adaptor
must be staggered at 120· so that the fourth
ring installed has its lap back at the starting
point (Fig.5.1G).

«(

PARTS DESCRIPTION
PARTS DESCRIPTION
02 - Bonnet 13A - Packingring (braided)
02 - Bonnet 12 - Glandbushing 138 - Packingring (die-formed)
04 - Stem
04 - Stem 13A - Packing ring (braided) 11 - Packing flange 15 - Stud
11 - Packingflange 138 - Packing ring (die-formed) 12 - Gland bushing 16 - Nut
Figure 5.1E Insert braided end ring, Figure 5.1G Packings installed
followed by intermediate ring

13
V INFORMATION PERTINENT TO GATE, GLOBE AND CHECK VALVES

Subsequent packing rings should be repacked material caused by frequent temperature and (
in the same manner until the split packing pressure fluctuations, or by creep in high-
adaptors are no longer required and the temperature applications. It is recommended that
standard gland bushing can be used. the gasket joint be inspected for leakage
periodically. The joint bolt tension should be
(2) If valves are equipped with live-loading
checked at approximately one-year intervals.
(Belleville spring washers) remove spring
washers during precompression of packing
rings, and reinstall at final torque. 5.2.2 Body-Bonnet Bolt Torquing
5. Remove the nuts and lift packing flange and The recommendations in this section are for ideal
bushing and insert the last end ring (braided conditions. Due to the many interacting tolerances,
graphite type) lower gland bushing and check some latitude must be allowed in the acceptance
for bushing positive engagement with packing standards as follows:
chamber.
NOTE: As a rule of thumb approximately Va in The spiral wound gasket (19) may be fully (
(3mm) engagement of the gland bushing inside compressed (zero gap between interfaces of the
the packirig chamber is required. Lower the joint) at 110% of the torque given in Table 5.2. The
gland flange, relubricate the gland studs/nuts following criteria should be used (see Fig. 5.2A).
using anti-seize compound and torque to values
The bolt torque is satisfactory if: '-'
shown in Table 4.1.2 and/or project drawing.
a) The spiral wound gasket is fully compressed at
6. Cycle valve at least three to five times from fully 90 percent of the recommended bolt torque,
closed to fully open position, and tighten after provided that 100percent torque is finally applied.
each cycle. When cycling is completed, ensure
b) The spiral wound gasket is fully compressed at
that the packing flange nuts are tightened to the
100 percent torque.
required torque values (Table 4.1.2).
c) The gap between the interfaces of the joint is ( ..
5.1.5 Packing Torques not more than 0.003 in (0.08 mm) after
1. Clean all gland studs (15) and gland nuts (16). 125 percent torque has been applied and the
Visually inspect all threads to ensure removal bolts have been slackened individually and
of all foreign matter, rust, corrosion, burrs and retorqued at 100 percent torque.
previous lubricant. Gasket recess UA" dimension (Fig. 5.2A)
2. Liberally cover the stud threads and the female 0.085 - 0.090 in (2.15 - 2.30 mm)
threads of the nuts with anti-seize compound Gasket thickness (
FEL-PROC5-A or approved equivalent. Va in (3.2 mm) nominal
3. With gland nuts (16) hand-tight, tighten them NOTE: Bonnet machining does not control
a little at a time on each side, then torque down gasket compression. Any repair to the body
to the correct torque in accordance with the valve recess should maintain the "A" dimension.
type, size and pressure class, as shown in
Table 4.1.2.
4. Values given in Table 4.1.2 are approximate
for standard Velan valves. Whenever possible,
refer to the Project Engineering drawing for a
particular valve and its torque.

5.2 BODY-BONNET JOINT TIGHTNESS

5.2.1 General (Fig. 2.3, 2.4, 2.5A and 2.58)

To maintain the joint tightness of a factory-tested

bolted bonnet valve, it is essential to exert
sufficient bolt tension at all times by having the
proper torque on the nuts. The original torque
might be lessened due to vibration, relaxation of Figure 5.2A Gasketrecess

14
INFORMATION PERTINENT TO GATE, GLOBE AND CHECK VALVES V

(( 5.2.3 Torque Procedure 5.2.4 Application of Torque

1. Clean all studs and nuts and inspect all threads
When applying the torque to the bolts, each bolt
to ensure removal of all foreign matter, rust,
should be torqued in steps of approximately
corrosion, burrs and previous lubricant.
20 percent of the final torque. As the final torque
2. Liberally cover the cap screw (stud) threads and is approached, the required step will be much less
surface under the nut head with anti-seize than 20 percent.
compound FEL-PROC5-A or approved
equivalent. Also lubricate the female threads of
CAUTION:
the nuts. Wipe off, with approved solvent, any
excess lubricant that may adhere to the steel 1. If tightening sequence is not followed,
parts. Approved solvents for this work are it is possible that the spiral wound gasket
acetone, alcohol or Freon PCA. will not be compressed evenly, causing
the body-bonnet joint to leak.
NOTE: The use of other solvents is not
I( recommended.
2. Over-torquing could deform the bonnet
flange and cause joint leakage.
3. With bolts hand-tight, follow the bolt-tightening 3. Do not use an impacting device to draw
sequence shown in Fig.5.28. The sequence up the bolting on body and bonnet
depends upon the number of bolts employed (cover) closures.
and the sketch shows only one possible
tightening sequence. The bolts must be
torqued to the recommended values shown
in Table 5.2. 5.2.5 Replacement of Spiral Wound Gasket
1. The gasket seating faces (the recess in the body
and the bonnet face) must first be checked for
smoothness. Scratches can normally be
removed with an emery cloth. The faces should
then be solvent degreased and dried before
assembly. Approved solvents are acetone,
alcohol or Freon PCA.
2. Install new spiral wound gasket between the
body and bonnet joint. The body is now ready
for installation of the bonnet assembly and
tightening of the bolting in accordance with the
torquing procedure.
Figure 5.28 Bolt tightening sequence
CAUTION: Valve must be partially open
when torquing bolts to prevent damage to
Table 5.2 seating surface.
Torque values (100%) for body-bonnet bolting
Bolting Material
Bolt Size
B7,630 660
Y,&-18UNC 12 (16) 10 (14)
%-16UNC 20 (27) 20 (27)
Y,&-14UNC 30 (41) 30 (41)
~-13UNC 50 (68) 45 (61)
%-12UNC 70 (95) 62 (84)
%-l1UNC 95 (129) 85 (115)
~-10UNC 170 (231) 150 (203)
%- 9UNC 270 (366) 240 (325)
Note: 1) All values lb-tt (Nm). Torque tolerance +10%.
2) For other sizes and bolting materials,
please contact the manufacturer.

15
VI GATE VALVES

6.1 SEAT LEAKAGE 5. Thoroughly clean off the lapping compound (

with a suitable cleaning fluid, such as acetone
or alcohol. Do not use bearing solvents
6.1.1 General containing chloride or fluoride.
An indication that a valve leakage exists after a valve CAUTION: Lapping may be slow due to
has been properly closed may be found by observing the erosion-resistant surface, but too
the pressure loss in the line on the high pressure
much lapping must be avoided.
side of the valve. In the case of hot water or steam
lines, note whether the downstream pipe remains
hot beyond the usual length of time. This type of
6.1.3 Seat Repairs: Gate Valves
leak may be the result of a distorted seat, caused by
improper welding of the valve into the pipeline, or 1. Automatic grinding and lapping of seat faces
by stress-relieving temperature that may have been can be done by specialized equipment.
used during installation, or by foreign matter damage. Information on this type of equipment can be
obtained from certain Velan authorized repair (
Leaks can also be caused by failure to close the facilities. For further details on such operations,
valve tightly, resulting in high-velocity flow through contact Velan Customer Service Department.
a small opening. In spite of the fact that the
2. In those cases where the automatic grinding
hardfacing material (Stellite) is corrosion- and
and lapping machine is not emploved, seat
erosion resistant, grooves, pit marks or other
faces must be repaired using a lapping plate.
surface irregularities may still form on the mating
The plate should be made of cast iron if
faces. Valves which leak should be repaired as soon
possible and should be large enough to cover
as possible to prevent greater damage caused by
the face of the seat. Apply lapping compound
high-velocity flow.
mixed with olive oil and distribute evenly over
the plate. Lap seat by moving lapping plate in a ( ....
6.1.2 Wedge Repairs: Gate Valves circular motion on seat face. Lift the plate as
1. Disassemble valve as described in Section 6.2 often as possible to prevent accumulation of
and inspect the wedge and seats for scratches, particles in one area and to allow for proper
pitting marks or other damage. distribution of the lapping compound. Lap until
both seats have smooth faces and then clean
2. If seating faces are scratched, they quite often
off the lapping compound very thoroughly with
can be polished with very fine emery cloth on a suitable cleaning fluid such as acetone or
a perfectly flat surface. alcohol.
3. If polishing is not sufficient, the wedge must be (
lapped. Slight pitting, grooving or indentation
can be removed by lapping. If defects cannot
be corrected by lapping, the wedge can be
ground or machined. No more than 0.005 in
(0.13 mm) per side should be removed. Relap
the wedge after grinding (or machining).
4. A flat plate, preferably cast iron, should be used
for lapping, and an abrasive lapping compound
mixed with olive oil should be evenly distributed
over the plate. Only light, even pressure should
be applied with the wedge on the plate. Lift the
wedge as often as possible to prevent accumu-
lation of particles in one area and to allow for
proper distribution of lapping compound.
The lapping plate should be turned slightly
every few strokes to keep a flat surface. The
wedge should be lapped until seating faces are
smooth. Velan recommends the use of Clover
Compound (silicon carbide) Grade 0 or C, or an
(
approved equivalent.

16
GATE VALVES VI

6.1.4 Fitting of Repaired Parts: Gate Valves 2. If a part cannot be repaired, new parts must be
fitted and installed. All spare part wedges can
1. After the seating faces of the wedge and/or
be supplied slightly oversized. They must be
seats have been relapped and cleaned, you
ground or machined and lapped as needed to
must check the wedge-seat fit. Place the
fit over the full circumference of the seat.
marked-up side of the wedge together with
Contact Velan Customer Service Department.
marked-up side of the seat. Slowly lower the
for ordering details.
wedge into the body and find the correct
mating point of the faces. Use bearing blue to 3. Figure6.1A illustrates a wedge with a full
check seat contact. Spread a light coating of seating circumference. This must be achieved
bearing on wedge seating faces, slip wedge when fitting a wedge.
onto the stem. Lower stem/wedge together 4. When fitting a wedge, it is also important that
with the bonnet. Secure bonnet with the wedge guide slots have sufficient clearance
studs/nuts. With the handwheel, close the to allow the wedge to move freely along the
valve firmly and than open partially, remove wedge guides, as shown in Fig.6.18 (top view).
f( bonnet nuts and lift entire bonnet assembly. Otherwise the wedge may be prevented from
Care should be taken that the wedge does not making full contact with seats.
slip off the stem UT" head. Check wedge seating
face for 100% contact as shown in Fig.6.1A.

Full circumferential
contact with seat

II( L..- .!-- ----ll.-.- -----'

Figure 6.1A Wedge seating face

Note: Shaded area represents the preferred seating face.

Clearance

Top view
~(- Section A-A

Figure 6.18 Gate valve wedge

1'10 17
VI GATE VALVES

6.2 DISASSEMBLY OF GATE VALVES Studs may have been damaged when removing (
seized nuts or when lifting the yoke-bonnet
assembly. If cap screws (studs) are damaged,
6.2.1 General remove and replace them.
There are two basic ways to disassemble Velan NOTE:When lifting the yoke-bonnet assembly,
valves: (a) total disassembly, and (b) partial care should be taken to prevent internal parts
disassembly to allow access to the area which from disengaging from the stem. The
requires maintenance. The appropriate method to wedge (05) is attached to the stem (04) with a
use depends on the nature of the problem: "T" slot, and it can slip off the stem when
Total disassembly: valve internal problems, spiral disengaging from the guides in the body.
wound gasket, wedge, etc.
Partial disassembly: valve top works, handwheel.
6.3 REASSEMBLY OF GATE VALVES
CAUTION: Make sure all pressure has been (
relieved from both sides of the valve before 6.3.1 General
starting disassembly work. The reassembly procedures are not as detailed as
the disassembly procedures since in most cases
the reverse procedure is required.
6.2.2 Total Disassembly
1. The most important consideration is the
The disassembly instructions below cover Velan's cleanliness of all parts. Rust and dirt should be
basic designs. As general disassembly progresses, removed from all parts with a wire brush or
place matching marks on parts so that the same emery cloth. Oil and grease should be removed
orientation of parts can be maintained at with suitable solvents.
reassembly. Refer to Fig. 2.3. 2. Threaded parts (cap screws, nuts, studs) must be
1. The valve should be in a partially open position. well relubricated. Old grease should be removed
from the stem and stem nut threads before a new
2. If the valve has a leakoff pipe, it must be coat of grease is applied. Recommended
disconnected first. Cut the leakoff pipe lubricants can be found in Table 4.2.
approximately six inches from the bonnet side
and not at the welded joint on the bonnet. NOTE: Use correct lubricant for each
3. Remove body-bonnet cap screws (nuts) (56). individual part.

NOTE: If a valve has been in hiqh-ternperature 3. Repaired or replaced parts must be checked (
to make sure that repair procedures have been
service for extensive periods of time, the cap
done and that replaced parts (e.g., packing
screws (nuts) may be seized to the body (studs).
rings, spiral gasket, etc.) have been checked
Tight nut threads can sometimes be loosened by
for size so that they will fit into the valve you
applying penetrating oil or heat to the nut and
are servicing.
working it free. As a last resort, a hacksaw,
cutting torch or cold chisel can be used to cut nut 4. All orientation marks assigned during
disassembly must be observed so that correct
away from stud.
assembly is maintained.
4. Once all the cap screws (nuts) are removed, the
entire yoke-bonnet assembly can be lifted out
of the valve body as shown in Fig. 2.3.
5. Remove used spiral wound gasket (19).
6. The valve is now ready for inspection and
repairs of wedge, seat, etc.
7. During inspection, check the condition of the
body-bonnet cap screws (studs) (56).

18
,'I ,
GLOBEVALVES VII

7.1 SEAT LEAKAGE 5. It is important to apply only light, even pressure

when lapping seats and to rotate reciprocally.
For best results, use an air or electric hand tool
7.1.1 General with adjustable speed and reciprocal movement.
The lapping tool should be lifted frequently and
An indication that a valve leakage exists after a valve
turned to a new starting position.
has been properly closed may be found by observing
the pressure loss in the line on the high pressure
side of the valve. In the case of hot water or steam 7.1.3 Fitting of Repaired Parts: Globe Valves
lines, note whether the downstream pipe remains 1. After the seating faces of the disc and seat have
hot beyond the usual length of time. This type of been relapped and cleaned with a suitable
leak may be the result of a distorted seat, caused by cleaning fluid, such as acetone or alcohol, the
improper welding of the valve into the pipeline, or by results of the lapping must be verified by a
stress-relieving temperature that may have been blueing test to check for full circumferential
used during installation.
l( contact. A blueing ink should be distributed
smoothly and equally over the seating diameter
Leaks can also be caused by failure to close the valve of the disc. Slowly lower the part into the body
tightly, resulting in high-velocity flow through a small and find the correct mating point of the faces.
opening. In spite of the fact that the hardfacing
material (Stellite) is corrosion- and erosion-resistant, 2. When fitting the disc, it is important that the
grooves, pit marks or other surface irregularities may inside diameter of the body be checked for
still form on the mating faces. Valves which leak sufficient clearance to allow the disc to move
should be repaired as soon as possible to prevent freely up and down. A visual examination of
greater damage caused by high-velocity flow. the body wall is recommended. Any grooves or
scratches should be polished with a fine emery
cloth. It is also important to verify that the disc
7.1.2 Seat Repairs: Globe Valves cannot be forced sideways against the outlet
1. Disassemble the valve as described in side of the waterway bore and become jammed
Disassembly of Globe Valves, Section 7.2, in that position.
and inspect the disc and seat for scratches, 3. Contact between the valve disc and stem is
pitting marks or other damage. made by a radius on the end ofthe valve stem
2. If there are deep pitting marks, use a cast iron (Fig. 7. 1A), which is designed to give center
lapping disc with the proper seat angle and a loading for the disc. If particles get trapped
suitable lapping compound to roughen the between the end of the valve stem and the disc,
surface first. With the use of a new, or already the center loading of the stem can be shifted
refinished original disc, you can use a finer and the disc will not seat tightly. The contact
lapping compound to finish lapping the disc surfaces of the stem and the disc must be
and seat together. checked first on leaky valves in order to ensure
that the stem-disc contact is in proper condition.

3. a) Use a guiding plate for the stem to maintain NOTE: A quick test is to take the stem-disc
alignment during the lapping operation. It assembly and check if the disc can be rocked.
can be made from wood or any other The rocking will allow the disc to self-align to
suitable material, to the dimensions of the the seat.
gasket and the bonnet spigot. The section
of the plate where the stem extends
through must be 'W4 in (0.4 mm) larger than
the outside diameter of the stem.
b) If the valve has a soft-seated disc, all body
lapping must be done with a lapping disc
and not with a soft-seated disc
4. Evenly distribute a small quantity of lapping
compound mixed with olive oil on the two
mating surfaces.

19
VII GLOBE VALVES

screws (nuts) may be seized to the body (studs). (

Tight nut threads can sometimes be loosened by
applying penetrating oil or heat to the nut and
working it free. As a last resort, a hacksaw,
cutting torch or cold chisel can be used to cut
nut away from stud.
4. Once all the cap screws (nuts) are removed, the
entire yoke-bonnet assembly can be lifted out of
the valve body as shown in Fig. 2.4.
5. Remove used spiral wound gasket (19).
6. The valve is now ready for inspection and
repairs of disc, seat, etc.
7. During inspection, check the condition of the
body-bonnet cap screws (studs) (56). Studs (
may have been damaged when removing
seized nuts or when lifting the yoke-bonnet
Figure 7. fA Stem disc contact area assembly. If cap screws (studs) are damaged,
remove and replace them. NOTE: When lifting
the yoke-bonnet assembly, care should be taken
7.2 DISASSEMBLY OF GLOBE VALVES to prevent internal parts from disengaging from
the stem. Some discs (6) are attached to the
7.2.1General stem (4) with a "T" slot, and they could slip off
the stem when it disengages from the guides in
There are two basic ways to disassemble Velan the body.
valves: (a) total disassembly, and (b) partial
disassembly to allow access to the area which
requires maintenance. The appropriate method to 7.3 REASSEMBLY OF GLOBE VALVES
(
use depends on the nature of the problem:
Total disassembly: valve internal problems, spiral 7.3.1General
wound gasket, disc, etc.
The reassembly procedures are not as detailed as
Partial disassembly: valve top works, handwheel. the disassembly procedures since in most cases the
reverse procedure is required.
CAUTION: Make sure all pressure has been 1. The most important consideration is the
(
relieved from both sides of the valve before cleanliness of all parts. Rust and dirt should be
starting disassembly work. removed from all parts with a wire brush or
emery cloth. Oil and grease should be removed
with suitable solvents.
7.2.2. Total Disassembly 2. Threaded parts (cap screws, nuts, studs) must be
well relubricated. Old grease should be removed
The disassembly instructions below cover Velan's from the stem and stem nut threads before a
basic designs. As general disassembly progresses, new coat of grease is applied. Recommended
place matching marks on parts so that the same lubricants can be found in Table 4.2.
orientation of parts can be maintained at NOTE: Use correct lubricant for each
reassembly. Refer to Fig. 2.4. individual part.
1. The valve should be in a partially open position. 3. Repaired or replaced parts must be checked
2. If the valve has a leakoff pipe, it must be to make sure that repair procedures have been
disconnected first. Cut the leakoff pipe done and that replaced parts (e.g., packing
approximately six inches from the bonnet side rings, spiral gasket, etc.) have been checked
and not at the welded joint on the bonnet. for size so that they will fit into the valve you
are servicing.
3. Remove body-bonnet cap screws (nuts) (56).
NOTE: If a valve has been in high-temperature
4. All orientation marks assigned during
disassembly must be observed so that correct
<-
service for extensive periods of time, the cap
assembly is maintained.

20
CHECK VALVES VIII

( 8.1 SEAT LEAKAGE 8.1.3 Seat Repairs: Swing Check Valves

If repairs are required on the seat of a swing check
8.1.1 General
valve, the procedure is the same as described in
An indication that a valve leaks could be caused by Section 6.1.3, Seat Repairs Gate Valves. The only
improper welding of the valve into the pipeline, difference between these seats is the angle of the
or by stress-relieving temperature that may have seat face. They can be repaired with an automatic
been used during installation. grinding or lapping machine or manually.

In spite of the fact that the hardfacing material 8.1.4 Fitting of Repaired Parts: Piston Check Valves
(Stellite) is corrosion and erosion resistant,
grooves, pit marks or other surface irregularities 1. After the seating faces of the disc and seat have
may still form on the mating faces. Valves which been relapped and cleaned with a suitable
;Ij( leak should be repaired as soon as possible to cleaning fluid, such as acetone or alcohol, the
results of the lapping must be verified by a
"'. , prevent greater damage.
blueing test to check for full circumferential
contact. A blueing ink should be distributed
8.1.2 Seat Repairs: Piston and Ball Check Valves smoothly and equally over the seating diameter
1. Disassemble the valve as described in of the disc. Slowly lower the part into the body
Disassembly of Small Bolted Cover Piston and and find the correct mating point of the faces.
Ball Check Valves, Section B.2.2, and inspect the 2. When fitting the disc, it is important that the
disc and seat for scratches, pitting marks or inside diameter of the body be checked for
other damage. sufficient clearance to allow the disc to move
2. If there are deep pitting marks, use a cast iron freely up and down. A visual examination of
lapping disc with the proper seat angle and a the body wall is recommended. Any grooves or
suitable lapping compound to roughen the scratches should be polished with a fine emery
surface first. With the use of a new, or already cloth. It is also important to verify that the disc
refinished original disc, you can use a finer cannot be forced sideways against the outlet
lapping compound to finish lapping the disc side of the waterway bore and become jammed
and seat together. in that position.
3. a) Use a guiding plate for the shaft to maintain
alignment during the lapping operation. It can 8.1.5 Supplementary Instructions for Soft-Seated
be made from wood or any other suitable Piston Check Valves
material, to the dimensions of the gasket and
the bonnet spigot. The section of the plate Velan soft-seated piston check discs come in three
where the shaft extends through must be %4 in basic designs.
(0.4 mm) larger than the outside diameter of 1. EPDM SEAT If replacing an EPDM seat
the shaft. (Fig. B.1A), remove tack weld or staked area by
b) If the valve has a soft-seated disc, all body grinding or filing. .Carefullv unscrew the disc
lapping must be done with a lapping disc and nut (16) from the disc. Remove the seat holder
not with the soft-seated disc. (71), then the EPDM soft seat (72A). Thoroughly
4. Evenly distribute a small quantity of lapping clean the piston disc soft seat area and disc post
compound mixed with olive oil on the two threads, removing any burrs and or particles of
mating surfaces. foreign matter. Install a new EPDM seat,
replace seat holder and screw on the disc nut.
5. It is important to apply only light, even pressure
when lapping seats and to rotate reciprocally. NOTE: The disc nut should be tightened metal-
For best results, use an air or electric hand tool to-metal to protrude through the soft seat %2
with adjustable speed and reciprocal to V16 in (0.8 - 1.6 mm). To prevent the disc
movement. The lapping tool should be lifted nut from unscrewing, it should be tack-welded
frequently and turned to a new starting position. or staked.
2. CTFEor PTFEDISC SWAGED SEAT (Fig.B.1B)
Because the seat is disc-swaged, it cannot be
replaced independently. The seat and disc
must be replaced as a unit.

I? 'I 21
VIII CHECK VALVES

3. CTFEor PTFE SEAT (Fig. B.1e) Table 8.1 Locking nut torques
If replacing a CTFEor PTFEseat, carefully Size Nut size
unscrew the disc nut (16) from the disc. in (mm)
Remove washer (57) and soft seat (728).
Clean the piston disc soft seat area and disc
post threads. Install a new CTFEor PTFEseat,
replace washer, screw new self-locking nut
with torque given in Table B.1.
2 (50) %-24UNF 110 (12.4)
o.tAA@I~:r---+----'~>ooc:oo-@ EPDM
configuration 8.1.6 Fitting of Repaired Parts: Swing Check Valves
before insertion
into disc After the seating faces of the disc and seat have been
relapped and cleaned with a suitable cleaning fluid, (
such as acetone or alcohol, the results of the lapping
must be verified by a blueing test to check for full
circumferential contact. A light coating of blueing
ink should be distributed smoothly and equally over
16 the seating surface of the disc. Slowly lower the di~~
with hanger into the body. Insert the hanger into t,,-"
hanger seat hole, and match up with pin hole, while
holding the disc away from seat insert the pin (61)
PARTS DESCRIPTION slowly. Release the disc and press firmly against the
06 - Disc 71 - Seat holder seat. Remove the pin (61) Fig. 2.58. Pull out hanger
16 - Disc nut 72A - Soft seat EPDM with disc and check for positive contact.
Figure 8.1A Piston disc with a replaceable
EPDM soft seat
8.2 DISASSEMBLY OF CHECK VALVES
(
8.2.1 General
Total disassembly: valve internal problems, spiral
wound gasket, disc, etc.

CAUTION: Make sure all pressure has been

relieved from both sides of the valve before (
starting disassembly work.
PARTS DESCRIPTION
06 - Disc
72B - CTFEor PTFE seat disc swagged 8.2.2 Disassembly of Small Bolted Cover Piston and
Ball Check Valves
Figure 8.18 CTFE or PTFE disc-swaged seat
The disassembly instructions below cover all of '-
Velan's small bolted cover piston (ball) check valves.
As the general disassembly progresses, place
matching marks on parts so that the same parts will
be used at reassembly (refer to Fig. B.2A and B.28).
PARTS DESCRIPTION
06 - Disc 1. Remove cover cap screws (nuts) (56).
72B - Soft seat
CTFEor PTFE NOTE: If a valve has been in high-temperature
57 - Washer service for extensive periods of time, the cap
16 - FUJILOK screws (nuts) may be seized to the body (studs).
self-locking nut Tight nut threads can sometimes be loosened by
applying penetrating oil or applying heat to the (_
nut and working it free. As a last resort, a
Figure 8.1C Piston disc with replaceable hacksaw, cutting torch or a cold chisel can be
CTFE or PTFE soft seat used to cut nut away from stud.

('7 )
22
CHECK VALVES VIII

(( 2. Once all the cap screws (nuts) are removed, the 6. During inspection, check the condition of the
entire cover can be lifted off the valve body as body-cover cap screws (studs) (56). Studs may
shown in Fig.8.2Aand 8.28. have been damaged when removing seized
nuts or when lifting the cover. If studs are
3. Remove used spiral wound gasket (19).
damaged, remove and replace them as follows:
4. Lift spring (46) and piston disc or ball (06).
a) Screw on two nuts.
5. The valve is now ready for inspection and seat b) Lock the bottom nut to the top nut.
repairs.
e) Turn the bottom nut to remove the stud.
d) Apply anti-seize compound to the new stud.
e) Screw in the stud and tighten.

(C~------------------~

PARTS DESCRIPTION PARTS DESCRIPTION

01 - Body 46 - Spring 01 - Body 46 - Spring
06 - Disc 50 - Cover 06 - Ball 50 - Cover
19 - Spiral wound gasket 56 - Cap screw or stud and nut 19 - Spiral wound gasket 56 - Cap screw or stud and nut

Figure8.2A Bolted cover piston check valve Figure 8.28 Bolted cover ball check valve
exploded view exploded view

l'lb 23
VIII CHECK VALVES

8.2.3 Disassembly of Swing Check Valves 8.3 REASSEMBLY OF CHECK VALVES (

The disassembly instructions below cover all of
Velan's small bolted cover swing check valves, as
8.3.1 General
a general disassembly progresses follow Section The reassembly procedures are not as detailed as
8.2.2 para. 1,2, and 3, refer to Fig. 2.58 Swing the disassembly procedures since in most cases
check valve. the reverse procedure is required.
4. Remove lock pin (61). 1. The most important consideration is the
cleanliness of all parts. Rust and dirt should
NOTE: It may be necessary to use a pair of be removed from all parts with a wire brush or
pliers or vise grip and pull pin while twisting emery cloth. Oil and grease should be removed
back and forth. With the pin removed, pull out with suitable solvents.
hanger (51) together with the disc (08). Please 2. Threaded parts (cap screws, nuts, studs) must
note, it may be necessary to twist back and be well relubricated. Recommended lubricants (-
forth while pulling hanger/disc towards can be found in Table 4.2.
downstream. Once the hanger and disc have
3. Repaired or replaced parts must be checked
been removed from valve body, the disc and
to make sure that repair procedures have been
hanger can be disengaged by sliding out hinge done and that replaced parts (e.g., spiral wound
pin (54). gasket, etc.) have been checked for size so that "-
5. The valve is now ready for inspection and seat- they will fit into the valve you are servicing.
disc repairs. 4. All orientation marks assigned during
6. During inspection, check the condition of the disassembly must be observed so that correct
body-cover cap screws (studs) (56). Studs may assembly is maintained.
have been damaged when removing seized
nuts or when lifting the cover. If studs are
damaged, remove and replace them as follows:
a) Screw on two nuts.
8.3.2 Reassembly of Piston and Ball Check Valves
1. Install piston disc or ball (06) and spring (46)
c,
in valve.
b) Lock the bottom nut to the top nut.
c) Turn the bottom nut to remove the stud. 2. Place new spiral wound gasket (19) in recess on
d) Apply anti-seize compound to the new stud. top mounting face of body.
e) Screw in the stud and tighten. 3. Line up the cover (50) with the body (01) and
lower into the body. It is extremely important
to prevent damage to the gasket when aligning (
the cover.
4. Apply recommended lubricant to body-cover
cap screws (studs and nuts), and then install.
Tighten body-cover cap screws (nuts) in strict
accordance with the torque procedure found in
Section 5.2 and Table 5.2 of this manual. '-

8.3.3 Reassembly of Swing Check Valves

Install disc (08) and hanger (51) with hinge pin (54)
lower into body insert hanger into seat hanger hole
and line up with pin hole. Insert pin (61) and
proceed with body-cover reassembly. Follow
Section 8.3.2 para. 2, 3 and 4 to complete
assembly.

<-

24 11'1
WELDED BONNET VALVES IX

c 9.1 WELDED BONNET GATE, GLOBE AND cutting wheel. Once the weld is removed, the
bonnet can be unscrewed from the body.
CHECK VALVES
Tight body-bonnet threads can sometimes be
Welded bonnet valves can be repacked and the top
loosened by applying penetrating oil to threads and
works serviced in the same way as bolted bonnet
by tapping the side of the body using a mallet
valves. However, the servicing of the seating faces
while unscrewing the bonnet. If valves have been
or back seat can only be achieved by removing the
i~ high temperature service for extensive periods of
bonnet assembly, which is threaded into the body
time, the bonnet may be seized to the body, and it
and welded. This section provides a method for
may be necessary to heat the body and bonnet to
removing the bonnet without the necessity of
free them.
cutting the valve from the line (Figs. 9.1A, 9.18
and 9. 1C). Servicing of internal components is the same as for

«: 9.1.1 Disassembly
bolted bonnet valves, described in Sections V to VII.

9.1.2 Reassembly
When Velan welded bonnet valves are serviced
because of a damaged seat or backseat, the weld Relap the seats and apply blueing ink to check
between the body and the bonnet must be carefully final results. Then tightly thread the bonnet
cut off, using an electric hand grinder with a flat assembly into the body and weld the body-bonnet
joint in accordance with an applicable Velan
welding procedure.

c
PARTS DESCRIPTION
01 - Body
06 - Disc
\' 46 - Spring
50 - Cover
66 - Nameplate
67 - Rivet (or tack weldl

Figure 9.1A Welded cover piston check

25
IX WELDED BONNET VALVES

~--------------~(

Stellite 6 seat face

PARTS DESCRIPTION PARTS DESCRIPTION

01 - Body 15 - Gland stud 01 - Body 15 - Gland stud
02 - Bonnet 16 - Gland nut 02 - Bonnet 16 - Gland nut
04 - Stem 27 - Yoke bushing 04 - Stem 27 - Yoke bushing
06 - Disc 30 - Handwheel nut 05 -Wedge 30 - Handwheel nut
11 - Packing flange 33 - Handwheel 09 - Seat 33 - Handwheel
12 - Gland bushing 57 -Washer 11 - Packing flange 57 - Washer
13 - Packing ring 66 - Nameplate 12 - Gland bushing 66 - Nameplate
13 - Packing ring 88 - Stem nut

Figure 9.18 Welded bonnet globe valve Figure 9.1C Welded bonnet gate valve (

26
TERMS AND CONDITIONS OF SALE

CONTRACT: Orders are subject to acceptance by costs comparable to Seller'S normal

( the Velan Companies hereinafter referred to as the
seller. No terms or conditions of Purchaser's order
manufacturing costs those parts proven defective,
or (iii) in discharge of Seller's maximum liability
contrary to the Seller's terms and condition shall herewith, refunding all monies paid by Purchaser
be binding upon the Seller unless specifically to Seller for the Product and, at discretion of
agreed to by the Seller in writing. Seller, having the product removed and returned
MINIMUM ORDER CHARGE: $500.00 net. to Seller at Purchaser's expense. All transportation
PRICES: All quoted prices are subject to change by charges relative to corrective work, defective parts
the seller without prior notice and, unless or replacement parts shall be borne by Purchaser.
otherwise stipulated by Seller, are understood to Purchaser shall give Seller immediate notice upon
discovery of any defect. The undertaking of repairs
be F.O.B. Seller'S plant, with delivery to carrier
constituting delivery to purchaser. Right to or replacements by Purchaser or its agents
possession of the material to secure the payment without Seller's written consent shall relieve seller
of the purchase price shall remain in Seller until all of all responsibility herewith.

c payments therefore shall have been fully made.

For the protection of the Purchaser and the Seller,
verbal customer orders must be confirmed by a
Finished materials and accessories purchased
from other manufacturers are warranted only to
the extent of the manufacturer's warranty to
formal written purchase order. If a written Seller.
purchase order is not received within ten days or a
Any alteration in material or design of Seller's
verbal order, product descriptions, quantities, product or component parts thereof by Purchaser
specifications, etc., as set forth in Seller's or others without written authorization by Seller
acknowledgement and invoice shall be conclusive voids all obligations of Seller regarding the product
and binding on both parties. Any order that is and any associated warranty herein stated or
shipped before receipt of confirmation which implied.
might have been entered incorrectly and would
require remedial action would be for the Seller'S sole liability shall be exclusively as set
forth herein, and Seller shall not be liable for any
incidental or consequential damages due to its
( ~~~:;~e~l~ ~~i::~:t;e exclusive of taxes. Sales,
breach of any warranty herein contained, or
use and other taxes, by whomsoever levied, are to
otherwise. Without limitation to the foregoing, in
be paid by the Purchaser, and unless invoiced, are
no event shall Seller be liable for the loss of use of
to be paid by the Purchaser directly to the
the product or of any other product, process,
appropriate governmental agency.
plant, equipment, or facilities of the Purchaser or
DELIVERY: Delivery or shipment specified is end-user whether partially or wholly due to
Seller's best estimate and Seller shall not be liable defects in material and/or workmanship and/or
( 'for delay in deliveries resulting from any cause design of Seller'S product, and in no event shall
.. whatsoever. Failure to ship on or near the Seller be liable for removal of appurtenances or
estimated date shall not entitle Purchaser to cancel incidentals such as connections, pipe work and
his order without charge. similar items of obstruction or for any cost
RETURN OF MATERIALS: Materials may be brought about by the necessity of removing the
returned only with prior written agreement of product from its point of installation.
Seller. Seller makes no warranty of any kind whatsoever,
CANCELLATION: Cancellation of orders may be expressed or implied, other then is specifically
made only with the Seller's written consent and stated herein; and there are no warranties of
Purchaser shall be subject to cancellation charges. merchantability and/or fitness for a particular
PRODUCT WARRANTY: Seller warrants the purpose which exceed the obligations and
equipment of its own manufacture to be free of warranties specifically stated herein.
defects in material and workmanship, under Parts furnished without charge as replacements
normal use and proper operation for a period of for original parts under warranty are warranted for
one year from the date of shipment from Seller's that period of time during which the original parts
plant. Seller'S obligation under warranty shall be warranty is effective.
strictly limited, at Seller's option, to: (i) furnishing
replacement parts for or repairing without charge ALL SHIPMENTS WILL BE F.O.B. PLANT LOCATION.
to Purchaser, F.O.B. Seller'S plant or (ii) issuing SHIPMENTS WILL BE MADE VIA MOST
written authorization for Purchaser or others to ECONOMICAL CARRIERS UNLESS OTHERWISE
replace or repair without charge to Purchaser, at REQUESTED.TERMS: NET 30 DA YS FROM DATE OF
INVOICE: 1!1% PER MONTH OF ALL OVERDUE
ACCOUNTS, ALL TAXES EXTRA. PRICESSUBJECT
TO CHANGE WITHOUT NOTICE.
27
~.(

SALES OFFICES MANUFACTURING PLANTS

U.S.A. CANADA EUROPE INDIA U.S.A. CANADA
BillHannon! Don Bowers Charles Pogue! Paul Dian! John Smith! Brian Hall S.Giridhar VELAN VALVE VELAN INC.
94 Avenue C B. lawson! T. Harfield ! Jacques Godbout! VELAN ENGINEERING Block A-I, Flat 604 CORPORATION 7007 Cote de lie sse
Williston, VT 05495~9732
Tel: (802) 864~335O
M. Tilley
730 N. Post Oak Road
Woody Bowler
7007 Cote de liesse
CO. LTD.
Cambridge Rd.,
Whetstone
Glaxo Apartments
Mayur Vihar-PH~1
Delhi-ll0091
94 Avenue C
Williston, VI 05495-9732
Tel: (802) 863-2562
Montreal, cc H4T 1G2
Tel: (514) 748-7743
Fax: (514) 748~8635
(
Fax: (802) 865-3030 Suite 311 Montreal, QC H4T 1G2
Houston, TX 77024 Tel: (514) 748-7743 leicester lE86lH Tel/Fax: 91-11-271-2196 Fax: (802) 862-4014 VELAN INC.
Ronald J_ Harrington England Fax: 91~11~225~8799
Tel: (713) 682~1084 Fax: (514) 748~8635 FRANCE 2125 Ward Avenue
43 Wyckoff Avenue Tel: 44-6~275-0206
Waldwick. NJ
Fax: (713) 682~6071
George S. lysakowski CHINA VELANSA Montreal, nc H4M 1T6
Fax: 44~6-275~0224 Room 4003 of No. 13 Tel: (514) 748-7743
07463~1721 Christopher G. Hiett 871 Kowal Drive SO,rue Challemellacour
Tel: (201) 670-0995 21931 Harborbreeze lane Mississauga, ON Gordon Hogben Xiao-Ying Road F 69367 lyon Cedex 7 Fax: (514) 748-8635
Fax: (201) 670-6810 Huntington Beach, l5H 3T3 10 Reynolds Way Chao Yang District Tel: (33)4 78 616700 VELAN INC.
CA 92646 Tel: (905) 278-7522 Croydon, CRO 5JW Beijing 100101 Fax: (33) 4 78 72 12 18 550 McArthur Ave.
Paul R.lee
208 lindbergh Avenue
Tel: (714) 965~6277
Fax: (714) 965-6737
Fax: (905) 278~8155 England
Tel: 44~181-680-7409
Tel: 86-10~64968995
Fax: 86~10-64968997 ENGLAND Montreal, nc H4T lX8
Tel: (514) 748-7743
(
Wilmington, DE Bill Patrick VELAN ENGINEERING
John Aynn 8825,51"Avenue Fax: 44-181-760-1968 JAPAN co. LTD. Fax: (514) 341-3032
19804~3316
289 Antioch Road Edmonton, AB T6E 5H1 Tak Sakamoto Cambridge Rd., VELAN INC.
Tel: (302) 994-1176 J. M. Gatard
lake lure, NC 28746 Tel: (780) 465~1122 4~31~3Kamimeguro, Whetstone 1010 Cowie Street
Fax: (302) 994~6156 VELAN S.A.
Tel: (828) 625-9441 Fax: (780) 465~0403 Meguro~ku leicester lE86lH Granby, nc J2J lE7
Fax: (828) 625-9437 SO,rue Challemellacour Tokyo 153-0051 Tel: 44~6~275-0206
Michael Midgley leo Shewchuk Tel: (450) 378-2305
F69367 lyon Cedex7 Tel: 81-3-3792-1891
3160 Vera Valley Orive
Franklin, TN 37064
Joe Denny
1638 Estate Circle
80 Sienna HillsCourt
S.w.
France
Tel: (33) 4 78 61 6700
Fax: 81-3-3792~1891
Fax: 44-6~275-0224
PORTUGAL
Fax: (450) 378-6865
PRoaUIP
"-
Tel: (615) 599-5910 Calgary, AB T3H 2W3
Naperville, Il60565 Fax: (33) 4 78 72 1218 MIDDLE EAST VELAN VALVULAS 835 Fourth line
Fax: (615) 599-6949 Tel: (403) 232~6482
Tel: (630) 579-1833 INDUSTRIAlS, LOA. Oakville, ON l6l5B8
Cherif Demian
Fax: (630) 579~1834 Fax: (403) 686~6485 Wolfgang Maar Av. Ary dos Santos Tel: (905) 842-1721
larry A. Woodworth Hadayik AI-Obour Bid #34
1343 Paddock Place David Brodnax VELAN GmbH Salah Salem Road 1679~018Famoes Fax: (905) 849-0923
Bartlett, Il 60103 Daimlerstrasse 8 lisbon
503 Comanche Trail MEXICO. 0-47877 Willich
Floor #16 Flat #3
Tel: (351~1)934~78oo KOREA
Tel: (630) 736-9395 West Monroe, LA 71291 CENTRAL Cairo, Egypt
Fax: (630) 736-9397 Gennany Fax: (351~1)934-7809 VELAN LTD.
Tel.: (318) 396~7517 & SOUTH Tel: 00 212-500~4040
B 608-7 Panwollnd.
Tel: (49) 2154/4938-0
Fax: (318)396-4995 AMERICA Fax: (49) 2154/4938-99
Fax: 00 202-402-9766 TAIWAN Estate
Tony Boland Sergio Pensotti VELAN-VALVAC
45 W. Franklin Street Frank Keegan P.O. Box 12
Bellbrook. OH 45305 Unit 14, VELAN VALVE CORP. SINGAPORE P.O. Box 2020 Ansan City, Kyunggi~do
9007 Highland Road 730 N. Post Oak Road Gary Tan Taichung, Taiwan, R.O.C. Tel: (82) 345-491-2811
Tel: (937) 848-2011
Fax: (937) 848-2144 Baton Rouge, LA 70810 Suite 311 No.4 Pioneer Place Tel: (04) 2792649 Fax: (82) 345-491~2813
Tel: (2251767~7965 Houston, TX 77024 Singapore 627 893 Fax: (886142750855
fax: (2251767~8160 Tel: (7131682~1837 Tel: (651862-0572
Fax: (7131682-6071 Fax: (651862-0573
GENERAL INFORMATION
Tel: (514)748-7743 (-
Fax: (514)748-8635
Velan's valve distributors are located worldwide. Web: http://www.velan.com

PRINTED IN CANADA VEL-SFVM-2000

/g'
VOLUME-12 PIPING, VALVES AND ACCESSORIES Chapter-3

3.5 GEAR ACTUATORS

@
Contents 13/37
(

GEAR ACTUATORS
MAINTENANCE MANUAL

fEl]
VEl-GAM-96
1 INTRODUCTION

TABLE OF CONTENTS (
I INTRODUCTION
II LUBRICATION
2.1 LubricationA~~'~""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
TORAGEPROCEDURES •••••••••••••••••••••••••••••.••••••••• 2

III
2.2 Storaqe
INSTALLATION P
pm~;d~;~~·······························::::
..·:::·····.....................................
::::::
. .3
ROCEDURES"VT" . .
.1 Installation 01 "VT"' SERIES.... ..•..•.•.•..••.3
3.2 Instruct', senes .......•..................•. . 3
3.2.1 VT-20 onsand for thr diong 01 d rive nui'::::::::::'"
VT-30ea ••••••••••
:: .
3.2.2 VT-40 and VT .. . .

IV
3.2.3 VT-60 and VT
INSTALLATION PROCEDURES"V'
~g:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
:::::::::::::::::::::::::::::::::::::::::::::::::!
. 5 (-
'4.1 Installation 01 "V" seri • SERIES..•••••• .•.••...•..•.•.•....•.•.••.•...•...••..•.•.•
::::........•.•.•.•...•~
.1.1 V-20 and V-30 enes . .
• ,2V.0 _ andV-50
41'3 .....•... •......•.•........•....... 8
.. Spur qear attac.h.;;;~~i.::::::::::::::: ::::::::::::::::::::::::::::: :::::::::::::::::::::::::::: 8
V DISASSEMBLYAND RE •.•....•.•.••.•......•..•••.•.••.•.•. .•.•....•.•.•..•.•.•.••...•.••.•.•.. •.•..•..•..•.•.•...•. 9 ....
51 Gene I ASSEMBLY •.•..•••.....•.......•..•...•. 10
•.•.•.•.•..•..••.•.•.•..•

. '" :::: :::.:::".::::".::::".::: : .: ::::.:::.:::::.:::.::: ::::~:':.:::.::::::.:: ..:::.::~.:; ;

(
INTRODUCTION

1.1 GENERAL INTRODUCTION

hIs manual has been p,epa,ed by Velan Englnee", Deslgne" and MaIntenance
pe"onnel to assIst yOUIn obtaInIng many mo,e years 01 satlslacWY se",lce from
T
you' "V" and "VT" gea' actuato". It wnt assIst you In ,esto,;ng you, gea' actuato, to
the best wo,klng condItIon wIth a mInImum 01 tIme and expense.
ThIs booklet contaIns the Inst,ucdons 10' the InstallatIon and maIntenance 01 these
unIts plus some helplul Ideas and SUggestIons to enable you to become lamma, wIth

the units.
Belo,e begInnIng any majo, work. we ,ecommend that you ca,elully ,ead thIs booklet
at least once to unde"tand the physIcal constmcdon 01yo", gea'. II you need mo,e
technIcal assIstance N to o,de' soare parts, please get In touch wIth you, local Velan

representative or call the Head Office.

2
II LUBRICATION AND STORAGE PROCEDURES
(
II LUBRIFICATION AND STORAGE 2.2 STORAGE PROCEDURES
PROCEDURE
It is not recommended to store actuators for more
than one year without working parts and lubrica-
2.1 LUBRICATION tion. The oil in the grease will separate and may
cause weeping around the seals. The seal does not
Because actuators are factory lubricated and lubri-
remain absolutely tight at all times, therefore it is
cated for life, no tapping up or replacement of
not unusual to experience a small amount of
grease should be necessary. It is recommended
weeping around the seals. If the actuator is stored
that all actuators are checked for leakage during
for a long time, this may occur. The small amount
the overhaul program for the valve it is installed
of lubricant which may weep out can be cleaned
on. The frequency of this inspection should be
away. Once the actuator is in regular use, this
( based on operating experience.
should disappear. We recommend the input shaft
Note: of the actuator be rotated every three to four
Although all actuators come with a months to mix the lubrication.
grease fitting to allow injection of new
Note:
grease into the gear housing or thrust
If the actuators are purchased without
base assembly, we recommend you use
valves, they should be stored in a clean,
these grease fittings only if you know
dry, protected warehouse until they are
there is no grease in the actuator.
ready to be installed on the valves.
Mixing greases or filling in too much
grease may damage the actuator. For
recommended lubrication, see Table 2.

Table 2
Recommended lubricant type
Brand: Daikyo No.2
( Mobile No. 28
Century Oils CL2X

/Br./
3
III INSTALLATION PROCEDURES IIVTII SERIES
(
III INSTALLATION PROCEDURES "VT" SERIES

3.1 INSTALLATION OF "VT" SERIES (Ref. Fig. 3.1A)

Caution:
1. Do not attempt to install or remove gear actuator unless all
pressure has been relieved from both sides of the valve.
2. Do not use a cheater on the handwheel of the gear actuator.
Gears are sized to reduce handwheel pull and not designed to exceed maximum input torque.When drive
nut (2) has been supplied threaded, position the gear actuator above the valve stem (3) (it may require the
use of a hoist because of the weight of the actuator) and rotate the actuator several turns until a minimum
of six threads of engagement occurs between actuator drive nut (2) and valve stem (3). Using handwheel ('
and rotating in the proper direction, you can lower the unit to meet the valve top flange. Align bolt holes
and install bolting (4) or (7).

Some actuators may require an adaptor plate (5) to fit the valve
yoke (6) you are installing a gear on. This adaptor plate (5) '-'"
must be installed on the gear before installing gear and
valve stem (3). We recommend all bolting for gear to
adaptor (4) or gear to yoke and/or adaptor plate to
torque to the values shown in Table 3.2 always
tightening in a cross sequence.

Important: (
It is important to have the current bolt
thread engagement to guarantee that the
actuator will not fail at maximum thrust
or torque.

Figure 3.1A VT-20

1. Gearactuator
2. Drive nut (
3. Stem
4. Actuator/adaptor bolting
5. Adaptor plate
6, Yoke
7. Adaptor/yokebolting (optional)
not shown in Fig 3. 1A

3.2 INSTRUCTIONS FOR THREADING

OF DRIVE NUT f) Thread the bronze drive nut to suit the valve
stem threads. (Do not thread drive nut to a
a) When drive nut (2) has not been supplied larger size than the maximum size for that
threaded, remove base retaining plate from type of gear; see catalogue.)
bottom of gear. Care must be taken for the
larger gear sizes that set screws are removed g) Reassemble the unit after threading drive nut
before you can remove base retaining ring. (the reverse procedure).
Make certain all dirt and foreign material has
b) Remove "0" ring and first set of bearings.
been cleaned away first.
(Two thrust washers and one roll bearing.)
h) Inject grease into the base of the actuator
c) Pull out bronze drive nut.
through grease fitting to lubricate the bearing (
d) Remove second set of bearings. for the drive nut using recommended \
(Two thrust washers and one roll bearing.) lubrication from Table 2.
e) Remove key and place bearing set and key in i) Return to installation first paragraph and
a clean and dry area. mount actuator as described.

4
III INSTALLATION PROCEDURESIIVT" SERIES
(
3.2.1 VT-20 AND VT-30

(~ Figures 3.2A
a)
VT-20 and VT-30
Remove retaining plate (4) and pull out drive
Common Parts List"VT" Series

nut (7) and bearing (9).

Ref. Part VT-20 VT-30
Description OTY OTY
b) Remove end cover (3).
01 Upper housing 1 1
c) Pull out pinion (6) and bearing (8) assembly.
02 Lower housing 1 1
Note the number and the position of any
shims. 03 End cover 1 1
04 Retaining plate 1 1
( d) Disassemble upper housing (1) from lower
05 Ring gear 1 1
housing (2).
06 Gear pinion 1 1
e) Remove ring gear (5) and ball bearing (24).
07 Drive nut 1 1
f) Reassembly is accomplished by reversing 08 Bearing 2 2
steps a) to e). It is recommended that all Bearing
09 2 2
seals are replaced.
10 Bearing shim NR NR
11 Spacer 2 2
12 Retaining ring 1 1
13 "0" ring 1 1
14 "0" ring 1 1
15 "0" ring 1 1
16 "0" ring 1 1
17 Capscrew 4 8
18 Capscrew 4 4
19 Lock washer 4 8
20 Lock washer 4 4
( 21
22
Dowel pin
Grease fitting
1
1
1
1
23 Key 1 1
24 Ball NR NR

5
III INSTALLATION PROCEDURES IIVT" SERIES
(
3.2.2 VT-40 AND VT-50

Figures 3.28 VT-40 and VT-50 Common Parts List"VT" Series

a) Remove retaining plate (4) and pullout drive
nut (7) and bearing (9).
Ref. Part VT-40 VT-50 (
Description QTY QTY
b) Remove end cover (3). 01 Upper housing 1 1
c) Pull out pinion (6) and bearing (8) assembly. 02 Lower housing 1 1
Note the number and the position of any 03 End cover 1 1
shims. 04 Retaining plate 1 1
05 Ring gear 1 1
d) Disassemble upper housing (1) from lower 06 Gear pinion 1 1
housing (2). 07 Drive nut 1 1 (
e) Remove ring gear (5) and ball bearing (24). 08 Bearing 2 2
09 Bearing 2 2
f) Reassembly is accomplished by reversing
10 Bearing shim NR NR
steps a) to e). It is recommended that all
11 Spacer 2 2
seals are replaced. 12 Retaining ring 1 1
13 "0" ring 1 1
14 "0" ring 1 1
15 "0" ring 1 1
16 "0" ring 1 1
17 Capscrew 8 9
18 Capscrew 4 4
19 Lock washer 8 9
20 Lock washer 4 4
21 Dowel pin 1 1
22 Grease fitting 1 1
23 Key 1 1
24 Ball NR NR
26 Capscrew 6 6
27 Lock washer 6 6
28 Adaptor 1 1
29 Dowel pin 3 3
30 Capscrew 1 1
31 Washer 1 1

6
III INSTALLATION PROCEDURESIIVT" SERIES
(
) 3.2.3 VT-60 AND VT-70

\
Ref. Part VT-60 VT-70
Description Oty Oty
01 Upper housing 1 1
02 Lower housing 1
04 Retaining plate 1
05 Ring gear 1
06 Gear pinion 1
07 Drive nut
08 Bearing 2 2
09 Bearing 2 2
10 Bearing shim AIR AIR
11 Spacer 2 2
12 Retaining ring 1 1
14 "0" ring 1 1
15 "0" ring 1 1
Figure 3.2C VT-60 & VT-70
16 "0" ring 1 1
Cr' a) Remove bolts (39) and washers (38),
spur gear cover (33) followed by gears (34, 46). 17 Capscrew 9 9
18 Capscrew 8 8
b) Remove bolt (47) and pull off gear (36).
c) Remove bolts (18) followed by spur gear
19 Lock washer 9 9
housing (32). 20 Lock washer 8 8
d) Pull out pinion (6) and bearing (8) assembly. 22 Grease fitting 2 2
Note the number and the position of any shims. 23 Key
( e) Remove retaining plate (4) and pull out drive 24 Ball AIR AIR
nut (7) and bearing (9). 30 Capscrew 1
f) Disassemble upper housing (1) from lower 31 Washer 1
housing (2). 32 Spur gear housing
g) Remove ring gear (5) and ball bearing (24). 33 Spur gear cover 1
h) Reassembly is accomplished by reversing 34 Gear 1
steps a to g. It is recommended that all seals
35 Gear 1 1
are replaced.
36 Gear 1 1
37 Key 1 1
38 Washer 10 10
39 Capscrew 10 10
40 Bushing 4 4
) 44 2 2
Cap
) 45 Retaining ring 1
46 Gear
(_ 47 Capscrew
48 Lock washer 1
49 Washer 1

7
IV INSTALLATION PROCEDURESIIV" SERIES
(
IV INSTALLATION PROCEDURES "v" SERIES
4.1 INSTALLATION OF "V" SERIES Table 4.1
(Ref. Fig. 4.1A)
Recommended torque values
"V" series requires a special mounting kit to be Thread size Torque
installed on the valve in field. This kit can be Ft.lb. Nm
purchased together with the gear. Ref. Fig. 4.1A }.I" - 13UNC 75 102
a) Handwheel must be removed from valve in '%" - 11UNC 145 197
the field. :y." - 10UNC 255 346
b) Using a hand grinder, grind off the tack weld ~" - 9UNC 405 550
and unscrew the yoke sleeve. 1" - 8UNC 615 834 (
c) Screw in adaptor plate into the thread where 1X" - 7UN 900 1220
the yoke sleeve was and tack weld. 1W' - 8UN 1500 2034
d) Install yoke nut drive (5) together with key (4)
on valve yoke nut (6)
e) Position the gear actuator above the adaptor
plate so that the two driving lugs fit into
the two driving lugs of the yoke nut
drive. Align bolt holes and install
bolting. Torque bolting to
values shown in Table 4.1,
always tightening in a
(
cross sequence.

Figure 4.1A
1. Gear actuator housing
2. Adaptor/gear bolting
3. Adaptor
4. Key
5. Yoke nut drive
6. Yoke nut
7. Stem

8
IV INSTALLATION PROCEDURESIIV" SERIES
,.

4.1.1 V-20 AND V-30

I
~

Figure 4.1B V-20 & V-30 Common Parts List - "V" Series
a) Remove end cover (3).
Ref. Part V-20 V-30
b) Pull out pinion (6) and bearing (8) assembly. Description Qty Qty
Note the number and the position of any
shims. 01 Upper housing 1 1
c) Disassemble upper housing (1) from lower 02 Lower housing 1 1
housing (2). 03 End cover 1 1
d) Remove bolts (26) and disassemble gear ring 05 Ring gear 1 1
(5) from adaptor (25). 06 Gear pinion 1 1
e) Reassembly is accomplished by reversing 08 Bearing 2 2
steps a) to d). It is recommended that all 10 Bearing shim AIR AIR
seals are replaced.
11 Spacer 2 2
12 Retaining ring 1 1
13 "0" ring 1 1
14 "0" ring 1 1
15 "0" ring 1 1
16 "0" ring 1 1
17 Capscrew 4 8
18 Capscrew 4 4

1 19
20
Lock washer
Lock washer
4
4
8
4
I
1 22 Grease fitting 1 1
24 Ball AIR AIR
25 Adaptor 1 1
26 Capscrew 6 6
27 Lock washer 6 6

I 9o
9
IV INSTALLATION PROCEDURES "v" SERIES
(
4.1.2 V-40 AND V-50

Figures 4.1C V-40 and V-50 Common Parts List - "V" Series
a)
b)
Remove end cover (3).
Pull out pinion (6) and bearing (8) assembly.
Ref. Part
Description
V-40
Oty
V-50
Oty
(
Note the number and the position of any
01 Upper housing 1 1
shims.
02 Lower housing 1 1
c) Disassemble upper housing (1) from lower
housing (2). 03 End cover 1 1
05 Ring gear 1 1
d) Remove bolts (26) and disassemble ring gear
06 Gear pinion 1 1
(5) from adaptor (25). (
08 Bearing 2 2
e) Reassembly is accomplished by reversing
steps a) to d). It is recommended that all 10 Bearing shim AIR AIR
seals are replaced. 11 Spacer 2 2
12 Retaining ring 1 1
13 "0" ring 1 1
14 "0" ring 1 1
15 "0" ring 1 1
16 "0" ring 1 1
17 Capscrew 8 9
18 Capscrew 4 4
19 Lock washer 8 9
20 Lock washer 4 4
22 Grease fitting 1 1
24 Ball AIR AIR
25 Adaptor 1 1
26 Capscrew 6 6 (
27 Lock washer 6 6
29 Dowel pin 3 3

10
V DISASSEMBLY AND REASSEMBLY
(
4.1.3 SPUR GEAR ATTACHMENT
Parts list Spur Gear Attachment
I

Spur Gear
Ref. Part Attachm.
Description
Qty
01 Upper housing 1
08 Bearing 2
11 Spacer 2
12 Retaining ring 1
18 Capscrew 4
20 lock washer 4
22 Greasefitting 1
32 Spur gear housing 1
33 Spur gear cover 1
34 Gear 1
35 Gear 1
36 Gear 1
37 Key 1
38 Washer 6.
39 Capscrew 6
40 Bushing 2
41 Bushing 2
42 Bushing 1
43 Cap 1

Figure 4.1D Spur gear attachment

a) Remove bolts (38,39), then remove spur gear cover (33) followed by gears (36, 34, 41).
\., Cb)) Remove bolts (18) and pull off spur gear housing (32). f
(
Continue the disassembly of main gear box by following the steps a) to e) for the type 0 gear
you are disassembling.

V DISASSEMBLY AND REASSEMBLY

5.1 GENERAL
Note:
There are no special tools required for assembly If you are changing any major parts in the gear actu-
and disassembly of a bevel gear unit or a spur gear ator, it may be required to assemble gear at once
attachment. The most important fact to be consid- without seals and "0" ring to ensure minimum
ered is the cleanliness of all parts. You must assign backlash between the ring gear and pinion gear.
orientation marks at time of disassembly to main-
tain orientation at reassembly. Caution:
., Caution should be taken when removing ring gear .
Each part should be cleaned of old grease and re- Each actuator has a set of hardened balls. The
(_ lubricated at reassembly. All bearing shims and
bearings must be returned to the same position as
quantity of balls must always be maintained to the
maximum which can fit into the groove. If you are
found at disassembly. Gasket compound or sili- missing some, do not reassemble actuator. You
cone sealer can be used on all metal/metal faces. must replace the missing ones.

11
(
Forged steel gate, globe and !,{"-2"
API 602, 606
ANSI 150-1500
check valves ANSI B16.34
Forged steel Y-pattern globe valves !,{"-4" ANSI 900-4500 ANSI B16.34
Cast carbon, alloy and stainless steel 2"_48" ANSI 150-1500 API 600
gate, globe and check valves
Cast stainless steel gate, globe API 603
~"-24" ANSI 150-300
and check valves ANSI B16.34
Forged pressure seal and bolted bonnet ANSI PS 600- 4500
2"-24" ANSI B16.34
gate, globe and check valves, Y-pattern BB 600-1500 (
Industrial ball'valves
ANSI 150-600
Ball valves for slurry X"-24" ANSI B16.34
1000- 2000WOG
Metal-seated ball valves
All stainless steel knife gate valves TAPPI TIS 405-8
2"-36" 150psi
lilting disc check valves SP-81
Globe: }{"- 8"
Bellows seal valves ANSI 150- 2500 ANSI B16.34
Gate: }{"-12"

Cryogenic valves
Globe: }{"- 12"
ANSI 150- 2500 ANSI B16.34 (
Gate: X" - 48"

SALES OFFICES MANUFACTURING PLANTS

U.S.A. EUROPE U.S.A. CANADA KOREA
Bill Hannon! Don Bowers Larry A. Woodworth David Brodnax JohnSm~ VElAN VALVECORPORAnON VELANINC VELANLTO.
18 Avenue C BARTtETT.1L 60103 503 Comanche Trail VElAN ENGINEERINGCO.LTO. 18 Avenue C 2125 Ward Avenue a 608-7 Panwollnd. Estate
Griswold Industrial Park 1343 Paddock Place West Monroe. LA 71291 Cambridge Rd.• Whetstone Griswold Industrial Park Montreal. nc H4M 1T6 P.O. Box 12
Williston. VT 05495-9798 Tel: (7081736-9395 Tel.: (3181396-7517 Leicester LE8 3LH Williston. VT 05495-9798 Tel: (5141748-7143 Ansan C~. Kyunggi-do (_
Tel: (8021864-3350 Fax: (7081736-9397 Fax: (3181396-4994 bt- Tel: (8021863-2562 Fax: 15141748-8635 Tel: (821345-491-2811
Fax: (8021865-3030 Tel: 0116 275-0206 Fax: (8021862-4014 Fax: (821345-491·2813
Tony Boland Frank Keegan Fax: 0116 275-0224 VELANINC.
RonaldJ. Harrington 45 W. Franklin Street Unit 14. 9007 Highland Road FRANCE 550 McArthur Ave. TAIWAN
45 North Broad Street BeUbrook. OH 45305 Baton Rouge. LA70810 Gordon Hogben GECALSTHOM-VELAN Montreal. oc H4T lX8 VELAN-VALVAC
Su~e 505 Tel: (5131848-2011 Tel: (5041767-7965 10 Reynolds Way 90, rue Challemellacour Tel: (5141748-7143 P.O. Box 2020
Ridgewod. NJ 07450 Fax: (5131848-2144 Fax: (5041767-8160 Croydon. CRO 5JW 69367 Lyon Cedex 7 Fax: (5141341-3032 Taichung. Taiwan. R.O.C.
Tel: (201)670-0995 Eogl .... Tel: (33178 6167 00 Tel: (0412792649
Fax: (201) 670-1;810 Charles Pogue I CANADA Tel: 0181-680-7409 Fax: (33178 72 12 18 VELANINC. Fax: (886142750855
Bruce lawson I Rein Maasikl Paul Dian Fax: 0181-760-1968 1010 Cowie Street
Paul R. Lee Tom Hartfield 2125Ward Avenue PORTUGAL Granby. oc J2J lE7
208 lindbergh Avenue 730 N. Post Oak Road Montre.l. QC H4M 1T6 Jacques Chanois VELAN VALVULAS Tel: (5141378-2305
Wilminglon. DE Suite 311 Tel: 15141748-7743 GECAlsthom-Vol.n Industriais.lda. Fax: (5141378-6865
19804-3316 Houston. TX 71024 Fax: (5141748-8635 10-12. Avenue de. Olympiades Av. Ary dos Santos
Tel: (3021994-1116 Tel: (7131682-1084 94132 Fontenay Sou. Bois Cedex lisbon-26750divelas
Fax: (3021994-1;156 Fax: (7131682-1i071 George S. lysakowski Fraooce Tel: (351-11933-1195
871 Kowal Drive Tel: 33 (1) 43 94 86 72 Fax: (351-11932-7790
Jim Cate Christopher G. Hiett Mississaug •• ON LSH3T3 Fax: 33 (1143 941961
P.O. Box 430 21931 Harborbreeze Lane Tel: (9051278-7522
Hi...... TH 37343-0430 Huntington aeach. CA Fax: (9051278-8155 Manfred Hanke SINGAPORE CHINA
Tel: (4231842-5295 92646 VELANGmbH Pierre Cohen Shi Ung Yan! Pan Forster Zhang
Fax: (4231842·7631 Tel: (7141965-6277 Bill Patrick Oaimlerstrasse 8 Seletar Base Yihong 1st Fl.. Hong Shan Rd.' 31
Fax: (7141965-6737 21931Harborbreeze Lane 47877 Willich 17 Hyde Park Gate 0411 Rm. 4th Roor Fruit lake. Wuchang
Edmonton. AB T6E 6G6 Singapore 799546 Catic Plaza Wuhan. P.R. China 430071
G.... "'"
Tel: (4031465-1122 Tel: (4912154/421001/04 Tel: (651484-1734 118 Beichen Rd. TeVfax: 027·6815254
Fax: (4031465-0403 Fax: (4912154-41695 Fax: (651484-1735 East Chao Yang District
GENERAL INFORMATION: Beijing 100101
Tel: (5141748-7743 Tel: 8610494 0601
Fax: 86104940602
Fax: (5141748-8635

(
Note: Although every attempt has been made to ensure that the information contained in this manual is correct, Velan reserves the right to change designs or,
materials or specifications without notice. Please get in touch with your local Velan representative for more information.

Printed in Canada VEL-GAM-96 I? j

VOLUME-12 PIPING, VALVES AND ACCESSORIES Chapter-3

3.6 PRESSURE SEAL VALVES

r,;;;
~tontents 14/37
•
PRESSURE SEAL VALVES
MAINTENANCE MANUAL
Cast and Forged Steel, Gate, Globe, Parallel Slide and Check Valves
2- 24" (50-600 mm)

,.
:;.;
,f
,
~,

~.
r'\
','
:'','.

___ \"S' VEL- FPSM - 99

TABLE OF CONTENTS

GENERAL INFORMATION

INTRODUCTION
1.1 General Introduction
PAGE

6
6
•
1.2 Essential Features of Velan Valves 7
1.3 The Different Styles of Pressure Seal Valves 8

II RECEIVING & PREPARATIONFOR INSTALLATION 9

2.1 Receiving Inspection 9
2.2 Quality Control Documentation 9
2.3 Storage 9
2.4 Handling and Preparation 9
2.5 Special Instructions for Gate Valves 9
2.6 Special Instructions for Globe Valves 10
2.7 Special lnstructions for Check Valves 10
2.8 Special Instructions for Tilting Disc Check Valves 11
2.9 Recheck for Bolt Tightness 11
2.10 Special Note on Live-loaded Bolting 12

III WARNINGS 13

IV GENERAL MAINTENANCE 14
4.1 Trouble Shooting Chart 15
4.2 Operation 15
4.2.1 General 15
4.2.2 Smoothness of Operation 15
4.3 Recommended Lubrication 15
4.4 General Assembly Information 15
4.5 Bonnet/Gasket Torquing Procedure 16
4.5.1 General 16 _
4.5.2 Application of Torque 16

V INFORMATION PERTINENTTO GATE, GLOBE, CHECK AND PARALLELSLIDE VALVES 19

5.1 Packing 19
5.1.1 Number of Packing Rings Required 19
5.1.2 Packing Ring Removal On Line 19
5.1.3 Removal With Blowout 20
5.1.4 Repacking With Graphite Packing Rings 20
for Valves Without a Leak-off Connection ..
5.1.4.1 Packing Consolidation Method 21
5.1.5 Repacking With Graphite Packing Rings 22
for Valves With a Leak-off Connection .
5.1.6 Packing Torques 22
5.1.7 Live-loading Packings 24
5.2 Detailed Maintenance 24
5.2.1 Packing Chamber Leakage 24
5.2.2 Body/Bonnet (Gasket) Leakage 25 •
5.2.2.1 General 25
5.2.2.2 Leakage of Body-Bonnet Joint 25
5.2.2.3 Body-Bonnet Joint - Seating Face Repairs 25

2
TABLE OF CONTENTS

• 5.2.3 Seat Leakage

5.2.3.1 General
5.2.3.2 Wedge & Disc Repairs - Gate & Parallel Slide Valves
26
26
27
5.2.3.3 Seat Repairs 28
5.2.3.3.1 Gate & Parallel Slide Valves 28
5.2.3.3.2 Globe, Needle, Stop & Piston Check Valves 28
5.2.3.4 Fitting Of Repaired Parts 29
5.2.3.4.1 Gate Valves 29
5.2.3.4.2 Parallel Slide Valves 31
5.2.3.4.2 Globe, Stop Check and Piston Check Valves 32
5.2.3.5 Seat Tightness - Closing Torques 33
5.2.4 Backseat Repairs 34
5.3 Torque Values - Actuator, Yoke/Bonnet Bolting 35
GATE VALVE PAGE
VI GATE VALVE 36
6.1 Types of Gate Valves : 36
6.2 Exploded View 39
6.3 Partial Disassembly - Gasket Replacement 41
6.3.1 Style I 41

•
6.3.2 Style II and 111 41
6.4 Total Disassembly 41
6.4.1 General 41
6.4.2 Disassembly of Body/Bonnet and Wedge/Stem 41
6.4.2.1 Style I 41
6.4.2.2 Styles II and III 42
6.4.3 Disassembly of Top Works 46
6.5 Assembly 47
6.5.1 Top Works Assembly 47
6.5.2 Body/Bonnet and Wedge/Stem Assembly .47
6.5.2.1 Style I 47
6.5.2.2 Styles II and III 48
GLOBE VALVE - INCLUDES STOP & PISTON CHECK VALVES PAGE
VII GLOBE VALVE 49
7.1 Types of Globe Valves 49
7.2 Exploded View 53
7.3 Partial Disassembly - Gasket Replacement 54
7.3.1 Style I 54
7.3.2 Style II and 111 54
7.4 Total Disassembly of Globe and Stop Check Valves 54
7.4.1 General 54
7.4.2 Disassembly of Body/Bonnet and Disc/Stem/Union 54
7.4.2.1 Style I 54
7.4.2.2 Styles II and III 55

•
7.4.3 Disassembly of Top Works 58
7.5 Total Disassembly of Piston Check Valve 58
7.6 Assembly , 59
7.6.1 Top Works Assembly 59
7.6.2 Body/Bonnet and Disc/Stem Assembly 60

1'1 b 3
-~:
A:

..
TABLE OF CONTENTS
t. -

7.6.2.1 Style I 60
7.6.2.2 Styles II and III 61

PARAIl.ELSLIDEVALVE PAGE

VIII PARALLELSLIDE VALVE •.••••••••••••••••••••....••••........••..•••••.•...••.••••••••.....•.•••..•••...........••.•..•.••.•... 62

8.1 Types of Parallel Slide Valves 62
8.2 Partial Disassembly - Gasket Replacement 64
8.2.1 Style I 64
8.2.2 Style II and 111 · · 64
8.3 Total Disassembly 64 All
8.3.1 General 64 •
8.3.2 Disassembly of Body/Bonnet and Discs/Stem 65
8.3.2.1 Style I 65
8.3.2.2 Styles II and III 66
8.3.3 Disassembly of Top Works 71
8.4 Assembly- 72
8.4.1 Top Works Assembly 72
8.4.2 Body/Bonnet and Discs/Stem Assembly 72

CHECK VALVES - INCLUDES SWING CHECK & TILTING DISC VALVES PAGE

IX CHECK VALVES
9.1 Types of Check Valves
9.2 Partial Disassembly - Gasket Replacement
9.3 Total Disassembly
9.3.1 Body/Bonnet Disassembly
9.3.2 Disc Disassembly
· ·..· ·..· ··
75
75
78
79
79
80
•
9.3.2.1 Swing Check 80
9.3.2.2 Tilting Disc 82
9.4 Detailed Maintenance 83
9.4.1 Body/Bonnet(Gasket) Leakage 83
9.4.1.1 General 83
9.4.1.2 Leakage of Body-Bonnet Joint 83
9.4.2 Seat Leakage - Swing Check 83
9.4.2.1 Swing Check Disc Repairs 83
9.4.2.2 Swing Check Seat Repairs ····· 84
9.4.3 Seat Leakage - Tilting Disc 84
9.4.3.1 Tilting Disc Disc Repairs 84
9.4.3.2 Tilting Disc Seat Repairs 84
9.5 Assembly 84
9.5.1 Disc Assembly Fit-Up 84
9.5.1.1 Swing Check Disc Unit 84
9.5.1.2 Tilting Disc Unit 85
9.5.2 Bearing Blue or Developer Test ·····..· 86
9.5.2.1 Swing Check 86
9.5.2.2 Tilting Disc 87
9.5.3 Paper or Light Test 87
9.5.3.1 Swing Check 87
9.5.3.2 Tilting Disc 88
9.5.4 Internal and Mid-Section Assembly - Swing Check 88
9.5.5 Body-Bonnet and Cover Assembly - Swing Check & Tilting Disc 89

4
TABLE OF CONTENTS

• ApPENDIX PAGE

X ApPENDIX ........................................................................................................................•... 90
10.1 Procedure for Removing Manual Gear Actuator 90
10.1.1Style 1 90
10.1.2Style II 91
10.2 Procedure for Removing Motor Actuators ................................................•.........•.............................
92
10.3 Procedure for Removing Motor Hydraulic or Pneumatic Actuators ....•.................•.........................94
10.4 Spare Parts 95
10.5 Special Tools for Valve Assembly and Disassembly 96
e. TERMS AND CONDITIONS OF SALE ............................................••.............................................•.... 99

l
• 5
1it,

•
INTRODUCTION ·?I.,r:·,
..
::
1.1 GENERAL INTRODUCTION -t.,

hiS manual has been prepared by Velan

T
engineers, designers and maintenance
personnel to assist yOU in obtaining many years
of satisfactory service tram your pressure seal valVes.h
will also assist yoU in restoring your valve to the best
working condition with a minimum of time and

.'
expense.
VelanvalVesare designed and manutactured based on
many years of research and product development and
are constantly being improved. Before beginning any
major work, we recommend that you read this booklet
carefully at least once to understand the valve's
physical condition.
Please note that if you do not understand the reason
for the service problem, we Suggest that you get in
touch with your local Velanrepresentative or call the
customer Service Manager for technical assistance.
•
Before beginning any major work, we recommend that
yOUcarefully check the nameplate on the valve and
record the figure number to identify the type and size of
valVe.See the .fsselllial featUres of Velan Valves"
form on the following page for an eXplanationof Velan
"Figure Numbers".

6
• I
-, J
INTRODUCTION

• 1.2 ESSENTIAL FEATURES OF VELAN VALVES

The figure numbers shown on this key are designed to cover essential features of Velan valves. Please use figure numbers to ensure prompt and accurate pro-
cessing of your order. A detailed description must accompany any special orders.

Gate, Globe and Check Valves

Typeof Connection Size 01connection Class Tvpe Body/Bonnet Style Body Material Trim Material

• •• •• •• ••
A B C 0 E F G
D 1II III
B 1 6 3 0 5 4 P 0 2 T S
e.g.: is a 10" (250 mm) Class 1500 carbon steel pressure seal gate valve with TS trim and buttweld ends.

Customers have the choice of specifying valve size as part 01the valve figure I"B") using the numbers below. or indicating valve size separately.
e.g.: 816-3054P-02TS (valve size is part of figure number), 10" (250mm) 8-3054P-02TS (valve size is shown separately).
08 2' (50 mm) 12 4' (100 mm) 16 10' (250 mm) 21 lS' (450 mm) 26 26' (650 mm) 34 34' (S50mm) 99 SPEOAl
09 2W (65 mm) 13 5' (125 mm) 18 12' (300 mm) 22 20' (500 mm) 28 2S' (700 mm) 36 36' (900 mm)
103'(80mmr 14 6' (150 mm) 19 14' (350 mm) 23 22' (550 mm) 30 30' (750 mm) 42 42' (1050 mm)
20 16' (400 mm) 24 24' (600 mm) 48 48' (1200 mm)

~
I

.~~~~~~~~~~~
I. Base material is either the same as body or solid trim at manufacturer's option. 2. NACE service valves are supplied with bolting with maximum hardness of
Rc. 22. Use NS for special NACE trim and specify details on order.

<wO 7
INTRODUCTION

1.3 THE DIFFERENT STYLES

OF PRESSURE SEAL VALVES
Velan pressure seal valves have in the past been
gasket. The internal fluid pressure also forces
the bonnet upward toward the thrust ring,
increasing the pressure on the gasket.
.1
built in three basic styles for a large range of sizes 3. Style III (Fig. 1.3C)
and pressure classes. These basic styles (shown The upward tightening force for the pressure
in Fig. 1.3A, 1.38 and 1.3C)apply to gate, parallel seal gasket is achieved by tightening the nuts
slide, globe and stop check valves. In a continuous on the studs in the bonnet which protrude
innovative effort to improve pressure seal valve through the bonnet retainer. The internal fluid
design, Velan is presently phasing in a live-loaded pressure also forces the bonnet upward
bolted bonnet configuration as its standard. toward the thrust ring, increasing the pressure
An example of this is illustrated in Fig. 1.3D. on the gasket.
1. Style I (Fig. 1.3A) 4. Live-loaded bolted bonnet (Fig. 1.3D)
Turning the bonnet retainer clockwise (with spring washers)
develops the upward force for tightening the Compression of the pressure seal gasket is
pressure seal gasket. The internal fluid pres- achieved by tightening the nuts on the studs in
sure also forces the bonnet upward toward the the bonnet which protrude through the bonnet
yoke, increasing the pressure on the gasket. retainer and by the internal fluid pressure.
The Belleville washers allow for greater ener-
2. Style II (Fig. 1.38) gy storage and consequently, automatically
When the cap screw is turned clockwise, the
reapply bolt load to the gasket when hydro
upward force on the bonnet retainer pulls the
pressure is removed or pressure is reduced.
bonnet upward against the pressure seal

•
Figure 1.3C Style 11/

Figure 1.3A Style I

Figure 1.38 Style /I

8
Figure 1.3D Live-loadedbolted bonnet
J,DI
•
RECEIVING & PREPARATIONFOR INSTALLATION II

• 2.1 RECEIVING INSPECTION

All valves must be examined for signs of damage
that may have occurred during transportation.
Any damage should by analyzed and a report
2.4 HANDLING AND PREPARATION
On large valves, a hoist is needed to assist
installation. A sling should be placed under the
valve body so that the unit can be lifted vertically
should be issued. Serious damage should be to its final destination. End protectors must be
reported to your local Velan representative or to removed from all types of valves and connections
the Customer Service Manager so that a suitable must be checked for cleanliness. Any visible for-
arrangement for repairs can be made eign matter must be removed from end connec-
without delay. tions on flanged and weld-end valves. The weld-
end preparation must be cleaned properly with a

e 2.2 QUALITY CONTROL DOCUMENTATION

suitable solvent such as acetone or alcohol. Do
not use solvents containing chloride or fluoride.

For valves purchased with Quality Control (QC)

certification, check the package of documents to 2.5 SPECIAL INSTRUCTIONS
see that the Quality Control certificates are com- FOR GATE VALVES
plete as per the purchase order.
The flow through gate valves can be from either
end. There may be exceptions to this if bypass
2.3 STORAGE piping is welded to the valve body or if a pressure
relief hole is drilled in one side of the valve gate.
Valves should be stored in a suitably sheltered Check your piping layout drawing to ensure cor-
place to prevent contamination by weather, dirt

•
rect position and direction of flow. Gate valves
or dampness. The valve is shipped with end should be installed and welded into the pipeline
protectors on the inlet and outlet which should with the wedge or disc in the fully closed position.
stay on the valve until it is ready for installation. If the valve is left open or partially open, it could
NOTE: If actuators are involved, please distort and leak during operation. Also, leaving
the valve in a fully closed position helps prevent
refer to the applicable manufacturer's instruc-
weld spatter from falling directly onto the mating
tions for storage.
faces of the seats.
WARNING: During installation, welding and
construction stage the valve mid-section The preferred orientation of a gate valve is
around the packing flange and stem should upright. The valve may be installed in other
be protected at all times; as foreign debries orientations, but any deviation from vertical is a
from welding, grinding, etc. can fall in compromise. Installation upside down is not
between the tapered area of the packing recommended because of possible dirt build-up in
the bonnet. It is best to consult Velan Engineering
flange and stem that can cause extensive
department during quotation review process as to
damage to stem and associated parts during
remedial measures required (hardfacing of guides)
valve cycling. In any case, prior to cycling,
when valves over 12" are tilted beyond 45° from
the area between the stem, packing flange the stem vertical orientation.
and gland bushing must be thoroughly
cleaned oft of all foreign matter. NOTE: Gate valves should not be used for
throttling to control the flow, they are
normally fully open or fully closed. If left in
partially open position could result in severe
damage to body seats, wedge, stem & guide
rails .

• 9
II RECEIVING & PREPARATION FOR INSTALLATION

2.6 SPECIAL INSTRUCTIONS 2.7 SPECIAL INSTRUCTIONS

FOR GLOBE VALVES FOR CHECK VALVES
Globe valves are usually installed with the inlet Check valves must be installed with the inlet in
below the valve seat. This must be checked care- direction of arrow. This must be checked carefully
fully to prevent incorrect installation. If throttling before installing the valve. Placing a check valve
service is particularly severe, Velan recommends in the opposite direction to the flow will prevent
that the valve be installed so that the flow enters the disc from swinging free and will therefore pre-
over the top of the seat and goes down through it. vent normal operation of the valve.
This maintains the valve in a more stable condi- NOTE: All check valves should be installed at
tion, the amount of wear is minimized and there is
least ten pipe diameters away from upstream
less external noise. Valve operation also becomes
pumps, elbows, fittings or equipment. If
easier because less torque is required to close
the valve.
closer installation is required, please consult
the Velan Customer Service Manager.
t
Globe type valves should be installed and welded
with the disc in a fully closed position to prevent CAUTION: Velan piston check and stop
damage to the valve during installation. Leaving check valves without springs should be
the disc in a fully closed position also prevents installed with the bonnet up, and the angle
weld spatter from falling directly onto the mating of incline of the line should be no more
faces of the seat and disc. than 45° from horizontal. Also, the roll
angle of the valve bonnet should be no ~
PRECAUTION: Allow time for welding to

•
more than 45° from side to side
cool before trying the valve for the first
time in the pipeline.

Figure 2.7 Check valve: Angle of incline and roll angle

10
RECEIVING & PREPARATION FOR INSTALLATION II

• 2.8 SPECIAL INSTRUCTIONS FOR TILTING NOTE:

DISC CHECK VALVES a) Pressure seal design without live load
bonnet (no spring washers):
Tilting disc check valves can be installed The gasket bolt tightness must be
horizontally or vertically according to the design rechecked after operating test pressure
specifications and with the inlet in the direction and temperature has been achieved.
of the arrow. However, for vertical installation Without live-loading, bolt tightness will be
special disc machining is required and prior lost, when the system loses pressure.
knowledge of design condition is necessary to b) Pressure seal design with live load bonnet:
ensure correct applications. Placing a check valve A live-loaded bonnet bolt may also lose
in the opposite direction to the flow will prevent some bolt load, due to vibration in transit
the disc from swinging free and will therefore or bolt creep. It is advisable that live-loaded
prevent normal operation of the valve. bonnets be checked for bolt torque at
e NOTE: All check valves should be installed at
least ten pipe diameters away from upstream
operating pressure. Once torqued at
operating pressure, no future tightening of
gasket bolting will be necessary, unless the
pumps, elbows, fittings or equipment. If clos-
valve has been dismantled, in which case,
er installation is required, please consult the the gasket bolts must be torqued to values
Velan Customer Service Manager. given in Tables 4.5A & B on page 17 and
bolt tightness rechecked after operating
~ 2.9 RECHECK FOR BOLT TIGHTNESS test pressure and temperature has been
achieved.
In order to ensure a pressure seal between the
valve's body and bonnet, it is essential that bolt CAUTION: If the pressure seal gasket
tightness be verified. Whenever possible firmly is not pulled up concentric to the body
•
backseat the valve and bring up the line pressure /bonnet top-bore axis, under lower
as close as possible to normal operating pressure pressure the gasket may not be properly
and temperature. Recheck and retighten the gas- seated. Consequently, leakage may
ket bolts (i.e., body/bonnet bolts) as necessary to occur. Moreover, non-uniform contact
the values given in Tables 4.5 on pages 17. The
may be the source of leaks in the future.
following procedure is used:

e. If possible fully open and firmly back seat

the valve.
Therefore, when possible, backseat the
valve fully when pulling up the pressure
seal gasket bolts. The packing bolts must
2. Remove one nut or cap screw at a time, also be verified against Table 5.1A & B
lubricate stud and nut thoroughly with an on page 23.
approved anti-seize compound and torque to
recommended values shown in tables 4.5.
3. Remove opposite nut or cap screw and repeat
procedure until all nuts or cap screws have
been retorqued.
4. Recheck bolt torque by going once around
clockwise.
NOTE: If gasket must be replaced, follow
Body-Bonnet Torquing Procedure, Section 4.5.

,.
11
II RECEIVING & PREPARATION FOR INSTALLATION

2.10 SPECIAL NOTE ON

LIVE LOADED BOLTING
As a result of continuous design improvements
and application requirements, Velan is phasing-in
live-loaded bolting as a standard feature in future
designs and as an option in certain existing designs.
At the present time, live-loading is available in
6 - 24" (150 - 600 mm) (Class 1500) and 8 - 24"
(200 - 600 mm) (Class 2500). For applications in
smaller sizes, please contact your local Velan
representative.

Standard Pressure Seal Design (Fig. 2. 11A)

1. Bonnet tends to move up or down as pres-
sure changes.
2. Bolt load nominal to create initial seal. Figure 2. 11B
3. Gasket deforms during hydrotest, bolts lose
torque and must be retightened after
hydro-test. Stored Bolt • Standard design
Energy (Ibf) • With live loading
30,000 -r---r-r--..,....--r-.,.....--r----:r--...,.-.....,.--,

•
.005 .010 .015 .020
Compensation for bonnet movement (in)

Figure 2.11C Graphically illustrates the stored

bolt energy in live-loaded bolting.

Figure 2.11A 4. Standard design now on market.(Fig. 2. 11C)

5. Velan solution with live-loading, ensures
New Generation of Live-Loaded Pressure Seal Design automatically zero leakage over large range
(Fig. 2.11B)
of pressures.
1. Automatically reapplies bolt load to the
The torque requirements on various live-loaded
gasket when hydro pressure is removed or
configurations differ from the standard bolting
pressure is reduced.

•
torque requirements and may require altering
2. When torqued once at installation under certain parts (e.g., packing flanges and bonnet
operating pressure no future tightening will retainers in case of retro-fit live-loading).
be required. For further details regarding specific applications
by size and pressure class please contact
3. Live-loading compensates for large bonnet
Customer Service Manager.
movement.
12
:...i
WARNING III

•
FOR SAFETY REASONS,
it is important to take these precautions
Personnel making any adjustments on the valves should wear
safety equipment normally used to work with fluid in the line
where the valve is installed.
(... Before removing the yoke bushing under pressure, the valve should be in
fully open position in order to prevent injuries.
Before removing a valve from a line, line pressure must be relieved with
no exception.
Velan valves can be equipped with a variety of manual gear, electric motor,
hydraulic or pneumatic actuators. Generally, all pressure must be relieved from
both sides of the valve before the actuator is removed.

• A valve in the fully open position (backseated),should not be jammed-tight (over-

torqued), to avoid thermal binding. It is our recommendation that the valve be
removed 1/4 turn of the handwheel from the fully open position. This will also
ensure that packing tightness is verifiable. In gear-operated valves, because of the
backlash, it is difficult sometimes to ensure this position.
Valve standards, such as API and MSS, caution users that successful completion
of a backseat test should not be construed as a recommendation by the manufactur-
er that a valve may be repacked while it is under pressure. The backseat may
be used as a means of stopping or reducing packing leakage until the packing
can be replaced under no pressure. Removal of packing with the valve under
pressure is at the owner's risk.

C... Do not attempt to force out the pressure seal gasket by using a
crane, hoist, chain-block, etc. Thegasket may be tight inside
the valve body and if pulled using a crane,jack, or other
means, it may suddenly release,causing
personal injury and/or extensive damage.

• z_ob
13
IV GENERAL MAINTENANCE

4.1 TROUBLE SHOOTING CHART

AREA
•
GENERAL MAINTENANCE IV

I.
• 4.2 OPERATION

4.2.1 General
4.4 GENERALASSEMBLY INFORMATION
1. The most important fact to be considered is
the cleanliness of all parts. All rust and dirt
should be removed from all parts with a wire
All valves require examination before being
brush or emery cloth. Oil and grease should
put into operation. In addition, valves should be
inspected regularly during operation and should be removed with suitable solvents.
receive prompt attention when trouble arises. 2. All threaded parts (cap screws, nuts, studs)
As a general rule, valves should be subjected must be well relubricated. The stem and yoke
to scheduled maintenance. nut threads should be clean of old grease
before the new application. Recommended,
4.2.2 Smoothness of Operation lubricants can be found in Section 4.3. Use

e Stem threads, gearing and other working

components outside the fluid area should be
3.
correct lubricant for each individual part.
Repaired or replacement parts must be
lubricated frequently and at least once every six checked to see that all repair procedures
months. Specific lubricants and frequency of have been done and that all replacement
application are shown in the recommended parts (e.g., packing rings, gasket, etc.) have
lubrication table of Section 4.3. Valves that are been checked for size so that they will fit into
not operated frequently and which may remain the valve being serviced.
open or closed for long periods of time should
4. All orientation marks assigned during
be worked (even if only partially) about once a
disassembly must be observed so that correct

•
month.
orientation is maintained. Where applicable,
IMPORTANT: Excessive handwheel effort can orientation marks should be made on parts
indicate the following: near the body serial number (e.g., wedge,
1. Improperly lubricated or damaged valve disc, seat, etc.).
stem.
2. Valve packing compression too tight (check
torque Table 5. 1A) .
3. Faulty or damaged valve parts.
4. Foreign debries on stem threads and/or
packing area

4.3 RECOMMENDED LUBRICATION

Table 4.3 Recommended lubrication

ApPLICATION FREQUENCY

Stem Exxon: Ronex MP, Castro I MP Directly to When threads

,~
threads or equivalent MP group (up to 6500F) threads appear dry
Ronex Extra duty 2 (above 6500F)

Yoke nut Exxon: Ronex MP, Castrol MP Inject through Concurrently

or equivalent MP group (up to 6500F) grease fitting with stem
Ronex Extra duty 2 (above 650oF) at hub of yoke thread lubrication

All threaded parts

•
- Anti-seize compound No. 425-A Thin coat on On valve
except (Crane) or equivalent threads assembly only
t stem and yoke nut - Nickel Anti-Seize to MIL-A-90TE
or MOLYKOTE P37
Recommended lubricant subject to change without notice.

15
IV GENERAL MAINTENANCE

4.5 BONNET/GASKET TORQUING PROCEDURE

1
~, •
4.5.1 General
1. Clean all studs and nuts. Visually inspect
all threads to ensure removal of all foreign
matter, rust, corrosion, burrs and previous
3 5
lubricants.
2. liberally cover the stud threads and the
surface under the nut head with FELPRO
type C5A Hi-Temp or nuclear grade (never
SEEZ5000) nickel base antiseize compound
or approved equivalent. Also, lubricate the
female threads of the nuts and nut flats and
wipe off any excess lubricant that may 6 4
adhere to any of the stainless steel parts
with recommended solvents.
Recommended solvents for this work are:
a) unused or redistilled acetone
2
b) alcohol
3. After tightening bolts by hand, follow the
bolt tightening sequence shown in Fig. 4.5A. Figure 4.5A Bolt tightening sequence
This sequence depends on the quantity of
bolts used. The drawing illustrates the logical
sequence one should follow.
IMPORTANT: To maintain proper alignment,
whenever possible valve should be fully
backseated prior to retightening bolts.
If the type of valve you are servicing is a

•
pressure seal, Style I, the bolt tightening
sequence shown in Fig. 4.5A will not apply.
The bonnet retainer nut must be torqued
down using a crawfoot wrench as in Fig. 4.58
and torque to value shown in Table 4.5A.

4.5.2 Application of Torque

When applYing the torque to the bolts, each bolt
should be torqued in steps of approximately 20%
of the final torque shown in Table 4.5A or 8
torque values with or without live-loading.
If possible, after the final torque has been applied
to the screwed bonnet retainer, cap screw or
pull-up bolts, bring up the line pressure as close Figure 4.58 Crawfoot Wrench for 2 - 2 W'
as possible to normal operating pressure and (50-65 mm) for screwed bonnet
temperature. Recheck and retighten the bolts if retainer
necessary.

•
frequent temperature and/or pressure cycling.
IMPORTANT: It is possible to retro-fit certain
For further details, refer to Section 2.71, Special
sizes of Velan pressure seal valves with longer
Note on Live-Loaded Boltinq. For torque values
bolts and Belleville spring washers to achieve a
consult Table 4.58. For Belleville spring washer
live-loading of the bonnet bolts. This is
configuration refer to Fig. 4.5C & D.
applicable when the system undergoes

16
IV GENERAL MAINTENANCE

• Table 4.5A Bonnet/Gasket Torque Values Without Live-Loading

I • NOTE: (1) For graphite gasket use the following values.

a. If the valve is not pressurized, use 125% of above torque values.
b. If pressurized to design pressure (operating) use 50% of the above values.
c. For pressures between zero and the design pressure, the torque to be used is approximated by linear interpolation.
(2) Torque tolerance ±10%.
(3) For temperatures above 750°F (400°C) use 75% of the values.
(4) Above Torque Values are with the bolts lubricated.

e Table 4.58 Bonnet/Gasket Torque Values With Live-Loading (Spring Washers)

BOLTING MATERIAL
STUD SIZE B7,B16,630,A-574
ftlb N·m
~"-13UNC 60 81
78" - llUNC 120 163
W' -10UNC 200 271
7,t" -9UNC 320 434
1-8UN 490 664
1~" - 8UN 710 963
lW'-8UN 1000 1360

NOTE: (1) For graphite gasket use the following values.

•
a. If the valve is not pressurized, use 125% of above torque values.

t b. If pressurized to design pressure (operating) use 50% of the above values .

c. For pressures between zero and the design pressure, the torque to be used is approximated by linear interpolation.
(2) The torque values listed above are for standard Velan valve designs with live loading.
(3) Torque tolerances ±10%.
(4) Above Torque Values are with the bolts lubricated.

'l-f 0
17
GENERAL MAINTENANCE IV

PRECAUTION:
I
I
1.lf tightening sequence is not followed,
it is possible that the gasket will not be (3) belleville
compressed evenly, and may result in spring washer ,.....
gasket leakage.
2. Over-torquing can cause deformation
of the body/cover retainer and/or gasket
retaining ring, causing valve to leak.
<. I-
?0-
~
f-::

3. Do not use impacting devices to tighten

up the bolting on the body/bonnet
,
(cover). Use suitable mechanical
devices for tightening.
4. When the valve is positioned such that
the stem is horizontal, care should be
taken to prevent the bonnet from tilting ~ -/ / / 1
I
/
to one side by gravity. To maintain Figure 4.5C Belleville spring washer
concentricity, first open valve fully, configuration
backseat firmly and repack. Torque in
steps of 20% of the final torque value
and ensure that the gland bushing slides
smoothly into the packing chamber.
5. Use hand torque wrenches. If torque
wrenches are not suitable, use standard
wrenches and the following guidelines
(5) belleville
will apply:

•
spring washer
BOLT SIZE LENGTH OF WRENCH
inches
5"
mm
125 ~
I-
~
~
1--=
-
3/8" ~ ~
1/2" 6" 150
9" 225 ~
9/16" ~
12" 300
5/8"
3/4"
7/8"
18"
24"
450
600
,
1" 30" 750
1 '/8" 36" 900

On sizes of bolts larger than 1-'/8", special torque

/

V///
multipliers with ratios 1:7 or 1:6 should be used
for torquing.

Figure 4.5D Belleville spring washer

configuration

18
PERTINENT TO GATE, GLOBE, CHECK &

•
INFORMATION V
PARALLEL SLIDE VALVES

(
5.1 PACKING

5.1.1 Number of Packing Rings Required

(see Figs 5.1A & B)

All Velan pressure seal gate, globe and parallel

slide valves require seven packing rings
(Fig 5. 1C). For valves equipped with a leak-off
connection, four packings are placed below the
lantern ring and three above (Fig. 5.10). Figure 5.1A Graphite ribbon packing

e 5.1.2 Packing Ring Removal on Line

Follow warning instructions in Section III before

replacing packing rings on line.
1. Remove the packing flange nuts and, if fit with
live-Ioa_ding,remove Belleville spring washers.
2. Lift packing flange and gland bushing as high
as possible and secure.
3. For braided packing rings: Fig. 5.1C and 0 use

•
special flexible removal tools (cork screw tip) Figure 5.1B Braided graphite packing ring
Fig. 5. 1Escrew into the packing ring and pull
I out. For graphite ribbon packing Fig 5.1C and 0
with special "C" -saw tool Fig. 5.1F cut through
the packings, apply downward pressure as Braided _____.."",__
you work the tool in a back and forth motion.
Blowout packing remains using instrument air
or suck out with a vaccum cleaner. Care must :;:.[_____""'" > >. >.
be taken not to scratch the stem or the walls of ribbon
packings
the packing chamber during the removal of
the packing rings. >.
Braided ___.
4. If the valve is equipped with a leak-off pipe, packing
there is a lantern ring after the third packing
ring. To remove the lantern ring, insert two Figure 5.1C Seven packings shown
hooks into the holes at the top of the lantern
ring or insert screw-in extracting wires where
tapped holes are provided. These tapped
holes are 6-32 for valves 2% - 4"(65 -100 mm)
and 8-32 UNC for valves 6"(150 mm) and
larger. ~~~~~~~Braided~ packing
5. After the lantern ring is lifted, the last four
packing rings can be removed using the
procedure described in step 3. o lantern
"_ring

NOTE: All of our designs can be equipped

with a blowout plug option. If this connection

•
is provided, the packing rings can be removed
by applying gas or hydraulic pressure from
below as shown in Fig. 5.1G. See Section
5.1.3.
Figure 5.10 Lantern ring configuration

19
V INFORMATION PERTINENT TO GATE, GLOBE, CHECK &
PARALLEL SLIDE VALVES

4. Remove blowout plug and gasket.

Attach the pressure source to the connection.
The packing rings will be pushed out of
the packing chamber.
NOTE: When applying gas pressure, this
operation will happen quite quickly and it is
possible that trapped liquid will spray out.
5. All packing rings can be removed simultane-
ously. This is a fast and efficient operation.

5.1.4 Repacking with Graphite Packing Rings for

Figure5.1E Flexible packing removal tool
cork screw tip
Valves without Leak-off Connection t
1. Before repacking, check the stem and
the packing chamber wall for damage.
Packing Chamber: Scratches (damage) no
deeper than 0.010" (0.25 mm) per side can
be removed by polishing the surfaces with a
buffing wheel (120 - 220 grit) or by machining
the entire packing chamber .surfece.
The surface finish should be 16 RMS or better. '-"
Stem: Scratches (damage) no deeper than
0.010" (0.25 mm) per side can be removed by
machining the entire stem. Smooth portion
up to the back seat. Surface finish should be
t 4
16 RMS or better.

Figure5.1F "en-saw packing removal tool 2. Insert the first packing ring (braided graphite
type, end ring) manually and place as deep

•
into the packing chamber as possible
followed by 1 graphite ribbon (intermediate
packing ring). Refer to Fig. 5.1H.

Figure 5.1G Removal with blowout

5.1.3 Removal with Blowout (Fig.5.1G)

1. Fully open the valve and tighten the stem
firmly against the backseat.
2. Loosen packing flange nut and live-loading
assemblies (if so equipped).
Figure 5.1H Repacking without leak-off
3. If valve is equipped with a leakoff pipe, block connection
off connection.
20
INFORMATION PERTINENT TO GATE, GLOBE, CHECK & V
PARALLEL SLIDE VALVES

I •
repeat the procedure above until all intermediate
graphite ribbon packings have been torqued
Split packing
adaptor NOTE:
a) The split lap joints of each consecutive ring
must be staggered at 1200 so that the fourth
ring installed has its lap back at the starting
point (Fig. 5.1J). Subsequent packing rings
should be repacked in the same manner until
the special packing adaptors are no longer
required and the standard gland bushing can
be used.
b) In case valves are equipped with live-loading
(Belleville spring washers), remove spring
washers during precompression of packing
rings, and reinstall at final torque.
Figure 5.11 Repacking with split packing ring 6. Remove the nuts and split packing adaptor and
insert the last end ring (braided graphite type),

..•...
' :,
..

_:~.
'". 3. Insert the split packing adaptor. Push the
packing rings to the bottom of the chamber,
making sure that the lap joint is not reversed
lower gland bushing and check for bushing
positive engagement with packing chamber.
NOTE: As a rule of thumb y." (6 mm) min.

•
during the operation.
engagement is required. Lower the gland flange,

I 4. Placethe gland bushing and packing flange

into position (Fig. 5.1/) and compress the
bottom packing by tightening the nuts to 130%
relubricate the gland studs/nuts using anti-seize
compound and torque to values shown in
Table 5. 1A and/or project drawing.
of the torque value shown in Table 5. 1Aor B.
7. Cycle the valve once for approximately the length
NOTE: Ensure gland bolts/nuts are well
lubricated with anti-seize compound. of the packing chamber. First cycle open then
close and retighten packing flange nuts to the

•
5. Remove the nuts and split packing adaptors,
required torque value Table 5.1A.
insert the next graphite ribbon packing and
NOTE: If above procedure using split bushings
cannot be followed, use alternate procedure,
refer to Section 5.1.4.1.

5.1.4.1 Packing Consolidation Method

1. Insert the first packing ring, braid graphite type
(end ring) and place as deep into the packing
chamber as possible, followed by five graphite
ribbon (intermediate packing rings)
refer to Fig. 5.1e.
NOTE: The split lap joints of each consecutive
ring should be staggered at approximately
120 degrees apart.
2. Install the last packing braided graphite type

•
(end ring). Lower the gland bushing and check

t for positive engagement with packing chamber.

NOTE: The gland bushing should enter the
packing chamber as a rule of thumb approx.
W' (6 mm) minimum engagement.
Figure 5.1J Seven packings installed
'l-It 21
V INFORMATION PERTINENT TO GATE, GLOBE, CHECK &
PARALLEL SLIDE VALVES
• t
3. Place the packing flange into position refer 4. Place (1) braided and (1) graphite ribbon
to Fig. 5.1J. Ensure gland bolt/nuts are well packing ring above the lantern ring and
lubricated with anti-seize compound. precompress to 130% of torque value of
Compress the packing by tightening the nuts Table 5.1A.
to the torque value shown in Table 5.1A.
NOTE: In case valves are equipped with
4. Cycle the valve for approximately the length of live-loading (Belleville spring washers) remove
the packing chamber, first open then close and spring washers during precompression of
retighten to required final torque (Table 5.1A).
packing rings, and reinstall at final torque.
Do this procedure as many times as necessary
(approximately 4-5 times) until all packing 5. Insert (1) last end ring braided graphite type
become fully consolidated (no more loss of lower gland bushing and check for positive
torque). engagement. As a rule of thumb approx. X" (';
NOTE: For motor operated valves (mov) use (6 mm) engagement is required. Carefully
mov manual override handwheel to cycle align the gland bushing and packing flange.
open and close. Relubricate gland bolts/nuts and torque
down to values shown in Table 5.1A and/or
5.1.5 Repacking wit~ Graphite Rings for Valves with project drawing.
Leak-off Connection (Fig. 5.1K) 6. Cycle the valves once for approximately the
. 1. Follow the same procedure as described in length of the packing chamber. When cycling
steps one through four of the previous section is completed, retighten packing flange nuts to
Section 5.1.4, Repacking with Graphite Packing required final torque (Table 5.1A or 8).
Rings for valves without leak-off connection. NOTE: If above procedure using split bushings
2. Insert next intermediate graphite ribbon cannot be followed, use alternate procedure as
packing ring and repeat the procedure above. described in Section 5.1.4.1, except install four
3. Insert (1) braided graphite packing ring. packing rings below the lantern ring and three
Lower the lantern ring ensuring that it lines up packings above, refer to Fig. 5.10.
with the leak-off connection and repeat the
procedure above. 5.1.6 Packing Torques
Step 1: Clean all studs and nuts. Visually •
inspect all threads to ensure removal
of all foreign matter, rust, corrosion,
burrs and previous lubricants.
Step 2: Liberally cover the stud and nut
threads and the bottom of nut flats
with an anti-seize compound such as
nickel base Never-SEEZ5000, FELPRO
type C5A Hi-Temp or approved
equivalent.
Step 3: Tighten the packing flange nuts a little
at a time on each side, then torque in
accordance with valve type, size,
pressure class and packing type as
shown in Table 5.1A.
NOTE: Values in Table 5.1A and Bare
approximate for standard Velan valves.
Whenever possible, refer to project
engineering drawings for individual valves
Figure 5.1K Leak-off connection and their required torques.

22
( • Table 5.1A
INFORMATION PERTINENT TO GATE, GLOBE, CHECK &
PARALLEL SLIDE VALVES

Packing flange stud / nut torques for graphite packings

V

GATE FORGED GATE FORGED GATE FORGED GATE CAST PARALLEL SLIDE FORGED
600_900 1500 2500 600

[ • Table 5.1B Packing flange stud / nut torques for graphite packings

GLOBE GLOBE GLOBE "Y"_ PATTERN INCLINED GLOBE

600_900 1500 2500 1500 2500

NOTE:
(1) Globes 12" (300mm) and up and "Y" - Pattern 6" (250 mm) are cast.
(2) For other materials and/or valve sizs contact the Velan Service Department.
(3) Torques tolerance ±10%.

•
(4) Above torque values are with the gland stud and nuts lubricated.
)

23
INFORMATION PERTINENT TO GATE, GLOBE, CHECK & V -:'~

••
::
PARALLEL SLIDE VALVES

5.1.1 Live-Loading Packing double stack depending on application), and

a gland nut, refer to Fig. 5.1L.
Installation of the packing rings follows the
2. Tighten the gland nuts a little at a time on
procedures described in Sections 5.1.4 & 5. 1.5
each side up to the torque values indicated in
('without' and 'with' a leak-off connection,
Table 5. 1A or B.
respectively). The Belleville washers are not
to be used while compressing individual packing NOTE: Make sure that the Belleville washers
into the packing chamber. However, if "packing do not slide laterally while tightening.
consolidation method" is used as described in
Section 5.1.4.1 the Belleville spring washers
(live -loading) must be in place prior to applying
5.2 DETAILED MAINTENANCE
packing torque.
5.2.1 Packing Chamber Leakage ( ,
IMPORTANT: approximately Yo" (6mm)
engagement of the gland bushing into the If moisture or dripping occurs around the stem of
packing chamber is essential to ensure that the ID packing chamber, the following points must
the packing does not blowout. be investigated before removing the packing:

Velan's standard live-loaded packing configuration 1. Check if the packing flange is torqued
for pressure seal valves is illustrated in Fig. 5.1L. down to the correct torque as shown in
Table 5.1A or B.
Assembly Procedure: 2. Check if the live-load arrangement is in
correct order. Compare your live-loading
1. On each gland stud, place spacer ring on
arrangement with Fig. 5.1L. If it is not correct,
the packing flange, a guide sleeve, a stack of
Belleville spring washers (either single or
open the valve to the backseat position and
tighten up on the backseat firmly.
( t

Single stacked Double stacked

Figure 5.1L Live loaded packing

24
V INFORMATION PERTINENT TO GATE, GLOBE, CHECK &

•
PARALLEL SLIDE VALVES

determining if the leakage has stopped. The parts

CAUTION: You must determine the could have become loose during transportation or
effectiveness of the backseat seal as you storage. If tightening does not stop the leakage,
dismantle the live-loading arrangement. the pressure seal gasket is probably damaged and
If leakage occurs during disassembly, line the valve must be opened for examination. Such a
pressure must be shut off. Reassemble leak can be caused by any of the following:
live-loading arrangement in correct order,
1. Imperfect seal between bonnet and gasket
then torque down to the correct torque as An incomplete seal can be caused by
shown in Table 5.1A or B. corrosion or dirt chips or other foreign
matter pushed between the seating surfaces
3. Check if the gland bushing is binding of the body or bonnet and the seating faces

e against the packing chamber wall or stem.

If so, fully open the valve and tighten the
stem against the backseat firmly. Loosen the
of the pressure seal gasket. An imperfect seal
between the seal ring and the inside contact
surface of the body can be caused by an
packing flange and realign the gland bushing. imperfect surface caused by metal failure,
Tighten up the packing flange a little at a time sometimes after valve installation and use.
on each side, then torque down to the correct All Velan bodies and bonnets are of forged
torque. as shown in Table 5.1A or B. quality, eliminating the possibility of surface
4. After retightening, cycle the valve once porosity, and the contact area of all pressure
for approximetely the length of the packing seal bodies has been hardface deposited

• chamber, cycle first open then close and (stainless steel) as an added precaution.
retighten nuts to original torque value (Table Although the surface has a smooth finish
5.1A). Slacken the nuts slightly if torque is too and is die-penetrant inspected, surface
( high. If steps 1 through 4 do not stop leakage,
proceed with the removal and replacement of
indications can develop in service which
can cause subsequent leakage.
the packing rings. 2. Seal ring leakage
This may be caused by external flow on the
5.2.2 Body/Bonnet (Gasket) Leakage sealing edge of the ring.
3. Reusing the pressure seal ring
5.2.2.1 General Velan recommends that the pressure seal ring
not be reused. Spare rings should be kept on
To maintain the tightness of a factory-tested hand before opening the valve. If the pressure
pressure seal valve, it is essential to apply sufficient seal ring is removed from the body, it must be
bolt tension at all times by having the proper torque carefully examined for imperfections and
on the nuts or cap screws. The original torque score marks. These marks, usually made
might be lost due to vibration, relaxation of material during the removal operation, may cause
caused by frequent temperature and pressure leaks if the ring is reused. The seal ring, made
fluctuations, or by creep in high temperature of soft iron (silver-plated) or graphite, must be
applications. Joint bolt tension should be checked handled with great care to prevent scoring of
at approximetely one-year intervals and, if internal and external surfaces.
necessary, retighten bolts in accordance with
Section 2.9 Recheck For Bolt Tightness. 5.2.2.3 Body-Bonnet Joint - Seating Face Repairs
1. First, it is necessary to make a visual
5.2.2.2 Leakage of Body-Bonnet Joint inspection of the body and bonnet gasket
contact area. Wash the two contact areas
Whenever possible, begin by opening the valve with a suitable solvent and dry with a clean

•
fully and backseat firmly. Tighten under line rag. Leak indications can be discovered by

t pressure the screwed bonnet retaining ring - Style I,

Fig. 1.3A or cap screw - Style II, Fig. 1.38 or stud
and nut - Style Ill, Fig. 1.3C,to values shown in
correlating marks on the body or bonnet
seating areas with the corresponding clues
on the 00 and 10 of the pressure seal gasket
Table 4.5A. Wait three to five minutes before which has been removed from the valve.

25
V INFORMATION PERTINENT TO GATE, GLOBE, CHECK &

••
PARALLEL SLIDE VALVES

2. Very small imperfections no larger than 0.015"

(0.4 mm) on the sealing faces can be removed
by polishing with a 60 to 120 grit buffing wheel
or by honing. If imperfections are greater
than 0.015" (0.4 mm), it may be necessary to
machine the complete inside diameter of the
contact area in the body, requiring a new
oversized gasket (Fig. 5.2A).
NOTE: All Velan pressure seal bodies are sup-
plied with a 1 degree or 3 degreestaper to ensure
easy sliding of the gasket. If refinishing of the
body gasket seating area is necessary,refinish as (
nearly as possible with the same taper. Body
3. You may also discover that the gasket seal is
Figure 5.2A Machining of gasketcontact area
broken between the outer angular sealing sur-
face of the gasket. Therefore, any impression on
the bonnet must be removed completely before
reassembly. This can be done by polishing
using a 60 - 120 grit buffing wheel or by taking a
shaving or skim cut on the angular surface of the
bonnet. The bonnet must be chucked concentric
and square to all existing diameters and surfaces
so that the angle to be remachined remains at
Velan's standard angle of 45', plus W, minus 0'.
Refer to Fig. 5.28.
NOTE: Some pressure seal designs may
have different angular surface of the bonnet
then the Velan standard. Verify the bonnet Figure 5.28 Bonnet machining
surface angle before machining or contact
Velan customer service for more information.
4. When the valve is reassembled, it is critical that t
the gasket fit concentric in the body and on the
bonnet as shown in Fig. 5.2C.
The following points should be considered:
a) The gasket should not fall below the bottom
edge of the 1 degree or 3 degrees taper. If it
does, the new standard gasket may be too
small and should be measured. If the inside
diameter of the body at the bottom edge of
the taper is more than 0.015" (0.4 mm) larg-
er than the outside diameter of the gasket, a Figure 5.2C Gasket fitting
new oversized gasket is required.
b) The gasket should fit over the corner edge 5.2.3 Seat leakage
of the bonnet.
c) The body and bonnet should be round and 5.2.3.1 General
not oval.
d) Body, bonnet and gasket should be free An indication of a valve leak is a pressure loss in
from oil, grease, rust or dirt and should be the high pressure line side after a valve has been
cleaned with a suitable solvent such as properly closed. In the case of hot water or steam
acetone or alcohol. Do not use solvents lines, note whether the downstream pipe remains
containing chloride or fluoride. hot beyond the usual length of time. This type of
J-Iq
26
,. INFORMATION PERTINENT TO GATE, GLOBE, CHECK &

leak may be the result of a distorted seat caused

by improper welding of the valve into the pipeline,
PARALLEL SLIDE VALVES
V

or by stress relieving temperatures that may have

been used during installation. Leaks can also
develop from failure to close the valve tightly,
resulting in high-velocity flow through a small
opening. The hardfacing material (e.g., Stellite 6)
is corrosion and erosion-resistant, but grooves, pit
marks or other surface irregularities may still form
on the mating surfaces. Valves which leak should
be repaired as quickly as possible to prevent
greater damage caused by high velocity.
(
5.2.3.2 Wedge And Disc Repairs - Gate And Parallel
Slide Valves
Figure 5.2D Lapping of wedge
1. Disassemble valve as described in Section
6.4.2 for gate valves and Section 8.3.2 for the use of Clover Compound (silicone carbide)
parallel slide valves, and inspect the wedge Grade E, medium coarse or C, fine grit for
or disc for scratches or damage. finishing or an approved equivalent.
2. If seating faces are scratched, the wedge must 5. Thoroughly clean off the lapping compound
be lapped. Slight pitting, grooving or with a suitable cleaning fluid such as acetone or
indentations no deeper than 0.005" (0.1 mm) alcohol. Do not use solvents containing chloride
can be removed by lapping. If defects cannot or fluoride.
be corrected by lapping, wedge or disc should
be ground or machined. Velan recommends PRECAUTION: Lapping may be slow due
that a maximum of 0.015" (0.4 mm) on each to the erosion-resistant surface, but too
side be removed from a 10-degree seated much lapping must be avoided.
wedge and 0.010" (0.25 mm) on each side
for a 7-degree seated wedge. 6. Grinding the wedge.or disc using automatic
For parallel slide disc gate Velan recommends grinding machine can save considerable time
maximum removal of 0.040" (1 mm) per disc. refer to Fig. 5.2E. For major damages use 60-80
grit diamond or micron alumina stick on abrasive
NOTE: I f more than 0.030" (0.76 mm) total
discs. For minor damage use 120-180 grit and
must be removed from both discs and seats
for finishing 220 grit and up can be used. For
of a parallel slide valve than the retainer plate further details contact our customer service dept.
(45) must also be ground, milled or machined
to compensate for gap allowance, refer to
Section 8.4.2 steps 2,3,4 & 5 and Fig. 8.3/,
Disc type II & V retaining plate (45),
Disc type IV retaining ring (45) and
Disc type III Hex. head bolt (56A).
4. For the lapping, a flat plate, preferably cast
iron, should be used and an abrasive lapping
compound mixed with olive oil should be
evenly distributed over the plate as shown in
Fig. 5.20. Only light, even pressure should be
applied to the plate, lap to figure 8 and lift the

•
wedge or disc as often as possible to prevent
accumulation of particles in one area and to
allow for proper distribution of the lapping
compound. The lapping plate should be
turned slightly once in a while to maintain a Figure 5.2E Wedge or disc Automatic
flat surface. The part should be lapped until Grinding Machine
seating faces are smooth. Velan recommends
'jUl 27
V INFORMATION PERTINENT TO GATE, GLOBE, CHECK &
PARALLEL SLIDE VALVES
, fI
5.2.3.3 Seat Repairs lapping plate in a circular motion on seat
face. Lift the plate as often as possible to
5.2.3.3.1Gate and Parallel Slide Valves prevent accumulation of particles in one area
1. If seating faces are damaged, the body seat and to allow for proper distribution of the
must be repaired by lapping. Slight pitting, lapping compound. Lap until both seats have
scratches or indentations no deeper than smooth faces and then clean off the lapping
0.005" (0.12 mm) can be removed by lapping. compound very thoroughly with a suitable
If defects cannot be corrected by lapping, the cleaning fluid such as acetone or alcohol.
seats should be ground using specialized
automatic grinding/lapping equipment. Velan
recommends a maximum of 0.015" (0.4 mm)
per side that can be removed from a 10 degree
seated valve, and 0.010" (0.25 mm) per side on
a 7 degree seated valve. For parallel slide
valve a maximum of 0.040" (1 mm) per seat
can be removed, see "NOTE" in Section 5.2.3.2
step (3) Grinding the seats using automatic
grinding equipment can save considerable
time refer to Fig. 5.2F.

( 4

Figure 5.2G Lapping plate

(
5.2.3.3.2Globe, Needle, Stop and Piston Check Valves
1. Disassemble the valve as described in
Section 7.4.2for globe and stop check valves
and Section 7.5for piston check valves.
Inspect the disc and the seat for scratches,
pitting marks or other damage.
Figure 5.2F Automatic grinding lapping 2. If there are indentations or pitting marks
machine for gate valve seats
no deeper than 0.005" (0.12 rnrn), a cast iron
and wedges
lapping disc (Fig. 5.2H) with the proper seat
angle must be used with a suitable lapping
2. In those cases where the automatic grinding compound to roughen the surface first. With
and lapping machine is not employed, seat the use of a new or refurbished original disc
faces must be repaired using a lapping plate. (Fig 5.2/) and a fine lapping compound, lap
The plate should be made of cast iron if the disc and seat together one final time.
possible and should be large enough to cover
NOTE: For body seat damage exceeding
the face of the seat (Fig. 5.2G). Apply lapping
0.005" (0.12mm) up to maximum of 0.030"
compound mixed with olive oil and distribute
(O.76mm) can be removed from a Globe or a
evenly over the plate. Lap seat by moving
needle valve having a seat angle of 15 degrees.

).J. \
28
INFORMATION PERTINENT TO GATE, GLOBE, CHECK & V

••
PARALLEL SLIDE VALVES

Figure5.2H Figure 5.21 Figure5.2J

Cast iron lapping disc Original stem-disc assembly Automatic reseatermachine for
grinding / lapping globe seats

€. For globe stop check and piston check valves

having a seat angle of 30 degrees max. of
0.040" (1 mm) can be removed by grinding
4. It is important to apply slight pressure when
lapping seats and to rotate in reciprocally.
For best results, use an air or electric hand
or machining with automatic equipment. tool with adjustable speed and reciprocal
movement. The lap should be lifted frequently
For valve disc seating surface damage greater
and turned to a new starting position so that
than 0.005" (0.12mm) up to a maximum of
the lapping will be rotated over a new area.
0.030"(0.76mm) per side can be removed for
globe and needle disc having an angle of 12 5. In order to ensure that light pressure is applied
evenly, it is necessary, on large valves, due to
degrees. For globe and stop check and piston
weight to suspend the disc and stem assembly
check disc having an angle of 27 degrees,
from a coil spring as shown in Fig. 5.2H.
maximum of 0.040" (1mm) per side can be
removed by machining. Chuck and center 6. Automatic grinding and lapping of seat faces
can be done by specialized equipment which
the disc in a lathe machine, remove only as
can save considerable time, refer to Fig. 5.2J.
needed up to the maximum indicated above.
For major damages the use of 60-80 grit
The repaired disc should be mated final
diamond or Micron alumina abrasive discs is
lapped with the body seat as shown in Fig 5.21. suggested. For minor damage use 120-180grit
IMPORTANT: A guiding plate for the stem and for finishing 220 grit and up can be used.
is required to maintain alignment during the For further details contact our Customer Service
lapping operation. Refer to Fig 5.21. It should Department.
be made of wood or any other suitable material
to the same gasket dimensions as the bonnet.
The section of the plate where the stem 5.2.3.4 Fitting of Repaired Parts
extends through should be made 1,164" (004 mm)
larger than the stem diameter. 5.2.3.4.1 Gate Valves
Place a small quantity of lapping compound 1. After the seating faces of the wedge, discs or
mixed with olive oil and evenly distribute on seats have been relapped and cleaned, a blue
the two mating surfaces. ink test is recommended before reassembly.

29
V INFORMATION PERTINENT TO GATE, GLOBE, CHECK &
PARALLEL SLIDE VALVES

Top wedge dimension

••
T = (t-B) x 0 + B
d

Figure 5.2K Blue ink test Serial number of body

Bottom t
A blue ink should be distributed smoothly and wedge
equally over the full circumferential surface of dimension
both sides of the yvedge (Fig. 5.2K). Place the
side of the wedge or disc possessing the body NOTE:
serial number, together with the side of the seat Seat dimension B
also possessing the body serial number; (These should be
sides should have been marked-up during valve transferred
disassembly as discussed in Section 4.4, to wedge
General Assembly Information). Preassemble dimension
the yoke and stem nut. Engage the stem threads b± 0.005" (0.1 mm)
with stem nut. Slide the wedge T-slot into the
stem T-head. Using a chain hoist slowly lower
the entire yoke - wedge into the body. Secure the
Figure 5.2L Wedge dimensions
yoke to body. Close the valve manually using the
handwheel and tighten firmly. Release the tension
by backing off handwheel a few turns. Lift out of
the valve body and check for positive contact. (\
If above procedure cannot be followed use
alternate method as follows: slide stem T-head
into the wedge T-slot. Slowly lower the stem and
wedge into the body. Tap a few times on top of
stem using a plastic, brass or lead hammer. Lift
out the stem and wedge and check for positive
contact.
2. If a part cannot be repaired, new parts must be
fitted and installed. All spare part wedges are
supplied slightly oversized. In order to fit, they Figure5.2M
must be ground or machined followed by a blue
Full seating
ink test to confirm 100% seating contact, and
then finally lapped. Refer to Fig. 5.2L. circumference
NOTE: If the outside diameter of hardface and
top and bottom face-to-face dimensions of the while the seat is being ground or machined.
old wedge are given to Velan, it is possible that Shim only as much as required to obtain a full
there will be very little or no fitting required at fit over the full circumference of the seating 6
the site when replacing the part. faces. Determine new wedge dimensions per ~
Fig. 5.2L. Figure 5.2M illustrates a wedge with
3. In some cases the original seat angle may be a full seating circumference, which is essential
lost when the seat is ground in the body.
whenever fitting a wedge.
Therefore the wedge must be shimmed
30
.'~
~~ INFORMATION PERTINENT TO GATE, GLOBE, CHECK & V

••
PARALLEL SLIDE VALVES

4 Figure 5.20 Paralllel slide

NOTE: Numbers refer to four locations to be checked
by feeler gauge Preparation for blue ink test

Figure 5.2N Clearanceverification

2. Release bolt tension and remove stud and nut,
4. When fitting a wedge, it is also important lift out the disc and check for positive contact
(full seating circumference) Fig. 5.2P illustrates
that the clearance between the wedge and
a disc with a full seating circumference, which
(:'. the wedge guide slots be checkedwith a feeler
gauge at four locations, as shown in Fig. 5.2N.
is essential whenever fitting a disc.
Ideally, the clearance on both sides should be NOTE: Damages to the seat and disc exceeding
the same, however, a minimum clearance of 0.060" (1.5mm) may require new part to be
0.005" (0.1 mm) at any position along the replaced.
length of the guide must be maintained.

e 5.2.3.4.2 Parallel Slide Valves

1. After the seating faces of the disc and
seat have been relapped and cleaned with
a suitable cleaning fluid such as acetone or
alcohol, it is essential that the results be Figure5.2P
verified using a blue ink test, check for full Parallel slide
circumferential contact. A light coating of full seating
blue ink should be distributed smoothly and circumference
equally over the seating diameter of the disc.
To maintain the disc concentric with the seat,
place shim stock at the bottom of the valve
body and lower the disc. Using a wood disc,
a stud and nut and tension against the oppo-
site seat, refer to Fig. 5.20.
NOTE: Ensure that the same match marked
disc and seat are being checked.

t •
31
V INFORMATION PERTINENT TO GATE, GLOBE, CHECK & ,.~
••
PARALLEL SLIDE VALVES

5.2.3.4.3 Globe, Stop Check and Piston Check Valves freely up and down. We recommend a visual
examination of the body wall. Any grooves
1. After the seating faces of the disc and
or scratches should be polished with a fine
seat have been relapped and cleaned with
emery cloth or buffing wheel 60-120 grit.
a suitable cleaning fluid such as acetone or
alcohol, it is essential that the results be 3. Verification of contact between the valve
verified using a blue ink test check for full disc and the stem is made by a radius on
circumferential contact. A blue ink should the end of the valve stem and is designed
be distributed smoothly and equally over the to give center loading for the disc as closely
seating diameter of the disc. For globe and as possible. A hard thrust pad (Fig. 5.2Q),
stop check valves, preassemble the yoke and which can be found in some designs, will
stem nut. Engage the stem threads with stem help prevent galling. On valves without a
nut, lower the disc into the body, lower the thrust pad, the bearing surface in the disc has
yoke assembly into the body and secure. a hardface deposit on it (Fig. 5.25). If particles
Close the valve firmly by manual handwheel. get caught between the end of the valve stem
Release stem tension by backing off handwheel and the disc, the center of the stem could be
a few turns. Lift out and check for positive destroyed.
contact.
If this procedure is not possible, use alternate
procedure as follows: lower the disc into the
body, using a brass bar, place in center of disc
and tap a few times with a plastic, brass or lead
hammer. Lift the disc out of the valve body and
check for positive contact.
NOTE: This procedure should also be used on
piston check valves.
€.
Figure 5.2R illustrates a disc with a full seating
circumference, which is essential whenever
Thrust
fitting a disc. pad
2. When fitting the disc, it is also important that
the body inside diameter be checked for
sufficient clearance to allow the disc to move
Figure 5.2Q Tapereddisc - Thrust pad

Figure 5.2R
Tapered disc - Hardface
Full seating deposit
circumference
Figure 5.25 Tapereddisc - Hardface deposit

32
).~
INFORMATION PERTINENT TO GATE, GLOBE, CHECK & V

••
PARALLEL SLIDE VALVES

surfaces of the stem and the disc must be NOTE: Diagram 5.2A serves only as a general
checked first in leaky valves in order to ensure guide line to determine approximate closing
that the disc-stem contact is in proper and opening torques required. It is not to be
condition. used in e.g. motor actuator. bevel gear or
pneumatic actuator sizing.
5.2.3.5 Seat Tightness - Closing Torques
CAUTION: The use of wheel wrenches,
Even with a brand new valve, seat tightness will cheater bars, etc., is quite common.
only be achieved when sufficient load has been However, it must be emphasized that
applied to the wedge or disc. This load varies these devices should be used with
with the pressure differential against which the discretion, and then only to achieve
valve has to be closed or opened.
approximately the torque as calculated
from Diagram 5.2A.
As a guideline, Diagram 5.2A can be used to
estimate the torque required to open or close
a valve against a given differential pressure.
The torque calculated is that torque which has to
be applied directly to the valve stem and does not
take into account any mechanical advantage such
as that achieved with a gear actuator, etc.

Diagram 5.2A Closing torques

K,8.0 K2
7.0
6.0
5.0
4.0
./
/'
3.0
-: EXAMPLE:
2.0
/'

/
l/
1.0 Torque (Pressure x K,) + K2
0.9
0.8
0.7 Type Gate
0.6
7 10·
0.5 ~ t--'"
/1
Size

g~:;
0.4 I--
Pressure 1125 psi
0.3 I-- ~~"
~/ K, 0.41
0.2 I-- 00
K2 26
~~
0.1
0.09
I~~
~ I-
00
90
80
Torque (1125x0.41)+26
\

487 fUb.
0.06
0.07 70
0.06 6(j
II 50
0.0 5
0.04
II ;...- 40
V
0.0 3
v 30
V
V

•
0.0 2 20

V
0.0 1
V
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Valve size

33
V INFORMATION PERTINENT TO GATE, GLOBE, CHECK &
PARALLEL SLIDE VALVES

5.2.4 Backseat Repairs

1. The following valves are equipped with an
integral or welded-in backseat in the bonnet
(Fig. 5.2T).
a) Gate valve
b) Parallel slide valve
c) Globe valve
d) Needle valve
e) Stop check valve
The above valves have a stem with a
backseat shoulder. This should sit perfectly Weld in backseat
against the bonnet backseatto make a perfect
seal. It is possible that this seal may leak due
to scratches, pitting or other reasons.
Therefore this seal must be repaired by
relapping the mating faces.
2. Dismantle the valve in accordance with
Sections6.4.2 (gate), 7.4.2(globe and stop
check), and 8.3.2 (parallel slide).
3. Placethe bonnet and stem upside down
as shown in Fig. 5.2U and insert two or three
packing rings in the packing chamber to serve
as a guide for the centralizing of the stem to
( (I
the backseat. Add a fine mixture of lapping
compound between the two mating faces.
Gently rotate the stem back and forth and
occasionally lift the stem slightly and rotate Integral backseat
around backseat so that lapping will be over
a distributed new area. Figure 5.2T Types of backseats
(
NOTE: On larger valves, the stem must be
supported so that the weight of the stem does
not cause a groove or galling on the backseat.
4. When the lapping procedure is finished, all
lapping compound must be removed with a Bonnet
suitable cleaning fluid such as acetone or
alcohol.
5. Velan recommends that the lapping procedure
be verified for full contact by blue ink one of
the two faces. After verification, the surfaces
must be cleaned again.
NOTE: Velan recommends the use of "clover Packing
leaf lapping compound (silicone carbide) grade rings
"E" medium coarse and or grade "C" fine grit.

t
Figure 5.2U Backseat repair
)..)- ')
34
INFORMATION PERTINENT TO GATE, GLOBE, CHECK & V

••
PARALLEL SLIDE VALVES

5.3 TORQUE VALUES - ACTUATOR,

YOKE/BONNET BOLTING
The torque values shown in Table 5.3A are for all
bolting other than body/bonnet retaining bolting
or packing flange studs.

Table 5.3A Torque Values

ft.lb.
30

(.

NOTE: (1) Torque tolerance ± 10%.

(2) For temperatures above 750°F (400°C) use 75% of the values.
(3) Maximum temperature for 630 is 650°F (345°C).
(4) Above torque valves are with the bolts lubricated.

35
VI GATE VALVE
t

••
t
6.1 TYPES OF GATE VALVES
PARTS DESCRIPTION QTY. PARTS DESCRIPTION QTY. PARTS DESCRIPTION QTY. PARTS DESCRIPTION QTY.
01 . Body 1 268· Key 1 01 - Body 1 19 - Gasket 1
02 - Bonnet 1 28 - Housing cover 1 02 - Bonnet 1 20 - Spacer ring 1
03 - Yoke 1 30 - Handwheel nut 1 03 - Yoke 1 21 - Gasket retainer 1
04 - Stem 1 31 - lockwasher 2 04 - Stem 1 22 - Bonnet retainer 1
05 - Wedge 1 33 - Handwheel 1 05 - Wedge 1 23 - Bolting plate 1
09 - Seat 2 34 - Grease fitting 1 09 - Seat 2 25 - Torque arm 1
10 - Wedge guide 2 35A - Set screw 1 10 - Wedge guide 2 26A - Key 1
11 - Packing flange 1 358 - Set screw 2 11 - Packing flange 1 268 - Key 1
12 - Gland bushing 1 38 - Gland eyebolt 2 12 - Gland bushing 1 28 - Housing cover 1
13A - Pkg ring (end) 2 56 - Hex. hd. bolt 2 13A - Pkg ring (end) 2 29 - Bearing 2
138 - Pkg ring (inter) 5 57 - Washer 2 138 - Pkg ring (inter) 5 30 - Handwheel nut 1
168 - Nut 2 66 - Name plate 1 158 - Stud 2 33 - Handwheel 1
2 88 - Stem nut
ell
16E - Nut 1 168 - Nut 2 34 - Grease fitting 1
170 - HSH cap screw 4 92 - Eyebolt clamp 1 17A - HSH cap screw 4 35 - Setscrew 1
19 - PS Gasket 1 178 - HSH cap screw 4 66 - Name plate 1
22 - Screwed bonnet 17C - HSH cap screw 1 88 - Stem nut 1
retainer 170 • HSH cap screw 4 115 - Split ring 1

{ •
(

Figure 6.1A Style I, forged pressure seal Figure 6.18 Style /I, forged pressure seal
gate valve, 2 - 21/2" (50- 65 mm) gate valve, 3" (75 mm) and
4" (100 mm)
36
GATEVALVE VI

•• PARTS DESCRIPTION
01 - Body
02 - Bonnet
03 - Yoke
QTY.
1
1
PARTS DESCRIPTION
170 - HSH cap screw
19 - PS Gasket
QTY.
6
PARTS DESCRIPTION
01 - Body
02 - Bonnet
QTY.
1
1
Detail 1
1 03 - Yoke 1
20 - Spacer ring
04 - Stem 1 04 - Stem 1
05 - Wedge 21 - Gasket retainer 05 - Wedge 1
1
09 - Seat 2 22 - Bonnet retainer 09 - Seat 2
10 - Wedge guide 25 - Torque arm 10 - Wedge guide 2
2 11 - Packing flange 1
11 - Packing flange 1 26A - T.A. Key
12 - Gland bushing 1
12 - Gland bushing 1 26B - HW.Key 13A - Packing ring (end) 2
13A - Packing ring (end) 2 28 - Yoke housing cover 1 13B - Packing ring (inter) 5
29 - Bearing 2 15 - Stud 8
13B - Packing ring (inter) 5
15A - Stud 8
1SA - Stud 6 30 - Handwheel nut

e
158 - Stud 2
t, 158 - Stud
16B - Nut
2
2
33 - Handwheel
34 - Grease fitting
150 - Stud
16A - Nut
16B - Nut
4
8
2
16C - Nut 6 35A - Set screw
16C - Nut 8
17A - HSH cap screw 6 66 - Nameplate
160 - Nut 4
17C - HSH cap screw 2 88 - Stem nut 17A - HSH cap screw 8
Gland bolting configuration
170 - HSH cap screw 8 for S" & 10"
19 - PS Gasket 1
20 - Spacer ring 1
21 - Gasket retainer 1
22 - Bonnet retainer 1
25 - Torque arm 1
26A - T.A. Key 1
32 - Gear operator 1
66 - Nameplate 1

(. Figure 6.1C Style 11/, forged pressure seal

gate valve, 6" (150 mm)
Figure 6.1D Style 11/, forged pressure seal
gate valve, 8-14" (200 - 350 mm)

37
VI GATE VALVE
t
PARTS DESCRIPTION
01 - Body
02 - Bonnet
03 - Yoke
04 - Stem
OTY.

1
PARTS DESCRIPTION
11 - Packing flange
12 - Gland bushing
OTY.

13A - Packing ring (ends) 2

1

13B - Packing ring (inter) 5

15A - Stud 8
PARTS DESCRIPTION
16A - Nut
16B . Nut
16D· Nut
17A - HSH cap screw
17D • HSH cap screw
OTY.
8
2
4
12
8
PARTS DESCRIPTION
20 - Spacer ring
21 - Gasket retainer
22 - Bonnet retainer
25 - Torque arm
26A - T.A. Key
OTY.
••
05 - Wedge
09 - Seat 2 15B - Stud 2 18 • Backseat 32 • Gear operator
10 - Wedge guide 2 15D - Stud 4 19 - PS Gasket 66 - Nameplate

( •
(

Figure 6.1E Style 11/, forged pressure seal gate valve, 16- 24" (400 - 600 mm)

38
,. 6.2 EXPLODED VIEWS

PARTS DESCRIPTION r-,

1 . Body
2 •Bonnet
3 •Yoke
4 .Stem
5 .Wedge
9 .Seat
10 .Wedge guide
11 . Packing flange
12 • Gland bushing
13 • Packing
168 • Packing nut
16E • Jam nut
110; Socket head cap screw
19 . Pressure seal gasket
22 . Bonnet retainer ring
268 . Handwheel key
28 • Yoke housing cover
30 . Handwheel nut
33 . Handwheel
34 • Grease fitting
35A· Handwheel set screw
358 • Half dog set screw
38 . Gland eyebolt
56 . Hex head bolt
51 . Washer
88 • Stem nut
92 • Eyebolt clamp

Figure 6.2A Style I, typical exploded view-gate valve

l-)L
39
••
1 - Body
2 - Bonnet
3 - Yoke
4 - Stem
5 - Wedge
9 - Seat
10 - Wedge guide
11 - Packing flange
12 - Gland bushing
13 - Packing
15 - Stud (body/yoke)
1SA - Stud (pressure seal bonnet)
158 - Stud (packing)
16A - Nut (body/yoke)
168 - Packing nut
16C - Nut (pressure seal bonnet)
17e - Set screw (torque arm)
170 - Socket head cap screw
19 - Pressure seal gasket
20 - Pressure seal spacer ring
21 - Pressure seal gasket retainer
t.•
22 - Bonnet retainer
25 - Torque arm
26A - Torque arm key
268 - Handwheel key
28 - Yoke housing cover
29 - Bearing
30 - Handwheel nut
33 - Handwheel (
34 - Grease fitting
35A - Handwheel set screw
88 - Stem nut

Figure 6_28 Style /II, typical exploded view-gate valve

I
40
GATEVALVE VI

6.3 PARTIAL DISASSEMBLY 6.4.2 Disassembly of Body/Bonnet and Wedge/Stem

- GASKET REPLACEMENT
6.4.2.1 Style I (Fig. 6.2A)
Follow warning instructions in Section 11/ before
beginning disassembly. If valve is equipped with 1. The valve should be in a partially open position.
a gear or motor actuator, see Appendix for disas- 2. Remove small set screw (35A) in handwheel nut
sembly of actuators. As a general disassembly (30),then unscrew handwheel nut.
progresses, place matching marks on parts so that 3. Remove handwheel (33) and handwheel key
the same orientation of parts can be maintained at (268).
reassembly.
4. Remove yoke housing capscrews (17D),then
remove housing cover (28) over the stem (4)
CAUTION: Do not attempt to force out and stem nut (88).
, the pressure seal gasket by using a crane,
II
5. Unscrew stem nut (88) from the stem (4).
hoist, chain-block, etc. The gasket may
be tight inside the valve body and if 6. Remove packing flange nuts (16b).
pulled using a crane, jack, or other 7. Remove gland eyebolt (38) by loosening jam
means, it may suddenly release causing nuts (16E)and removing hex head bolts (56).
personal injury and/or extensive damage. The gland eyebolt clamp (92)will fall off after
the two hex head bolts (56) have been removed.
8. Loosen bonnet retainer (22).
6.3.1 Style I
NOTE: If a valve has been in high-temperature
service for extensive periods of time, the
To remove the pressure seal gasket follow
retainer (22) sometimes becomes seized to
steps 1 through 13 in Section 6.4.2.1 - Disassembly
the bonnet. Tight threads can be loosened
of Body/Bonnet and Wedge/Stem - Style I.
by applying penetrating oil or heat to the
Installation of the gasket follows steps 1 through 17
retaining nut and working it free.
in Section 6.5.2.1 - Body/Bonnet and Wedge/Stem
Assembly - Style I. 9. 8efore removing the yoke, it is necessary to
remove two half dog set screws (358) located
on the top outer edge of.the body.
6.3.2 Style II and III

•
IMPORTANT: The two half dog set screws
To remove the pressure seal gasket follow must be removed before unscrewing the
steps 1 through 9 in Section 6.4.2.2 - Disassembly yoke because they are set into the thread of
of Body/Bonnet and Wedge/Stem - Style II and III. the yoke. If not removed they could cause a
Installation of the gasket follows steps 2 through 11 considerable amount of damage to the thread
in Section 6.5.2.2 - Body/Bonnet and Wedge/Stem of the yoke and body.
Assembly - Style II and III. 10. Loosen yoke (3) approximately two turns.
11. Retighten bonnet retainer (22). This will pull
the tight pressure seal gasket up to the larger
6.4 TOTAL DISASSEMBLY diameter where it will become free.
12. Remove bonnet retainer (22) and unscrew
6.4.1 General yoke (3) from body.
13. Use the stem to lift total internal assembly out
Follow warning instructions in Section 1/1 before of the body. The bonnet (2) and pressure seal
beginning disassembly. If valve is equipped with a gasket (19) will come out when the backseat
gear or motor actuator, see Appendix for disassem- shoulder on the stem hits against the backseat
bly of actuators. As a general disassembly progress- in the bonnet.
es, place matching marks on parts so that the same
orientation of parts can be maintained at reassembly. NOTE: When lifting the bonnet-stem assem-
bly, care should be taken to prevent internal
t parts from disengaging from the stem. The
wedge (5) is attached to the stem (4) with a
T-slot and as soon as it is disengaged from the
guides in the body, it can slip off the stem.

41
VI GATEVALVE

6.4.2.2 Styles II (Fig. 6.18) and III (Fig. 6.28)

1. The valve should be in a partially open a) Removal of Types I and II:
,.
position. Loosen the capscrew (17C) and remove.
Slide torque arm (25) up along stem and
2. Before proceeding with disassembly of
remove torque arm key (26A) from stem.
valves, check if the valve is equipped with a
Torque arm will not come off at this point,
leak-off option (62). If so, disconnect it first.
but you must make sure that the torque
Leak-off pipes should be unscrewed or cut
arm slides freely over the stem.
approximately 6" (150 mm) from the bonnet
side and not at the welded joint on the bonnet. b) Removal of Types III and IV:
Loosen hex nuts (160), pull torque arm
3. Remove packing flange nut (16b) and if
apart and remove torque arm key (26A)
applicable, live-loading. from stem. The torque arm will come
NOTE:If the valve is equipped with totally off assembly at this point. (
live-loading, including guide sleeves and 5. Remove yoke-body nuts (16A).
Belleville washers (36) as shown in Fig. 5.1L,
make note of the order of these parts so 6. Turn the handwheel to close the valve. This
that at reassembly they will return in the will cause the yoke to rise and to unthread
same order. from the valve stem as shown in Fig. 6.48 for
Style II and Fig. 6.4Cfor Style III. As this takes
4. Remove torque arm. There are four types place, the weight of the yoke and top works
of torque arms (see Fig. 6.4A): should be supported by a hoist to prevent "-
Type I - one-piece with bearing damage to the stem thread. ~
Type II - one-piece without bearing
NOTE: When removing the yoke, Types I and
Type III - two-piece with bearing
Type IV - two-piece without bearing 11torque arms (25) and packing flange (11),
they must be helped along to prevent the two
(rJ~1 ~
parts from becoming jammed in sideways
against the stem and yoke.

PARTS DESCRIPTION
15D • Stud (torque arm)
~TYPEI TYPE II
160 . Nut (torque arm)
17C • Cap screw (torque arm)
25 . Torque arm
26A • Key (torque arm)
29 • Bearing
35 . Set screw

Figure 6.4A Torque arm 4 types

42
GATE VALVE VI

t
• PART DESCRIPTION
01 - Body
02 - Bonnet
03 - Yoke
04 - Stem
05 - Wedge
QTY.
1
1
1
1
1
PARTDESCRIPTION
21 - Gasket retainer
22 - Bonnet retainer
23 - Bolting plate
25 - Torque arm
268 - Key
QTY.
1

1
1
PARTDESCRIPTION
01 - Body
02 - Bonnet
03 - Yoke
04 - Stem
05 - Wedge
QTY.
1
1
1
1
1
PARTDESCRIPTION
19 - PS Gasket
20 - Spacer ring
21 - Gasket retainer
22 - Bonnet retainer
25 - Torque arm
QTY.
1
1
1
1
1
09 - Seat 2 28 - Housing cover 1 09 - Seat 2 268 - Key 1
10 - Wedge guide 2 29 - Bearing 2 10 - Wedge guide 2 28 - Housing cover 1
11 - Packing flange 1 30 - Handwheel nut 1 11 - Packing flange 1 29 - Bearing 2
12 - Gland bushing 1 33 - Handwheel 1 12 - Gland bushing 1 30 - Handwheel nut 1
13A - Pkg ring (ends) 2 34 - Grease fining 1 13A - Pkg ring (ends) 2 33 - Handwheel 1
138 - Pkg rings (inter) 5 35A - Set screw 1 138 - Pkg rings (inter) 5 34 - Grease fining 1
178 - HSH cap screw 4 66 - Name plate 1 15A - Stud 6 35A - Set screw 1
170 - HSH cap screw 4 88 - Stem nut 1 16C - Nut 6 66 - Name plate 1
19 - PS Gasket 1 17D - HSH cap screw 6

-
115 - Split ring 1 88 - Stem nut
20 - Spacer ring 1

l-r------_---J04
t

( • Figure6.4B Yoke removal-gate valve, Style /I Figure 6.4C Yokeremoval-gate valve, Style 11/
-
43
VI GATE VALVE

7. On some valves, the packing flange (11) will

not have to be removed in order to remove
PARTS DESCRIPTION
01 - Body
02 - Bonnet
QTY.
1
PARTS DESCRIPTION
19 - PS Gasket
20 - Spacer ring
Q1Y.
,•
the yoke (03). Therefore, the packing flange 04 - Stem 21 - Gasket retainer
can be removed together with the gland 05 - Wedge 1 22 - Bonnet retainer
bushing (12) and packing rings (13). Remove 09 - Seat 2 23 - Bolting plate
10 - Wedge guide 2 66 - Name plate
the packing rings in accordance with Sections
17B - HSH cap screw 4 115 - Split ring
5.1.2 and 5.1.3.
8. Removal of Bonnet - Style II (Fig. 6.4D):
a) Loosen the bonnet retaining capscrews
(17b).
b) Remove the split ring (115) (two pieces),
which is between the bonnet (02) and the
bonnet retainer (22).
c) Lift the bonnet retainer (22) over the stem
and off the valve body.
d) Remove bolting spacer (23) which is lying
flat on top flange of body.
e) Lower the bonnet (02) by pushing
downward or by tapping the bonnet with
a brass bar. The bonnet should clear the
four-segment gasket retainer. To loosen
the gasket retainer (21), tap well on all four
segments using a brass bar, then insert a
drive pin into the side holes of the body
flange. Tap lightly to remove the two
( ~I
smaller segment portions first, then the
larger portions.
f) Use the stem (04)to lift the spacer ring (20),
the pressure seal gasket (19), bonnet (02) and
internal assembly out of the valve body.
IMPORTANT: Do not use excessive force on (
the stem (04) if the bonnet (02) does not come
out easily. It may be necessary to remount
the bonnet retainer (22) with split ring (115)
installed around bonnet (02), and use the bon-
net retaining cap screws to pull the bonnet (02)
and gasket (19) out from their seating position.
By retightening the cap screw with the gasket
retainer (21) removed, the tight pressure seal
gasket will be pulled up to the larger diameter
where it will become free.
g) After the bonnet (02) and the pressure
seal gasket (19) become free, they can
be carefully lifted out of the body. When
lifting the bonnet-stem assembly, care
should be taken to prevent internal parts
from disengaging.
9. Removal of Bonnet - Style III (Fig. 6.4£):
a) Remove bonnet retaining nuts (16c).
b) Lift bonnet retainer (22) over stem and off Figure 6.4D Bonnet removal-gate valve, Style II
valve body.
44 )-71
GATE VALVE VI

c) Remove two bonnet retaining studs (15A). PARTS DESCRIPTION QTY. PARTS DESCRIPTION QTY.
Lower bonnet (02) by pushing downward 01 - Body 1 16C • Nut 6
02 - Bonnet 19 - PS Gasket
or by tapping on bonnet with a brass bar.
04 - Stem 20 - Spacer ring
The bonnet recess should clear the gasket 05 - Wedge 1 21 - Gasket retainer
retainer (21). Line up the bonnet (02) 09 - Seat 2 22 - Bonnet retainer
minus the two studs with the small portion 10 - Wedge guide 2 66 - Name plate
of the four-segment retainer. Insert a drive 15A - Stud 6
pin into the holes provided in the body top
flange. Tap lightly to remove the gasket
retainer (21).
NOTE: If the valve has been in high-pressure
service for a long period of time, it may be
necessary to tap lightly on the gasket retainer
inside the body first so that the drive pin will
be able to push out the gasket retainer more
easily.
d) Remove the two smaller portions of the
four-segment gasket retainer, then the
larger portions.
e) Use the stem (04) to lift the spacer ring (20),
the pressure seal gasket (19), bonnet (02)
and internal assembly out of the valve
body.

f • IMPORTANT: Do not use excessive force

on the stem (04). If the bonnet (02) does
not come out easily, it may be necessary to
remount the bonnet retainer (22) using two
or four bonnet retaining nuts (16C)to retighten
the bonnet. By retightening the nuts with the
gasket retainer (21) removed, the tight pres-
sure seal gasket will be pulled up to the larger
diameter where it will become free.
t} Once the bonnet (02) and pressure seal
gasket (19) are free, they can be carefully
lifted out of the body. When lifting the
bonnet-stem assembly, care should be
taken to prevent internal parts from
disengaging from the stem.
10. Use the stem to lift the total internal assembly
and bonnet out of the valve body.
NOTE: When lifting the bonnet-stem
assembly, care should be taken to prevent
internal parts from disengaging from the stem.
For example, the wedge (05) is attached to the
stem (04) with a T-slot and as soon as it is
disengaged from the guides in the body, it
can slip off the stem.
11. The valve is now ready for inspection and
repairs of seat, wedge, stem, etc.
Figure 6.4£ Bonnet removal-gate valve, Style 11/

:
VI GATE VALVE

6.4.3 Disassembly of Top Works (Fig. 6.4FJ

Follow warning instructions in Section III before

beginning top works disassembly.
~, I I ~
••
1. If line pressure is maintained in the valve,
backseat the valve in fully open position
before starting any disassembly.
2. Remove small set screw (35A) in handwheel
nut (30), then unscrew handwheel nut.
3. Remove handwheel (33).
4. Remove yoke housing bolting (17D) and
remove housing cover (28). (
5. Remove first set of bearings (29A) (3 pieces).
6. Unscrew stem nut (88) from the stem (04).
7. After the stem nut has been removed,
remove second set of bearings (29B).
8. Now valve and parts are ready for inspection,
repairs and replacement of stem nut,
bearing, etc.

( .•
(
PARTS DESCRIPTION
03 - Yoke
17D - HSH cap screw
26B - Key
28 - Housing cover
29A - Bearing
29B - Bearing
30 - Handwheel nut
33 - Handwheel
34 - Grease fitting
35A - Set screw
88 - Stem nut

Figure 6.4F Bonnet removal-gate valve, Style III

46
,. 6.5 ASSEMBLY
GATE VALVE VI

6.5.1 TopWorks Assembly NOTE: When you install the yoke (03),
(Referto Fig. 6.5AJ also install the bonnet retainer (22), gland
1. Apply new grease to threaded portion of stem bushing (14), and packing flange (11).
(04) above top flange on yoke (03). 5. Apply new grease to threaded portion of
2. Mount second set of newly-greased bearings the stem (04) above and below top flange
(29B) in recess of yoke.. on yoke (03).
6. Apply new grease to internal thread in
NOTE: Bottom race must fit loosely around
stem nut (88) and turn stem nut onto stem.

-
stem nut and top race must be tight around
stem nut. 7. Install yoke housing cover (28).
t, 3. Apply new grease to internal thread in stem 8. Insert handwheel key (26b) in keyway in
nut (88) and screw stem nut on stem. stem nut and mount handwheel (33).
4. Mount first set of newly-greased bearings 9. Return handwheel nut (30) and tighten.
(29A) on stem nut. Use the handwheel nut set screw (35A)
and lock handwheel nut in place.
NOTE: Bottom race must fit tightly around
10. Inject more new grease into yoke housing
stem nut and top race must be loose.
cover using the grease fitting (34) on the
5. After the bearings and stem nut are in place, side of the yoke (03).
mount yoke housing cover (28) on top and tie
11. Turn handwheel to open valve fully against
down with the housing cover bolting (170).

•
the backseat. This will centralize the stem
Bolting must be torqued down in accordance
and bonnet .
C 6.
with the values in Table 5.3A.
Insert handwheel key (26B) in keyway in stem
nut and mount handwheel (33).
7. Return handwheel nut (30) and tighten.
Use handwheel nut set screw (35A) to lock
handwheel nut in place.

• 8. Inject more new grease into housing cover

through the grease fitting (34) on side of
housing cover.
9. Verify operation by cycling at least once from
fully open to fully closed position.

6.5.2 Body/Bonnet and Wedge/Stem Assembly

(ValveInternal & Mid-section)

6.5.2.1 Style I (Fig. 6.2AJ PARTS DESCRIPTION

03 - Yoke
1. Install the wedge (05) and stem (04) assembly
170 - HSH cap screw
in the valve body. 26B - Key
2. Lower the bonnet (02) onto the stem (04) and 28 - Housing cover
29A - Bearing
into the valve body. 29B - Bearing
3. Install the new pressure seal gasket (19) 30 - Handwheel nut
33 - Handwheel
around the bonnet and into the valve body. 34 - Grease fitting
4. Install the yoke (03) on the valve body and 35A - Set screw
tighten. 88 - Stem nut

Figure 6.5A Valve top works assembly

47
VI GATE VALVE

12. Torque down the screwed bonnet retaining

rings (22) in accordance with the torque values
given in Table 4.5A.
NOTE: Use special tool for torquing screwed
d) Mount bonnet retainer (22) down on
top flange on body.
e) Install bonnet retaining nuts (16C)
and uniformly tighten the nuts by hand.
I
•
bonnet retaining ring, refer to Fig. 4.5B. NOTE: For live-loaded bonnet install
13. Install two half dog set screws (35B) back in Belleville spring washers in the same order
the correct location in the top outer edge of as during disassembly, refer to Fig. 4.5C and
the body. 4.50 (Belleville spring washer configuration)
14. Repack the valve in accordance with Section 4. Repack valve in accordance with Section 5.1.
5.1, Packing. NOTE: Do not torque down the packing
15. Install the gland eyebolt clamp (92) and flange (11) at this point of assembly.
gland eyebolt (38) by installing the two hex
head bolts (56) and tighten the jam nuts (16E).
5. Install yoke (03) by turning handwheel (33)
counter clockwise to open valve. This will
t I

16. Install packing flange nuts (16B) and torque cause the yoke to be lowered down on the
down in accordance with Section 5.1.6. valve body.
17. Verify operation by cycling at least three times NOTE: In some cases on the smaller size
from fully opened to fully closed position. valves, it will be necessary to install the
packing flange together with the yoke.
6.5.2.2 Styles II (Fig. 6.1 B) and III (Fig. 6.2B) Therefore, the packing flange (11) and the
~
1. Place the wedge on T-head of stem, making Type I or II torque arm (25) (Fig. 6.4A) must
sure that the marked-up side of the wedge be reinstalled in correct positions before the
mates with the marked-up seat in the body.
This is extremely important on valves with
yoke is completely lowered.
6. Install the body-yoke nuts (16A) or cap
( ((I
welded-in seats to ensure optimum sealing. screws (17A) and torque in accordance
Install wedge and stem in valve body. with Table 5.3A.
2. Bonnet Style II (Fig. 6.40) 7. Turn the handwheel to open the valve fully
a) Lower bonnet (02) onto stem (04) and against the backseat (18). This will centralize
into valve body (01). the stem and bonnet.
b) Install new pressure seal gasket (19) 8. Torque the bonnet retaining nuts (16C) or (
and spacer ring (20). bonnet retaining capscrews (178) in strict
c) Install gasket retainer (21) in groove in accordance with Section 4.5.1.
body wall. 9. Mount Type III or IV torque arm (25) on
d) Place bolting spacer (23) on top flange stem (04) and make sure the torque arm
of valve body. key (26A) fits properly in the stem and
e) Install bonnet retainer (22) around torque arm keyway.
bonnet (02). 10. Mount the live-loading option if so equipped,
f) Install split ring (115) between bonnet (02) and the packing flange nuts (16B), and torque
and bonnet retainer (22). in accordance with Section 5.1, Packing. '-'
g) Uniformly tighten the hex socket head NOTE: If the valve is equipped with
cap screw (17b) by hand. packing live-loading option, live-loading
3. Bonnet Style III (Fig. 6.4£) parts must return in the same order as
noted in disassembly, refer to Fig. 5.1L.
a) Lower bonnet (02) onto stem (04) and
into valve body (01). 11. Verify the operation by cycling at least
three times from fully opened to fully
b) Install new pressure seal gasket (19)
and spacer ring (20).
c) Install gasket retainer (21) in groove in
closed position.
f (4
body wall.

48
GLOBE VALVE VII

C
• 7.1 TYPES OF GLOBE VALVES
PART DESCRIPTION
01 • Body
02 - Bonnet
03 - Yoke
OTY.
1
1
1
PART DESCRIPTION
26A - T.A. Key
268 - HWKey
28 - Housing cover
OTY.
1
1
1
PART DESCRIPTION
01
02
03
- Body
- Bonnet
- Yoke
OTY.
1
1
1
PART DESCRIPTION
21 - Gasket retainer
22 - Bonnet retainer
23 - Bolting spacer
nrv,
1
1
1
04 - Stem 1 30 - Handwheel nut 1 04 - Stem 1 25 - Torque arm 1
06 - Disc 1 34 - Grease fitting 1 06 - Disc 1 26A - TAKey 1
11 - Packing flange 1 35A - Set screw 1 11 - Packing flange 1 268 - HWKey 1
12 - Gland bushing 1 358 - Set screw (half dog) 2 12 - Gland bushing 1 28 - Housing cover 1
13A - Pkg ring (ends) 2 38 - Gland eye bolt 2 13A - Pkg ring (ends) 2 29 - Bearing 2
138 - Pkg ring (inter) 5 '40 - Disc union 1 138 - Pkg ring (inter) 5 30 - Handwheel nut 1
168 - Nut 6 41 - Stem collar 1 15 - Stud 6 34 - Grease fitting 1
16E - Nut 2 56 - Hex head bolt 2 158 - Stud 2 35A - Setscrew 1
17C - HSH cap screw 4 57 - Washer 2 16A - Nut 6 40 - Disc union 1
170 - HSH cap screw 1 66 - Name plate 1 168 - Nut 2 41 - Stem collar 1
19 - PS Gasket 1 88 - Stem nut 1 178 - HSH cap screw 4 66 - Name plate 1
t 22 - Bonnet retainer
25 - Torque arm
1
1
92 - Eyebolt clamp 1
104 -Impactor handle assy 1
17C - HSH cap screw
170 - HSH cap screw
19 - PS Gasket
1
4
1
88 - Stem nut
104 - Impactor assy
115 - Split ring
1
1
1
20 - Spacer ring 1

,.

• Figure 7.1A Style I, forged pressure seal

globe valve, 2" (50 mm) and
21/2" (65 mm)

49
Figure 7.18 Style II, forged pressure seal
globe valve, 3" (150 mm) and 4"
(100 mm)
VII GLOBE VALVE

PART DESCRIPTION QTY. PART DESCRIPTION PART DESCRIPTION QTY. PART DESCRIPTION
1)(.
1 QTY. 01 - Body 1 QTY.
01 - Body
1 17C - HSH cap screw 1 02 - Bonnet 1 19 - PS Gasket 1
02 - Bonnet
- Yoke 1 170 - HSH cap screw 4 03 - Yoke 1 20 - Spacer ring 1
03
1 19 - PS Gasket 1 04 - Stem 1 21 - Gasket retainer 1
04 - Stem
20 - Spacer ring 1 06 - Disc 1 22 - Bonnet retainer 1
06 - Disc 1
21 - Gasket retainer 1 11 - Packing flange 1 25 - Torque arm 1
11 - Packing flange 1
12 - Gland bushing 1 26A - T.A. Key 1

)
12 - Gland bushing 1 22 - Bonnet retainer 1
13A - Pkg ring (ends) 2 23 - Bolting spacer 1 13A - Pkg ring (ends) 2 26B - HW.Key 1
5 25 - Torque arm 1 138 - Pkg ring (inter) 5 28 - Housing cover 1
138 - Pkg ring (inter)
6 26A - T.A. Key 1 1SA - Stud 6 29 - Bearing 2
15 - Stud
2 32 - Gear operator 1 158 - Stud 2 30 - Handwheel nut 1
158 - Stud
16A - Nut 6 40 - Disc union 1 150 - Stud 4 34 - Grease fitting 1
2 41 - Stem collar 1 168 - Nut 2 35A - Handwheel set screw 1
168 - Nut
178 - HSH cap screw 6 66 - Name plate 1 16C - Nut 6 40 - Disc union 1
115 - Split ring 1 160 - Nut 4 41 - Stem collar 1
17A - HSH cap screw 6 66 - Name plate 1
178 - HSH cap screw 8 88 - Stem nut
104 - Impactor assy
1
1 f

1
Figure 7.1C Style 1/, forged pressure seal
globe valve, 6" (150 mm)
Figure 7.1D Style III, forged pressure seal
globe valve, 8" (200 mm)
(

50
GLOBE VALVE VII

c)(e PART DESCRIPTION

01 - Body
OTY.
1
PART DESCRIPTION
16C - Nut
OTY.
6
PART DESCRIPTION
01 - Body
OTY.
1
PART DESCRIPTION .
17A - HSH cap screw
OTY.
8
02 - Bonnet 1 160 • Nut 4 02 - Bonnet 1 170 - HSH cap screw 4
03 - Yoke 1 17A - HSH cap screw 6 03 - Yoke 1 19 - PS Gasket 1
04 - Stem 1 170 - HSH cap screw 8 04 - Stem 1 20 - Spacer ring 1
06 - Disc 1 19 - PS Gasket 1 06 - Disc 1 21 - Gasket retainer 1
11 - Packing flange 1 20 - Spacer ring 1 11 - Packing flange 1 22 - Bonnet retainer 1
12 - Gland bushing 1 21 - Gasket retainer 1 12 - Gland bushing 1

)
23 - Bolting spacer 1
13A - Pkg ring (ends) 2 22 - Bonnet retainer 1 13A - Pkg ring (ends) 2 25 - Torque arm 1
13B - Pkg rings (inter) 5 25 - Torque arm 1 13B - Pkg rings (inter) 5 26A - T.A. Kev 1
15 - Stud 8 26A - lAKey 1 15 - Stud 2 32 - Gear operator 1
15A - Stud 6 32 - Gear operator 1 158 - Stud 2 37 - Adaptor plate 1
158 - Stud 2 37 - Adaptor plate 1 150 - Stud 2 40 - Disc union 1
150 - Stud 4 40 - Disc union 1 16A - Nut 2 41 - Stem collar 1
16 - Nut 8 41 - Stem collar 1 168 - Nut 2 66 - Name plate 1
168 - Nut 2 66 - Name plate 1 160 - Nut 2 80 - Yoke clamp ring 1
17 - HSH cap screw 4 115 - Split ring 1
t ((I

)
• Figure 7.1E Style /II, forged pressure seal Figure 7.1F Style /I, cast pressure seal inclined
globe valve, 10" (250 mm) globe valve, 6" (150 mm)

51
GLOBE VALVE VII

7.2 EXPLODED VIEWS

PARTS DESCRIPTION PARTS DESCRIPTION
1 - Body 21 - Pressure seal gasket
2 - Bonnet retainer
3 - Yoke 22 - Bonnet retainer
4 - Stem 23 - Bolting spacer
6 - Disc 25 - Torque arm
11 - Packing flange 26A - Key (torque arm)
12 - Gland bushing 26B - Key (handwheel)
13 - Packing 28 - Housing cover
15 - Stud 29 - Bearing
15B - Packing stud 30 - Handwheel nut
16A - Nut 33 - Handwheel
16B - Packing nut 34 - Grease fitting
17B - Socket head cap screw 35A - Handwheel set screw
17C - Cap screw (torque arm) 40 - Disc union
17D - Socket head cap screw 41 - Stem collar
19 - Pressure seal gasket 88 - Stem nut
20 - Pressure seal spacer ring 115 - Bonnet retainer split ring

r"'-
...........
I~·
I
,I
I
PARTS DESCRIPTION
4 - Stem
I
6 - Disc
40 - Disc union I
41 - Stem collar
I
42 - Thrust pad
~I
I

• Figure 7.28
Disc unit, exploded view

53
Figure 7.2A
Ii
Style II, typical exploded view-globe valve
VII GLOBE VALVE

7.3 PARTIAL DISASSEMBLY - GASKET 7.4.2 Disassembly of Body/Bonnet and

REPLACEMENT Disc/Stem union

Follow warning instructions in Section 111before 7.4.2.1 Style I (Fig. 7.1A)

beginning disassembly. If valve is equipped
1. The valve should be in a partially open
with a gear or motor actuator, see Appendix
position.
for disassembly of actuators. As a general
disassembly progresses, place matching marks 2. Remove small set screw (35A) in handwheel
on parts so that the same orientation of parts nut (30), then unscrew handwheel nut.
can be maintained at reassembly. 3. Remove handwheel and handwheel key (26B).
4. Remove yoke housing capscrews (170), then
CAUTION: Do not attempt to force out remove housing cover (28) over the stem (04)
the pressure seal gasket by using a crane, and stem nut (88).
hoist, chain-block, etc. The gasket may be 5. Unscrew stem nut (88) from the stem (04).
tight inside the valve body and if pulled
using a crane, jack, or other means, it may 6. Remove packing flange nuts (16B).
suddenly release causing personal injury 7. Remove gland eyebolt (38) by loosening jam
and/or extensive damage. nuts (16E) and removing hex head bolts (56).
The gland eyebolt clamp (92) will fall off after
the two hex head bolts (56) have been
7.3.1 Style I removed.
8. Loosen bonnet retainer (22).
To remove the pressure seal gasket follow
steps 1 through 14 in Section 7.4.2.1- Disassembly NOTE:If a valve has been in high temperature
of Body/Bonnet and Disc/Stem/Union - Style I. service for extensive periods of time, the
Installation of the gasket follows steps 1 through 18 retainer (22) sometimes becomes seized to
in Section 7.6.2.1 - Body/Bonnet and Disc/Stem the bonnet. Tight threads can be loosened
by applying penetrating oil or heat to the
Assembly - Style I.
retaining nut and working it free.

7.3.2 Style II and III 9. Before removing the yoke, it is necessary to

remove two half dog set screws (35B) located
To remove the pressure seal gasket follow on the top outer edge of the body.
steps 1 through 9 in Section 7.4.2.2 - Disassembly IMPORTANT: The two half dog set screws
of Body/Bonnet and Disc/Stem/Union - Style 1/ & 111. must be removed before unscrewing the
Installation of the gasket follows steps 2 through 11 yoke because they are set into the thread of
in Section 7.6.2.2 - Body/Bonnet and Disc/Stem the yoke. If not removed they could cause a
Assembly - Style 1/ and 111. considerable amount of damage to the thread
of the yoke and body.

7.4 TOTAL DISASSEMBLY OF GLOBE AND 10. Loosen yoke (03) approximately two turns.
STOP CHECK VALVES 11. Retighten bonnet retainer (22). This will pull
the tight pressure seal gasket up to the larger
7.4.1 General diameter where it will become free.
12. Remove bonnet retainer (22) and unscrew
Follow warning instructions in Section 111before yoke (03) from body.
beginning disassembly. If valve is equipped
with a gear or motor actuator, see Appendix
for disassembly of actuators. As a general
disassembly progresses, place matching marks
on parts so that the same orientation of parts
can be maintained at reassembly.

54
GLOBE VALVE VII

13. Use the stem to lift the total internal assembly

out of the body. The bonnet (02) and pressure
seal gasket (19) will come out when the
backseat shoulder on the stem hits against -"5;;;<>------{46 Spring
the backseat in the bonnet. (optional)
NOTE: When lifting the bonnet-stem
assembly, care should be taken not to tilt
the disc that can cause body gasket surface
damage.
14. If you are disassembling a stop check valve,
the stem is not attached to the disc. The disc (6)
and spring (optional) (46) must be lifted from
the valve body after the bonnet and stem
have been removed from the assembly
(see Fig. 7.2CJ.
15. For globe valves, the stem (04) and disc (06)
will come out in one piece.
16. A disc union (40) and the stem collar (41) are
used to make the connection between the
stem (04) and the disc (06). To remove this
connection, break the tack welds using a saw
or small sharp chisel or grind off tack welds
17. After the tack welds are removed, unscrew the
disc union from the disc, pull the disc off the
stem and remove the stem collar (41) (two
pieces) from the stem. Check inside the disc.
Some discs have a hardfacing deposit at the
bottom center and some have a small thrust Figure 7.2C Stop checkvalve-explodedview
pad (42).
18. Now the disc can be repaired or replaced. 4. Remove torque arm (25). There are four types
of torque arms (see Fig. 7.4A):
7.4.2.2 Styles II (Fig. 7.2AJ and III (Fig. 7.1OJ Type I - one-piece with bearing
1. The valve should be in a partially open position. Type II - one-piece without bearing
2. Before proceeding with disassembly of valves, Type III - two-piece with bearing
check if the valve is equipped with a leak-off
option (62). If so, disconnect it first. Leak-off Type IV - two-piece without bearing
pipes should be unscrewed or cut approximate- a) Removal of Types I and II:
ly 6" (150 mm) from the bonnet side and not at Loosen the capscrew (17c) and remove.
the welded joint on the bonnet. Slide torque arm (25) up along stem and
3. Remove packing flange nuts (16b) and if remove torque arm key (26A) from stem.
applicable, live-loading. Torque arm will not come off at this point,
but you must make sure that the torque arms
NOTE: If the valve is equipped with
slides freely over the stem.
live-loading, including guide sleeves and
Belleville washers (36) as shown in Fig. 5.1L, b) Removal of Types III and IV:
make note of the order of these parts so that at Loosen hex nuts (160), pull torque arm
reassembly they will return in the same order. apart and remove torque arm key (26A)

• 55
from stem. The torque arm will come totally
off assembly at this point.
VII GLOBE VALVE

PARTS DESCRIPTION
15D - Stud (torque arm)
16D - Nut (torque arm)
17C - Cap screw (torque arm)
TYPE. TYPE II
•
25 - Torque arm
26A - Key (torque arm)
29 - Bearing
35 - Set screw

Figure 7.4A Torquearm, 4 types

5. Remove yoke-body nuts (16A). c) Lift the bonnet retainer (22) over the stem
and off the valve body.
6. Turn the handwheel to close the valve. This will
cause the yoke to rise and to unthread from the d) Remove bolting spacer (23) which is lying
valve stem. As this takes place, the weight of flat on top flange of body.
the yoke and top works should be supported by e) Lower the bonnet (02) by pushing down-
(
a hoist to prevent damage to the stem thread. ward or by tapping the bonnet with a
NOTE: When removing the yoke, Types I and II brass bar. The bonnet should clear the
torque arms (25) and packing flange (11), they four-segment gasket retainer. To loosen
must be helped along to prevent the two parts the gasket retainer (21). tap well on all four
from becoming jammed in sideways against the segments using a brass bar, then insert a
stem and yoke. drive pin into the side holes of the body
flange. Tap lightly to remove the two
7. On some valves, the packing flange (11)will not smaller segment portions first, then the
have to be removed in order to remove the yoke larger portions.
(3). Therefore, the packing flange can be removed
f) Use the stem (04) to lift the spacer ring (20),
together with the gland bushing (12)and packing
the pressure seal gasket (19), bonnet (02)
rings (13). Remove the packing rings in accor-
and internal assembly out of the valve body.
dancewith Sections 5.1.2and 5.1.3.
8. Removal of Bonnet - Style II
a) Loosen the bonnet retaining capscrews (17B).
b) Remove the split ring (115) (two pieces),
which is between the bonnet (02) and the
bonnet retainer (22).

56
GLOBE VALVE VII

IMPORTANT: Do not use excessive force on IMPORTANT: Do not use excessive force
the stem (04) if the bonnet (02) does not come on the stem (04). If the bonnet (02) does
out easily. It may be necessary to remount not come out easily, it may be necessary to
the bonnet retainer (22) with split ring (115) remount the bonnet retainer (22) using two
installed around bonnet (02), and use the bon- or four bonnet retaining nuts (16c) to retighten
net retaining cap screws to pull the bonnet and the bonnet. By retightening the nuts with the
gasket (19) out from their seating position. gasket retainer (21) removed, the tight pres-
By retightening the cap screw with the gasket sure seal gasket will be pulled up to the larger
retainer (21) removed, the tight pressure seal diameter where it will become free.
gasket will be pulled up to the larger diameter
f) Once the bonnet (02) and pressure seal
where it will become free.
gasket (19) are free, they can be carefully
g) After the bonnet (02) and the pressure seal lifted out of the body. When lifting the
gasket (19) become free, they can be bonnet-stem assembly, care should be
carefully lifted out of the body. When lifting taken not to tilt the disc that can cause body
the bonnet-stem assembly, care should be gasket surface damage.
taken not to tilt the disc that can cause body 10. Use the stem to lift the total internal assembly
gasket surface damage. and bonnet out of the valve body.
9. Removal of Bonnet - Style III 11. The stem (04) and disc (06) will come out in
a) Remove bonnet retaining nuts (16C). one piece with the bonnet (Fig. 7.28).
b) Lift bonnet retainer (22) over stem and off 12. A disc union (40) and stem collar (41) are used
valve body. to make the connection between the stem (04)
c) Remove two bonnet retaining studs (15A). and disc (06). To remove this connection,
Lower bonnet (02) by pushing downward break the tack welds using a saw or a small,
or by tapping on bonnet with a brass bar. sharp chisel, or grind off tackwelds.
The bonnet recess should clear the gasket 13. After the tack welds are removed, unscrew the
retainer (21). Line up the bonnet (02) minus disc union from the disc, pull the disc off the
the two studs with the small portion of the stem and remove the stem collar (two pieces)
four-segment retainer. Insert a drive pin from the stem. Check inside the disc. Some
into the holes provided in the body top discs have a hardfacing deposit at the bottom
flange. Tap lightly to remove the gasket center and some have a small thrust pad (42).
retainer (21).
14. Now the disc can be repaired or replaced.
NOTE: If the valve has been in high pressure
15. If you are disassembling a stop check valve,
service for a long period of time, it may be
the stem is not attached to the disc. The disc
necessary to tap lightly on the gasket retainer
(06) and spring (46) (optional) must be lifted
inside the body first so that the drive pin
from the valve body after the bonnet assembly
will be able to push out the gasket retainer
has been removed (see Fig. 7.2C).
more easily.
16. The valve is now ready for inspection and
d) Remove the two smaller portions of the repairs of seat, disc, stem, etc.
four-segment gasket retainer, then the
larger portions.
e) Use the stem (04) to lift the spacer ring (20),
the pressure seal gasket (19), bonnet (02)
and internal assembly out of the valve body.

57
VII GLOBEVALVE

7.4.3 Disassembly ofTop Works (Fig. 7.48) 7.5 TOTAL DISASSEMBLY OF PISTON CHECK
Follow warning instructions in Section 11/ before VALVE (Refer to Fig. 7.5A)
beginning top works disassembly.
1. Remove two opposite bonnet retaining nuts
1. If line pressure is maintained in the valve, (16C) and the accompanying bonnet retaining
backseat the valve in fully open position studs (15A) from bonnet (02).
before starting any disassembly.
2. Screw two eyebolts twice the length of
2. Remove small set screw (35A) in handwheel original studs into these tapped holes in
nut (30), then unscrew handwheel nut. the bonnet (02).
3. Remove handwheel (33).
3. Fasten a chain hoist to the eyebolts, pulling
4. Remove yoke housing bolting (17D) and just enough to eliminate any slack in the hoist.
remove housing cover (28).
4. Remove all remaining bonnet nuts. For valves
5. Remove first set of bearings (29A) (3 pieces). with eight studs or more, remove one stud on
6. Unscrew stem nut (88) from the stem (04). either side of the eyebolts (four studs total).
7. After the stem nut has been removed, 5. Slacken chain hoist to lower bonnet until it
remove second set of bearings (29B). rests on the stops in the body.
8. Now valve and parts are readyfor inspection, NOTE: If bonnet does not lower when hoist
repairsand replacementof stem nut, bearing,etc. is slackened, tap on the eye bolts to free the
bonnet.
6. Remove eyebolts. For valves provided with
~, I I ~
a tapped hole in the center of the cover, insert
eyebolt. Fasten a chain hoist to this eyebolt,
lift cover and remove.
7. Insert a drive pin into the knock-out holes
provided in the top flange of the body. Tap
lightly to remove the four-segment gasket
retainer (21).
NOTE: If the valve has been in high pressure
service for a long period of time, it may be
necessary to tap lightly on the gasket retainer
PARTSDESCRIPTION inside the body first so that the drive pin will (
03 - Yoke
17D - HSH cap screw be able to push the gasket retainer out easily.
268 - Key Remove the two small portions of the four-
28 - Housing cover segment retainer and then the larger portion.
29A - Bearing
Remove pressure seal spacer ring (20).
29B - Bearing
30 - Handwheel nut 8. To remove pressure seal gasket, place three
33 - Handwheel
34 - Grease fitting
1" (25 mm) minimum spacer blocks on the
35A - Set screw body (see Fig. 7.58). Replacethe cover and
88 - Stem nut align holes so that the eyebolts can be
replaced in the bonnet.
9. Reattach hoist to eyebolts and raise bonnet
until it contacts the gasket.
10. For valves with fewer than eight studs,
use two opposite nuts to pull up gasket.
For valves with eight studs or more, use
four nuts to pull up gasket.
Figure 7.48 Valve top works disassembly
NOTE: Nuts or screws should be turned
uniformly a fraction of a turn at a time because
valve parts could be damaged by locking the

58
GLOBEVALVE VII

pressure seal gasket ring. This uniform

PARTS DESCRIPTION Q1Y PARTS DESCRIPTION Q1Y
turning is important to avoid pressure seal
01 • Body 1 20 • Spacer
02 • Bonnet 1 21 • Gasket retainer gasket from becoming seized
06 • Disc 1 50 • Cover
IMPORTANT. Once removed, it is
15A • Stud 6 59 • Equalizer pipe
16C . Nut 6 66 • Nameplate recommended to replace the pressure seal
19 • Gasket 1 gasket and spacer ring with a new one.
11. Lift the entire pressure seal enclosure
assembly out of the valve body. When putting
parts aside for inspection, it is very important
that they be placed carefully on a bed of rags
or other soft material to avoid damage of the
finely-machined gasket seating surfaces.
12. After the entire pressureseal enclosure has been
removed, the disc (06) and spring (46), if so
equipped, must be lifted from the valve body.

7.6 ASSEMBLY

7.6.1 Top Works Assembly (Refer to Fig. 7.6A)

1. Apply new grease to threaded portion of
the stem (04) above top flange on yoke (03).
2. Mount second set of newly-greased bearings
Figure 7.5A Forged piston check valve, 3-8" (29B) in recess of yoke.
(75 -200 mm) NOTE: Bottom race must fit loosely around
stem nut and top race must be tight around
PARTS DESCRIPTION stem nut.
01 . Body 20 . Spacer
02 . Bonnet 21 - Gasket retainer 3. Apply new grease to internal thread in stem
15 . Stud 38 . Eye bolt nut (88) and screw stem nut on stem.
Drive pin holes
16 . Nut 50 • Cover for removal of
19 . Gasket gasket retainer 4. Mount first set of newly-greased bearing (29A)
on stem nut.
NOTE: Bottom race must fit tightly around stem
nut and top race must be loose.
5. After the bearing and stem nut are in place,
mount yoke housing cover (28) on top and tie
down with housing bolting (170). Bolting must
be torqued down in accordance with the
values in Table 5.3A.
6. Insert handwheel key (26B) in keyway in stem
nut and mount handwheel (33).
7. Return handwheel nut (30) and tighten.
Use handwheel nut set screw (35A) to lock
handwheel nut in place.
8. Inject more new grease into housing cover
through the grease fitting (34) on side of
housing cover.
9. Verify operation by cycling at least once from
Figure 7.58 Use of shims to disassemble fully open to fully closed position.
pressure seal assembly ..

59
VII GLOBE VALVE

9. Mount torque arm (25) on stem (04) and

PARTS DESCRIPTION
make sure torque arm key (26A) fits properly
03 - Yoke 29B - Bearing
04 - Stem 30 - Handwheel nut in stem.
170 - HSH cap screw 33 - Handwheel 10. Return handwheel nut (30) and tighten.
26B - Key 34 - Grease fitting
35A - Set screw
Use the handwheel nut set screw (35A)
28 - Housing cover
29A - Bearing 88 - Stem nut and lock handwheel nut in place.
11. Inject more new grease into housing cover
using the grease fitting (34) on the side of
the yoke (03).
12. Turn handwheel to open valve fully against
the backseat (18). This will centralize the stem
and bonnet.
13. Torque down the bonnet retaining ring (22)
in accordance with the torque values given in
Table 4.5A.
14. Install two half dog set screws (358) back in
the correct location in the top outer edge of
the body.
15. Repackthe valve in accordance with
Section 5.1, Packing.
Valve top works assembly 16. Install the gland eyebolt clamp (92) and gland
eyebolt (38) by installing the two hex head

1.6.2 Body/Bonnet and Disc/Stem Assembly

bolts (56) and tighten the jam nuts (16E).
17. Install packing flange nuts (16B) and torque
('hi',
(ValveInternal and Mid-section) down in accordance with Section 5.1.6.
18. Verify operation by cycling at least three times
1.6.2.1 Style I (Fig. 7.1A) from fully opened to fully closed position.
1. Install the disc (06) and stem (04) assembly
in the valve body.
2. Lower the bonnet 0(2) onto the stem (04) (
and into the valve body.
3. Install the new pressure seal gasket (19)
around the bonnet and into the valve body.
4. Install the yoke (03) on the valve body
and tighten.
NOTE: When you install the yoke (03),
also install the bonnet retainer (22), gland
bushing (14), packing flange (11), and the
torque arm (25).
5. Apply new greaseto threaded portion of
the stem (04)above and below top flange on
the yoke (03).
6. Apply new grease to internal thread in the
stem nut (88) and turn stem nut onto stem.
7. Install yoke housing cover (28).
8. Insert handwheel key (26b) in keyway in
the stem nut and mount handwheel (33).

60
GLOBE VALVE VII

7.6.2.2 Styles II (Fig. 7.2A) and III (Fig. 7.10) . 6. Repack valve in accordance with
Section 5.1, Packing.
1. Globe Valve (Fig. 7.28)
NOTE: Do not torque down the packing
Install small thrust pad (42) into recess in flange (11) at this point of assembly.
bottom of disc (06). Place stem collar (41)
around groove on stem. Install stem and 7. Install yoke by turning handwheel to open
stem collar in disc and tighten down with valve. This will cause the yoke to be lowered
disc union (40). Check if disc can be rotated. down on the valve body.
If disc can be rocked, it is correctly installed NOTE: In some cases on the smaller size
on stem. The rocking will allow the disc to valves, it will be necessary to remove the
self-align to the seat. Tack weld disc union packing flange before installing the yoke.
to disc in two or three places depending on Therefore, the packing flange (11) and the
the valve size. Check again to see if the disc Type I or II torque arm (25) (Fig. 7.4A) must
can rock after tack welding has cooled. be reinstalled in correct positions before the
Install disc and stem assembly in valve body. yoke (03) is completely lowered on the stem.
2. Stop Check Valve (Fig. 7.2C) 8. Install the body-yoke nuts (16A) or cap
Insert disc (06) into valve body insert spring screws (17A) and torque in accordance
(46) (optional) into the disc. Insert stem (04) with Table 5.3A.
into valve body through spring and into disc. 9. Turn the handwheel to open the valve fully
3. Piston' Check Valve (Fig. 7.5A) against the backseat (18). This will centralize
Insert the disc (06) back into the valve body. the stem and bonnet.

4. Bonnet Style II (Fig. 7.2AJ 10. Torque the bonnet retaining nuts (16C) or
bonnet retaining capscrews (17B) in strict
a) Lower bonnet (02) onto stem (04) and into accordance with Section 4.5.1.
valve body (01).
NOTE: If the valve is equiped with live load
b) Install new pressure seal gasket (19) and
bonnet (Belleville spring washers) install the
spacer ring (20). spring washers in the same order as noted
c) Install gasket retainer (21) in groove in during disassembly. Refer to Fig. 4.5Cor
body wall. Fig.4.50 (spring washer configuration).
d) Place bolting spacer (23) on top flange of 11. Mount torque arm (25) Type III or IV on
valve body. stem (04) and make sure the torque arm key
e) Install bonnet retainer (22) around (26A) fits properly in the stem and torque
bonnet (02). arm keyway.
f) Install split ring (115) between bonnet (02) 12. Mount the live-loading option if so equipped,
and bonnet retainer (22). refer to Fig.5.1L torque the packing flange nuts
g) Uniformly tighten the hex socket head (16B), in accordance with Section 5.1, Packing.
capscrew (17B) by hand. NOTE: If the valve is equipped with packing
5. Bonnet Style III (Fig. 7.10) live-loading option, live-loading parts must
return in the same order as noted in
a) Lower bonnet (02) onto stem (04) and into
disassembly.
valve body (01).
b) Install new pressure seal gasket (19) and 13. Verify the operation by cycling at least
spacer ring (20). three times from fully opened to fully
c) Install gasket retainer (21) in groove in closed position.
body wall.
d) Mount bonnet retainer (22) down on top
flange on body.
e) Install bonnet retaining nuts (16C) and
uniformly tighten the nuts by hand.

61
VIII PARALLEL SLIDE VALVE

8.1 ASSEMBLY DRAWING

PART DESCRIPTION PART DESCRIPTION

01 - Body 26B - HW_Key 01 - Body 21 - Gasket retainer

02 - Bonnet 28 - Housing cover 02 - Bonnet 22 - Bonnet retainer
03 - Yoke 30 - Handwheel nut 03 - Yoke 23 - Bolting plate
04 - Stem 31 - Lock washer 04 - Stem 25 - Torque arm
07 - Disc 07 - Disc 26A - T.A. Key
33 - Handwheel
09 - Seat
09 - Seat 268 - HW. Key
10 - Disc guide 34 - Grease fitting 10 - Wedge guide
35 - Setscrew 28 - Housing cover
11 - Packing flange 11 - Packing flange 29 - Bearing
- Gland bushing 35A - Set screw 12 - Gland bushing
12 30 - Handwheel nut
- Packing ring (end) 358 - Setscrew 13A - Packing ring (end)
13A 33 - Handwheel
138 - Packing ring (inter) 38 - Gland eyebolt 138 - Packing ring (inter)
46 - Spring 34 - Grease fining
168 - Gland nut 15 - Stud 35 - Set screw
49 - Stroke limiter

•
16E - Nut 158 - Stud
56 - Hex HD bolt 35A - Setscrew
17C - HSH cap screw 16A - Nut
17D
19
-
-
HSH cap screw
PS Gasket
57
66
-
-
Washer
Nameplate
168
17A
-
-
Nut
HSH cap screw
45
46
49
-
-
-
Retaining ring
Spring
Stroke limiter
«i
22 - Screwed bonnet retainer 88 - Stem nut 178 - HSH cap screw
25 - Torque arm 92 - Gland eyebolt clamp 17C - HSH cap screw 66 - Nameplate
26A - T.A. Key 109 - Center piece 19 - PS Gasket 88 - Stem nut
20 - Spacer ring 109 - Center piece
115 - Split ring

Figure 8.1A Style I, forged pressure seal, Figure 8.18 Style II, forged pressure seal,
parallel slide valve, 2" (50 mm) parallel slide valve, 3" (75 mm)
and 21/2" (65 mm) and 4" (100 mm)

62
PARALLEL SLIDE VALVE VIII

• PART DESCRIPTION
01
02
-
-
Body
Bonnet
138
15
-
-
Packing ring (inter)
Stud
20
21
-
-
Spacer ring
Gasket retainer
33
34
-
-
Handwheel
Grease fitting
03 - Yoke 15A - Stud 22 - Bonnet retainer 35 - Set screw
04 - Stem 158 - Stud 25 - Torque arm 35A - Set screw
07 - Disc 16A - Nut 26A - T.A. Key
09 - Seat 43 - Disc carrier
168 - Nut 268 - HW. Key
10 - Wedge guide 45 - Retaining plate
16C - Nut 28 - Housing cover
11 - Packing flange 17C - HSH cap screw 46 - Spring
29 - Bearing 49 - Stroke limiter
12 - Gland bushing 170 - HSH cap screw 30 - Handwheel nut
13A - Packing ring (end) 66 - Nameplate
19 - PS Gasket 32 - Gear operator 88 - Stem nut

.:

t Figure B.1C Style 11/, forged pressure seal,

parallel slide valve, 6" (150 mm)
Figure B.1D Style /II, forged pressure seal,
parallel slide valve,
8-16" (200 - 400 mm)

63
VIII PARALLEL SLIDE VALVE

8.2 PARTIAL DISASSEMBLY - GASKET

REPLACEMENT
Follow warning instructions in Section III before PART DESCRIPTION
beginning disassembly. If valve is equipped with 01 - Body 20 - Spa cer ring
02 - Bonnet 21 - Gasket retainer
a gear or motor actuator, see Appendix for disas- 03 - Yoke 22 - Bonnet retainer
sembly of actuators. As a general disassembly 04 - Stem 25 - Torque arm
07 - Disc 26A - Key
progresses, place matching marks on parts so that 09 - Seat 268 - Key
the same orientation of parts can be maintained 10 - Wedge guide 28 - Housing cover
11 - Packing flange 29 - Bearing
at reassembly. 12 - Gland bushing 30 - Handwheel nut
13A - Packing ring (end) 32 - Gear operator
CAUTION: Do not attempt to force out 138 - Packing ring (inter) 33 - Handwheel

•
15 - Stud 34 - Grease fitting
the pressure seal gasket by using a crane, 1SA - Stud
35 - Set screw
hoist, chain-block, etc. The gasket may be 158 - Stud
1SA - Nut 35A - Set screw
tight inside the valve body and if pulled 168 - Nut 43 - Disc carrier
16C - Nut 45 - Retaining plate
using a crane, jack, or other means, it may 17C - HSH cap screw 46 - Spring
suddenly release causing personal injury 170 - HSH cap screw 49 - Stroke limiter
19 - PS Gasket 66 - Nameplate
and/or extensive damage.

8.2.1 Style I

To remove the pressure seal gasket follow

steps 1 through 14 in Section 8.3.2.1- Disassembly
of Body/Bonnet and Disc/Stem - Style I.
Installation of the gasket follows step 5 in Section
(
8.4.2 - Body/Bonnet and Disc/Stem Assembly.

8.2.2 Style II and III

To remove the pressure seal gasket follow

steps 1 through 11 in Section 8.3.2.2 - Disassembly
of Body/Bonnet and Disc/Stem - Style /I and III.
Installation of the gasket follows steps 6 and 7 in
Section 8.4.2 - Body/Bonnet and Disc/Stem
Assembly.

8.3 TOTAL DISASSEMBLY

8.3.1 General

Follow warning instructions in Section III before

beginning disassembly. If valve is equipped with
a gear or motor actuator, see Appendix for disas-
sembly of actuators. As a general disassembly
progresses, place matching marks on parts so that
the same orientation of parts can be maintained
at reassembly.

Figure 8.1E Style III, forged pressure seal,

parallel slide valve
t
64
PARALLEL SLIDE VALVE VIII

• 8.3.2 Disassembly of Body/Bonnet and Disc/Stem

8.3.2.1 Valve Style I (Fig.8.1A)

1. The valve should be in a normally closed
position.
NOTE: Velan parallel slide valves have two
types of stroke limiters. Stroke limiter Type I
(Fig. 8.38) is mounted on top of the stem and
fixed with a stud. Stroke limiter Type II
(Fig. 8.3C) is directly threaded to the stem and
secured via a set screw in the stem groove.
Stroke Limiter Type I (Fig. 8.38):
I"J Measure the distance, dimension A, the stud
(15) extends out of the top of the limiter (49).
Stroke Limiter Type II (Fig. 8.3C):
Measure the distance from top of stem to the
stroke limiter and record this value. This distance PART DESCRIPTION 30 - Handwheel nut
must be noted becausethe distance regulatesthe 4 • Stem 33 - Handwheel
closed-position of the parallel slide valve. 15 . Stroke limiter stud 35A - Handwheel
11 - Stroke limiter nut set screw
After the distance has been noted, remove cap screw 49 - Stroke limiter
stroke limiter (49). 26B - Handwheel key

2. Remove small set screw (35A) in handwheel

nut (30), then unscrew handwheel nut.
t \/:, 3. Remove handwheel (33) and handwheel
key (26B).
Figure 8.38 Stroke limiter Type I

4. Remove yoke housing capscrews (170),

then remove housing cover (28) over

t. the stem (04) and stem nut (88).

5. Unscrew stem nut (88) from the stem (04).
6. Remove packing flange nuts (16B).
7. Remove gland eyebolt (38) by loosening
jam nuts (16E) and removing hex head bolts
(56). The gland eyebolt clamp (92) will fall
off after the two hex head bolts have been
removed.
8. Loosen bonnet retainer ring (22) counter
clockwise using a special tool "crawfoot
wrench" refer to Fig. 4.58 page 16 or with
a wedge and hammer.
NOTE: If a valve has been in high temperature PART DESCRIPTION
service for extensive periods of time, the bon- 03 - Yoke 33 - Handwheel
04 - Stem 34 - Grease fitting
net retainer (22) sometimes becomes seized to 110 - HSH cap screw 35 - Set screw
the bonnet. Tight threads can be loosened by 26B - HW_ Key 35A - Set screw
applying penetrating oil or heat to the bonnet 28 - Housing cover 49 - Stroke limiter
30 - Handwheel nut 88 - Stem nut
retainer and working it free.

t Figure 8.3C Stroke limiter Type /I

65 .1
VIII PARALLEL SLIDE VALVE

14. Now the discs (07) and/or seats (09) can be

9. Before removing the yoke, it is necessary to
remove two half dog set screws (35B) located repaired or replaced.
on the top outer edge of the body. NOTE: If packing rings and or the stem must
be replaced. Remove the stem and push out
IMPORTANT: The two half dog set screws
the packing rings from the opposite side of the
must be removed before unscrewing the
packing chamber. If only the pressure seal
yoke because they are set into the thread of
gasket is being replaced it will not be necessary
the yoke. If not removed they could cause
to remove the packing rings or the stem
a considerable amount of damage to the
provided they are in a good condition.
thread of the yoke and body.
However, whenever replacing a pressure seal
10. Loosen yoke (03) approximately two turns. gasket ring, the body and bonnet gasket surface
11. Retighten bonnet retainer (22). This will pull contact line should be buffed smooth and free
the tight pressure seal gasket up to the larger of any damages.
• ..r.4
diameter where it will become free.
12. Remove bonnet retainer (22) and unscrew 8.3.2.2 Valve Styles II (Fig. 8.1B) and III (Fig. 8.1C)
yoke (03) from body. 1. The valve should be in a normally closed
13. Use the stem to lift the total internal assembly position.
out of the body. The bonnet (02) and pressure 2. Before proceeding with disassembly of valves,
seal gasket (19) will come out when the check if the valve is equipped with a leak-off
backseat shoulder on the stem hits against option (62). If so, disconnect it first. Leak-off
the backseat in the bonnet. pipes should be unscrewed or cut approximately
NOTE: When lifting the bonnet-stem 6" (150 mm) from the bonnet side and not at the
assembly, care should be taken to prevent welded joint on the bonnet.
internal parts from disengaging from the stem.
Use a C-wrench to keep the discs and spring
(jicl
from disengaging.

PARTS DESCRIPTION
150 - Stud (torque arm)
160 - Nut (torque arm) 25 - Torque arm
17C - Cap screw 26A - Key
TYPEn (torque arm) (torque arm)
29 - Bearing
35 - Set screw

TYPE IV

Figure 8.3A Torque arm 4 types

66
PARALLEL SLIDE VALVE VIII

3. Remove packing flange nuts (16B) and 7. Remove yoke-body nuts (16A).
live-loading where applicable. 8. Turn the handwheel to close the valve.
NOTE: If the valve is equipped with live- This will cause the yoke to rise and to unthread
loading, including guide sleeves and Belleville from the valve stem. As this takes place, the
washers (36) as shown in Figs. 5.1K and 5.1L, weight of the yoke and top works should be
make note of the order of these parts so that at supported by a hoist to prevent damage to
reassembly they will return in the same order. the stem thread.
4. Remove torque arm. There are four types of NOTE: When removing the yoke, Types I & II
torque arms (see Fig. 8.3A): torque arms (25) and packing flange (11), they
Torque arm Type 1- one-piece with bearing must be helped along to prevent the two parts
from becoming jammed in sideways against
Torque arm Type II - one-piece without bearing the stem and yoke.
f ,~ Torque arm Type III - two-piece with bearing
Torque arm Type IV - two-piece without bearing
9. On some valves, the packing flange (11) will
not have to be removed in order to remove
a) Removal of torque arm - Types I and II: the yoke (03). Therefore, the packing flange
can be removed together with the gland
Loosen the capscrew (17C) and remove. bushing (12) and packing rings (13). Remove
Slide torque arm (25) up along stem and the packing rings in accordance with Section
remove torque arm key (26A) from stem. 5.1.2 and 5.1.3.
Torque arm will not come off at this point,
but you must make sure that the torque 10. Removal of Bonnet - Style II
arms slides freely over the stem. a) Loosenthe bonnet retainingcapscrews(178).

tl'
b) Removal of torque arm - Types III and IV: b) Remove the split ring (115) (two pieces),

t Loosen hex nuts (160), pull torque arm

apart and remove torque arm key (26A)
from stem. The torque arm will come
which is between the bonnet (02) and the
bonnet retainer (22).
c) Lift the bonnet retainer (22) over the stem
totally off assembly at this point. and off the valve body.
IMPORTANT: Please note that the torque d) Remove bolting spacer (23) which is lying
arm assembly should not be allowed to come flat on top flange of body.
loose during valve operations. This is crucial to e) Lower the bonnet (02) by pushing
maintain the alignment of the stem T-head in
'A. the disc-carrier.
downward or by tapping the bonnet with
a brass bar. The bonnet should clear the
NOTE: Velan parallel slide valves have two four-segment gasket retainer. To loosen
types of stroke limiters. Stroke limiter type I the gasket retainer (21), tap well on all four
(Fig. 8.38) is mounted on top of the stem and segments using a brass bar, then insert a
fixed with a stud. Stroke limiter type II (Fig. 8.3C) drive pin into the side holes of the body
is directly threaded to the stem and secured via flange. Tap lightly to remove the two
a set screw in the stem groove. smaller segment portions first, then the
larger portions.
5. Stroke limiter Type I (Fig. 8.38): f) Use the stem (04)to lift the spacer ring (20),
Measure the distance the stud (15) extends the pressure seal gasket (19), bonnet (02) and
out of the top of the limiter (49) as shown in internal assembly out of the valve body.
Fig. 8.38.
NOTE: To keep the discs from separating
Stroke limiter Type II (Fig. 8.3C): apart during removal, use a Velan parallel slide
Measure the distance from top of stem to the disc clamp. In the absence of the disc clamp a
stroke limiter and record. This distance must standard C-clamp can be used.
be noted becausethe distance regulates the

t [~[t
IMPORTANT: 00 not use excessive force on
position of the two discs in a parallel slide valve. the stem (04) if the bonnet (02)does not come
\'
·~t
6. After this distance has been noted, remove out easily. It may be necessaryto remount the
the stroke limiter (49). bonnet retainer (22)with split ring (115) installed
around bonnet (02), and use the bonnet

J.-bO
67
VIII PARALLEL SLIDE VALVE

PARTS DESCRIPTION
(I
retaining cap screws (17B)to pull the bonnet 09 . Seat 16F • Nut 22 . Bonnet retainer
01 . Body
(02) and gasket (19) out from their seating 02· Bonnet 15 . Stud 19 • Gasket 46 . Spring
position. By retightening the cap screw with 04 . Stem 15A· Stud 20 • Spacer ring 56· Hex HDbolt
07· Disc 16C· Nut 21 • Gasket retainer 60· Tab washer
the gasket retainer (21) removed, the tight I 109 . Center piece
pressure seal gasket will be pulled up to the
larger diameter where it will become free.
-r.Jl~~~rul~ 16C
NOTE: If only pressure seal gasket ring is being
replaced, it will not be necessary to remove
the packing rings. Lift the stem together with
bonnet until the bonnet just clears the top of
body. Use Velan disc clamp or standard "C"
clamp to keep the disc halves from spreading
open. After the entire bonnet assembly has • ,I
been removed, the body and bonnet gasket
contact line surface must be buffed smooth
and should be damage free. The bonnet gasket
angular surface can also be machined if
necessary.
g) After the bonnet (02) and the pressure seal
gasket (19) become free, they can be
carefully lifted out of the body. When lifting
04~-----------+
the bonnet-stem assembly, care should be
taken to prevent internal parts from
disengaging.
11. Removal of Bonnet - Style III
tJ (I
a) Remove bonnet retaining nuts (16C).
b) lift bonnet retainer (22) over stem and off
valve body.
c) Remove two bonnet retaining studs (15A).
Lower bonnet (02) by pushing downward
or by tapping on bonnet with a brass bar.
The bonnet recess should clear the gasket
retainer (21). Line up the bonnet minus the
two studs with the small portion of the four-
segment retainer. Insert a drive pin into the
holes provided in the body top flange. Tap
lightly to remove the gasket retainer (21).
NOTE: If the valve has been in high-pressure
service for a long period of time, it may be
necessary to tap lightly on the gasket retainer
inside the body first so that the drive pin will
be able to push out the gasket retainer more
easily.
d) Remove the two smaller portions of the
four-segment gasket retainer, then the
larger portions.
e) Use the stem (04) to lift the spacer ring (20),
the pressure seal gasket (19), bonnet (02)
and internal assembly out of the valve body.
NOTE: To keep the discs from separating
t
apart during removal, use a Velan parallel Figure 8.30 Bonnet removal-parallel side valve
slide disc clamp (Fig. B.3EJ. ybl
68
PARALLEL SLIDE VALVE VIII

• IMPORTANT: Do not use excessive force on

the stem (04). If the bonnet (02) does not come
out easily, it may be necessary to remount the
bonnet retainer (22) using two or four bonnet
retaining nuts (16C)to retighten the bonnet.
By retightening the nuts with the gasket retain-
er (21) removed, the tight pressure seal gasket
will be pulled up to the larger diameter where
it will become free.
f) Once the bonnet (02) and pressure seal
gasket (19) are free, they can be carefully

f I., lifted out of the body.

NOTE: If only pressure seal gasket ring is
being replaced, it will not be necessary to
remove the packing rings. For valves equiped
with Disc Type V Fig. 8.31,turn the stem (04)
90 degrees either way and lift out the entire
bonnet assembly with stem. The disc will PARTS DESCRIPTION
remain in the valve body. Remove any 1 - Arm
imperfection (damage) by buffing smooth the 2 • Adjusted screw
body and bonnet gasket contact line surface. 3 - Cross member
4 - Pivot pin
The bonnet gasket angular surface can also
be machined if necessary. For valves equiped
with disc Type II Fig. 8.3G lift the bonnet Figure 8.3E Parallel slide disc clamp
together with stem until the bonnet just clears
top of body, push the stem together with
bonnet towards left or right hand side, this of the discs. Tighten adjusting screws until
will cause the stem to slide off the disc carrier the discs are free from seats. Now lift the stem,
T-head. Lift out stem with bonnet, the disc discs and clamp out of the valve body.
will remain in the valve body. To prevent

•
15. NOTE: Velan has five parallel slide disc designs.
debries from falling in, cover up the disc and
body base while performing buffing on body a) Disc Type I and IV (Fig. 8.3F):
gasket contact line surface. The bonnet On Type I, the discs and springs will come
gasket angular surface can be buffed or apart as soon as they are pulled out of the
machined in case of imperfection (damage). valve body. To keep them from separating
12. Lift the bonnet up over the stem and off the a "C" wrench should be used during
body as shown in Fig. 8.30. removal.
On Type IV, to disassemble disc from the
13. Before removing the discs from the stem,
stem, remove stem-disc assembly from the
note the orientation of the disc with respect
body. Remove disc retaining rings on either
to the body seats. Each disc has an
side. Carefully remove center piece, spring
identification mark on it which corresponds
and identify each for valve involved.
to an equivalent mark on a seat in the body.
These seats and discs must be mated when
reassembling.
14. Use a parallel slide disc clamp to remove the
stem and disc. Fig. 8.3E shows the general
principle of the clamp. Adjusting screws
should be slackened (counter-clockwise
rotation) sufficiently to allow the tips of the
arm to be placed over the two discs. The tips
should be placed slightly below the centerline

69
VIII PARALLEL SLIDE VALVE

PARTS DESCRIPTION
04 - Stem
07 - Disc
45 - Retaining ring
46 - Spring
109 - Center piece

Figure 8.3F Parallelslide discs Type1- no retaining ring and TypeIV usespart 45 retaining ring

b) Disc Type II (Fig.8.3G): c) Disc Type III (Fig. 8.3H);

Disassemble discs from stem and disengage To disassemble disc from the stem.
the stem (04) from the disc carrier (43) by The lock brackets (31) must be opened by
pushing stem T-head out of theT-slot in the prying the tabs upwards. The discs (07)
disc carrier. Remove the disc retainer plate can be removed for repair or replacement,
(45) and the disc will spring apart. Carefully if required, by removing the bolt (56A) and
store the springs (46). These should be the nut (16F), carefully remove the springs
identified for the valve size involved. The (46) and center piece (109). These should
valve is now ready for inspection and repairs be stored and identified for the valve size
of seat, disc, stem, etc. involved.

PART DESCRIPTION
4 - Stem
PART DESCRIPTION 7 - Disc
4 - Stem 16F - Hex head nut
7 - Disc 31 - lock bracket
43 - Disc carrier 46 - Spring
45 - Retaining plate 56A - Hex head bolt
46 - Spring 109 - Center piece

Figure 8.3H Parallel slide disc Type III

t
Figure 8.3G Parallel slide disc Type II

70
VIII PARALLEL SLIDE VALVE

• PARTS DESCRIPTION
04 - Stem
07 - Disc
43 - Disc carrier
45 - Retaining plate
46 - Spring
8.3.3 Disassembly of Top Works (Fig. B.3J)
1. If line pressure is maintained in the valve,
backseat the valve in fully open position
before starting any disassembly.
2. Remove small set screw (35A) in handwheel
nut (30), then unscrew handwheel nut.
3. Before removing stroke limiter (49), measure
Parts the distance the stud extends out of top of
Assembled stroke limiter. This distance regulates the
position of the two discs.
4. Remove stroke limiter (49) at the top of the
stem.
5. Remove handwheel (33).
6. Remove yoke housing bolting (17D) and
remove housing cover (28).
7. Remove first set of bearings (29A) (3 pieces).
8. Unscrew stem nut (88) from the stem (04).
9. After the stem nut has been removed, remove
second set of bearings (29B).
10. Now valve and parts are ready for inspection,
repairs and replacement of stem nut,
bearing, etc.
il't 0
'=1
ro)
" For gap
information
See Step (2)
"Disc type II"
NOTE: Valve Style I has no bearings.

for applicable
disc gap
-
(.
allowance .

• Figure 8.31 Parallel slide disc Type V

d) Disc Type V (Fig. B.3/):

PARTS DESCRIPTION
In this arrangement the stem (04) when
• Yoke
turned 90 degrees will disengage from · Stem
disc carrier (43) and retainer plate (45). • HSH cap screw
Once the stem is lifted the retainer plate · Key
• Housing cover
connecting the disc and disc carrier can • Bearing
then be removed • Bearing
• Handwheel nut
CAUTION: Use the disc clamp Fig. 8.3E • Handwheel
before removing the retainer plate. This • Grease fining
• Set screw
is to prevent discs from suddenly
spreading out.

18. The valve is now ready for inspection and

t repairs of seat, disc, stem, etc.

Figure B.3J Valve top works disassembly

71
VIII PARALLEL SLIDE VALVE

8.4 ASSEMBLY

8.4.1 Top Works Assembly Valve (Refer to Fig. 8.4A)

NOTE: Valve Style I is without bearings.
10. For Motor Actuated Valves: It is necessary to
readjust open-close limit switch. Open limit
switch should be adjusted as a rule of thumb
•
1. Apply new grease to threaded portion of stem W' (8 mm) off back seat. Closed limit switch
(04) above top flange on yoke (03). should be adjusted at pre-established closed
position.
2. Mount second set of newly-greased bearings
(29B) in recess of yoke.
CAUTION: To prevent torque switch trip
NOTE: Bottom race must fit loosely around out, stroke limiter must be backed off by
stem nut and top race must be tight around
~"-y." (3-8 mm) and set screw secured.
stem nut.
3. Apply new grease to internal thread in stem 11. Verify operation by cycling at least once from
nut (88) and screw stem nut on stem. fully open to fully closed position.
4. Mount first set of newly-greased bearing (29A)
on stem nut. 8.4.2 Body/Bonnet and Discs/Stem Assembly
NOTE: Bottom-race must fit tightly around 1. Disc Type I (Fig. 8.3F)
stem nut and top race must be loose.
Install the spring (46) and disc center piece
5. After the bearing and stem nut are in place, (109) in their respective holes in the discs (07).
mount housing cover (28) on top and tie down Use a "C" clamp to keep the discs together.
with the yoke housing bolting (17D). Bolting Slip T-head of stem (75) into disc T-slot and
must be torqued down in accordance with the partially lower into the body.
values in Table 5.3A. NOTE: The discs should be oriented as noted
6. Insert handwheel key (26B) in keyway in stem during disassembly (match marked position).
nut and mount handwheel (33). At this point remove "C" clamp and complete-
7. Return handwheel nut (30) and tighten. ly lower discs into valve body seats (09).
Use handwheel nut set screw (35A) to lock
handwheel nut in place.
PARTS DESCRIPTION
8. Inject more new grease into housing cover 03 . Yoke 30 - Handwheel nut
through the grease fitting (34) on side of 04 - Stem 33 - Handwheel
housing cover. 170 - HSH cap screw 34 - Grease fitting
268 - Key 35A - Set screw
9. Return the stroke limiter (49) to the top of the 28 - Housing cover 88 - Stem nut
stem, see Fig. 8.38 and 8.3C. 29A - Bearing
298 - Bearing
IMPORTANT: The position of the stroke
limiter must be the same as that noted during
valve disassembly. Ifthe original position has
not been noted, the following readjustment
procedure should be used:
a) Open valve fully to its back seated position
and mark up with a pen or marker.
b) Verify applicable valve project drawing for

,
valve "lift" (stroke). Measure from marked
up open position and draw a line (mark up)
indicating valve closed position.
c) Close the valve to its marked up closed
position and readjust stroke limiter.

Figure B.4A Valve top works assembly

72
VII GLOBE VALVE

t.

PART DESCRIPTION QTY. (C

01 · Body 1
02 · Bonnet 1
03 · Yoke 1
04 · Stem 1
06 · Disc 1
11 · Packing flange 1
12 _ Gland bushing 1
13A _ Pkg ring (ends) 2
13B _ Pkg rings (inter) 5
15 _ Stud 4
15A _ Stud 8
15B _ Stud 2
150 _ Stud 4
16A _ Nut 8
16B _ Nut·
16C _ Nut
160 _ Nut
2
8
4
C ""
)\ q.

170 _ HSH cap screw 4

19 _ PS Gasket 1
20 _ Spacer ring 1
21 _ Gasket retainer 1
22 · Bonnet retainer 1
25 _ Torque arm 1
26A _ T.A. Key 1
32 · Gear operator 1
40 _ Disc union 1 ~
41 _ Stem collar 1
66 · Name plate 1
80 _ Yoke clamp ring 1

Figure 7_1G Style 11/, cast pressure seal inclined globe valve, 8 - 12" (200-300mm)

52
PARALLEL SLIDE VALVE VIII

(' 2. Disc Type II (Fig. 8.3G)

Install spring (46) into the respective holes in
the discs (07). Install disc in the disc carrier
the discs (07) Install disc in the disc carrier
(43). Using the disc retainer plate (45). Lock
discs in place and use a disc clamp to squeeze
(43). Using the disc retaining plate (45) lock the disc halves together. Line up stem T-head
(04) in parallel with retainer plate and disc
discs in place. Slide T-head of stem (75)
carrier T-slot connection. Lower the stem
into T-slot on top of disc carrier (43) and use a
into T-slot connection and turn 90° to engage.
disc clamp or "C" type clamp to press the disc
Partially lower the stem and discs into the
halves together. Partially lower the stem and valve body seats. Remove the disc clamp
discs into the seats. Remove the disc clamp and measure the gap between disc retainer
(or "C" clamp) and measure the gap between plate (45) and disc (07)
disc retaining plate (45) and discs (07). For
NOTE: See step two "Disc Type II" for
valve sizes 2-12" (50-300 mm), a satisfactory
applicable disc gap allowance.
gap should be 0.015-0.020" (0.4-0.5 mm) per
side. For valves 14" (350 mm) and up, the gap 6. Valve Style I (Fig. 8.1A)
should be 0.020-0.030" (0.5-0.75 mm) per side. a) Lower bonnet (02) onto stem (04) and into
NOTE: The discs should be oriented as noted valve body (01).
during disassembly (match marked position). b) Install new pressure seal gasket (19).
The discs are now assembled with proper c) Install yoke (03) - Before lowering yoke, place
"float" allowance. bonnet retainer (22) over the stem, gland
3. Disc Type III (Fig. 8.3H) bushing (12), packing flange (11) and torque
arm if equipped with style I or II torque arm
Install the three springs (46) and the center (Fig. 8.3A). At this point completely lower
piece (109) in their respective holes in the

t (t discs (07). Slip T-head of stem (75) into the

T-head of discs and line up with bolt hole.
NOTE: The discs should be oriented as noted
yoke and screw into body.
d) Pull up bonnet by screwing bonnet
retaining nut clockwise until hand tight.
e) Install gland eye bolt clamp (92), packing
during disassembly (match marked position).
flange eye bolts (38), clamp bolt (56) and
Insert the hex HD bolt (56A) and lock bracket tighten with clamp jam nut (16E).
(31A). The two discs should be pressed f) Repack valve in accordance with

• 'f
together against the stem T-head with disc
clamp or "C" clamp. Lower the stem and
discs into the seats. Remove the disc clamp
or "C" clamp with the two disc halves placed
firmly against the body seats. Insert the
Section 5.1, Packing .
g) Before securing the yoke with set screws
observe match marked position.
h) At this time firmly tighten yoke and secure
second lock bracket (31B) and thread nut (16F) with half dog set screws (35B).
onto the bolt. Make sure to leave a gap of i) Reinstall stem nut (88) and top works
0.030"-0.045" (0.7-1.1mm) between the nut (follow Section 8.4.1).
and disc. Secure with lock bracket. NOTE: Open valve fully to its backseated
4. Disc Type IV (Fig 8.3F) position. Apply anti-seize compound to
bonnet threads and bottom flats of bonnet
Install spring (46) in center piece (109). Install
retainer ring. Using a "crawfoot wrench"
center piece between discs and squeezeeither
Fig. 4.58 torque the bonnet retainer ring in
side of disc, until you can install disc retaining
accordance with the torque values given in
rings (45) into machined groove. Slip T-head
Table 4.5A.
of stem into T-head of disc assembly. Partially
lower the stem and discs into the seats and j) Verify the operation by cycling at least
remove disc clamp or "C" clamp. Using a three times from fully opened to fully
feeler gauge check inner circle of retaining ring closed position.

t ,t
and disc for gap, see step 2 for gap allowance. 7. Valve Style II (Fig. 8.18)
5. Disc Type V (Fig. 8.31) a) Lower bonnet (02) onto stem (04) and into
Install spring (46) into the respective holes in valve body (01).

73
VIII PARALLEL SLIDE VALVE

b) Install new pressure seal gasket (19) 13. Torque the bonnet retaining nuts (16C) or
and spacer ring (20). bonnet retaining capscrews (17B) in strict
accordance with Section 4.5.1.
c) Install gasket retainer (21) in groove in
body wall. NOTE: If the valve is equiped with live load
bonnet (Belleville spring washers) install the
d) Place bolting spacer (23) on top flange of
spring washers in the same order as noted
valve body.
during disassembly. Refer to Fig. 4.5C or 4.50
e) Install bonnet retainer ring around (spring washer configuration)
bonnet (02).
f) Install split ring (115) between bonnet (02) 14. Mount torque arm (25) Type III and IV on stem
(4) and make sure the torque arm key (26A) fits
and bonnet retainer (22).
properly in the stem and torque arm keyway.
g) Uniformly tighten the hex socket head cap
screw (17b) by hand. 15. Mount the live-loading option if so equipped,
• i .,
the packing flange nuts (16B)' and torque in
8. Valve Style III (Fig. 8.1C)
accordance with Section 5.1, Packing.
a) Lower bonnet (02) onto stem (04) and into
NOTE: If the valve is equipped with packing
valve body (01).
live-loading option, live-loading parts must
b) Install new pressure seal gasket (19) and return in the same order as noted in disassem-
spacer ring (20.). bly. Refer to Fig. 5.1L
c) Install gasket retainer (21) in groove in
16. Return the stroke limiter (49) to the top of
body wall.
the stem.
d) Mount bonnet retainer (22) on top flange
IMPORTANT: The position of the stroke
on body.
limiter must be the same as that noted during
e) Install bonnet retaining nuts (16C)and valve disassembly. If the original position has
uniformly tighten the nuts by hand. not been noted, the following readjustment
9. Repackvalve in accordance with Section 5.1, procedure should be used:
Packing.
a) Open valve fully to its back seated position
NOTE: Do not torque down the packing flange and mark up with a pen or marker.
(11) at this point of the assembly.
b) Verify applicable valve project drawing for
10. Install yoke by turning handwheel to open valve "lift" (stroke). Measure from marked
valve counter clockwise. This will cause the up open position and draw a line (mark up) • (~
yoke to be lowered down on the valve body. indicating valve closed position.
NOTE: In some cases on the smaller size c) Close the valve to its marked up closed
valves, it will be necessary to remove the position and readjust stroke limiter.
packing flange before installing the yoke. 17. For Motor Actuated Valves: It is necessary to
Therefore, the packing flange (11) and the readjust open-close limit switch. Open limit
Type I or II torque arm (25) (Fig. 8.3A) must switch should be adjusted as a rule of thumb
be reinstalled in correct positions before the W' (8 mm) off back seat. Closed limit switch
yoke is completely lowered on the stem. should be adjusted at already established
11. Install the body-yoke nuts or cap screws closed position.
and torque in accordance with Table 5.3A.
CAUTION: To prevent torque switch trip
12. Turn the handwheel to open the valve fully
against the backseat. This will centralize the out, stroke limiter must be backed off by
stem and bonnet. %"-Y." (3-8 mm) and set screw secured.

18. Verify the operation by cycling at least three

times from fully opened to fully closed position,

t
74
SWING CHECK & TILTING DISC VALVES IX

l,' 9.1 TYPES OF CHECK VALVES

PART DESCRIPTION
01 - Body
QTY.
1 51 - Hanger 1
PART DESCRIPTION
01 • Body
QTY.
1 50 - Cover 1
02 • Bonnet 1 54 • Hinge pin 1 02 • Bonnet 1 51 - Hanger 1
08 . Disc 1 55 • Bushing 2 08 • Disc 1 54 · Hinge pin 1
09 • Seat 1 56 . Hex head bolt 2 09 · Seat (Stellite6) 1 55 • Bushing 4
15 • Stud 6 57 - Washer 2 15 • Stud 6 56 • Hex head bolt 2
16 • Nut 6 58 - Cotter pin 1 16 · Nut 6 57A • Disc nut washer 1
16A • Disc nutlwasher comb 1 60 - lock washer 2 16A • Disc nut 1 58 - Cotter pin 1
19 . PS Gasket 1 61A - Disc pin 1 19 - PS Gasket 1 60 • lock bracket 1
20 . Spacer ring 1 66 . Name plate 1 20 - Spacer ring 1 61A . Disc pin 1
21 - Gasket retainer 1 111 • Hangerspacer 2 21 - Gasket retainer 1 618 - Dowel pin 2
50 . Cover 1 48 - Hanger bracket 1 66 - Name plate 1

I~

VIEW "A"

, ..
~
.-9 F,gure 9.1A Forged pressure seal swing
check valve, 2" and 21/2"
(50 -65 mm)
Figure 9.18 Forged pressure seal swing
check valve, 3-10" (75 -250 mm)

75
IX SWING CHECK & TILTING DISC VALVES

PART DESCRIPTION QTY. PART DESCRIPTION QTY.

QTY. PART DESCRIPTION QTY.
PARTDESCRIPTION 51 _ Hanger
51 _ Hanger 1 01 _ Body
01 _ Body 1 _ Hinge pin
1 _ Bonnet 54
02 _ Bonnet 1 53 _ Hanger ring 02
_ Disc 1 54 _ Hinge pin 1 08 _ Disc 55 _ Bushing 4
08
09 _ Seat 1 55 _ Bushing 4 _ Seat 1 56 _ Hex head bolt 4
09
15 _ Stud 8 56 _ Hex head bolt 3 57A _ Washer
1 15 _ Stud 6
16 _ Nut 8 57A _ Disc washer _ Cotter pin 1
1 16 _ Nut 6 58
16A _ Disc nut 1 58 _ Cotter pin
3 16A _ Disc nut 60 _ Tab washer 4
19 _ PS Gasket 1 60 _ Lock washer
20 _ Spacer ring 1 61A _ Disc pin 1 19 _ PS Gasket 61A _ Disc pin
21 _ Gasket retainer 1 66 _ Name plate 1 61B _ Dowel pin
20 _ Spacer ring
50 _ Cover 1
21 _ Gasket retainer 66 _ Name plate
48 _ Hanger bracket 125 _ Stop bracket 3
50 _ Cover

Figure 9_lC Forged pressure seal swing Figure 9.1D Forged pressure seal swing
check valve, 12" (300 mm) and check valve, 16-24"
14" (350 mm) (400 - 600 mm)

76
SWING CHECK & TILTING DISC VALVES IX

PART DESCRIPTION QTY•

01 • Body 1
02 - Bonnet 1
08 - Disc 1
09 - Seat 1
15 - Stud 8
16 - Nut 8
19 - PS Gasket 1
20 - Spacer ring 1
21 - Gasket retainer 1
36 - Belleville washer 24
50 - Cover 1
54 - Disc pin (HDND) 2
55 - Bushing 2
56 - Hex head bolt 2
57 - Lock washer 2
66 - Name plate 1

• !.

, \t Figure 9.1E Forged pressure seal tilting disc check valve, 21j2- 20" (65 - 500 mm)

77
IX SWING CHECK & TILTING DISC VALVES

9.2 PARTIAL DISASSEMBLY - GASKET

REPLACEMENT
Follow warning instructions in Section III before
7. Reattach hoist to eyebolts and raise bonnet
until it contacts the gasket. For valves with
fewer than eight studs, use two opposite nuts
to pull up gasket. For valves with eight studs
or more, use four nuts to pull up gasket.
•
beginning disassembly. As a general disassembly
progresses, place matching marks on parts so that NOTE: Nuts or screws should be turned
the same orientation of parts can be maintained at uniformly a fraction of a turn at a time
reassembly. because valve parts could be damaged
by locking the pressure seal gasket ring.
CAUTION: Do not attempt to force out This uniform turning is important.
the pressure seal gasket by using a crane, 8. Before installing new pressure seal gasket
hoist, chain-block, etc. The gasket may ensure that body/bonnet gasket surface is
be tight inside the valve body and if free from any damage such as scratch marks,
pulled using a crane, jack, or other indentations, etc. Install new pressure seal
means, it may suddenly release causing gasket (19) and spacer ring (20) on bonnet (02).
personal injury and/or extensive damage. 9. Romove two opposite bonnet retaining studs
and replace with 8 -10" (200-250 mm) long
1. Remove two opposite bonnet retaining nuts eyebolts.
(16) and bonnet retaining studs (15) from
10. Using a hoist lower the bonnet (02) into the
bonnet (02). body (01) and remove the eyebolts.
2. Screw two eyebolts twice the length of original
11. Install new pressure seal gasket (19), spacer
studs into the tapped holes in the bonnet (02).

•
ring (20) and gasket retainer (21)
Fasten a chain hoist to eyebolts, pulling just
enough to eliminate any slack in the hoist.
3. Remove all remaining bonnet nuts (16) and PARTS DESCRIPTION
any two adjacent studs for valves with eight 01 . Body 20 . Spacer
studs or more (for valves with fewer than eight 02 . Bonnet 21 . Gasket retainer
15 . Stud 38 . Eye bolt Drive pin holes
studs, remove anyone stud). Slacken chain 16 . Nut 50 . Cover for removal of
hoist to lower bonnet until it rests on the stops 19 • Gasket gasket retainer

•
in the body.
NOTE: If bonnet does not lower when hoist
is slackened, tap on the eye bolts to free
the bonnet.
4. Remove eyebolts and place one eyebolt in the
tapped hole in the cover (50) (12" (300 mm)
and larger). Lift cover and remove.
5. Insert a drive pin into the holes provided in the
top flange of the body. Tap lightly to remove
the four-segment gasket retainer (21).
NOTE: If the valve has been in high-pressure
service for a long period of time, it may be
necessary to tap lightly on the gasket retainer
inside the body first so that the drive pin will
be able to push the gasket retainer out easily.
Remove the two small portions of the four-
segment retainer and then the larger portion.
Remove pressure seal spacer ring.
6. Place three 1" (25 mm) minimum shims on the
body (see Fig. 9.3A). Replace the cover and
L.____ ____.J t
Figure 9.3A Use of shims to disassemble
align holes so that the eyebolts can be
replaced in the bonnet. pressure seal assembly

yl)1
78
SWING CHECK & TILTING DISC VALVES IX

• 12. Install an eyebolt in the cover (50), lift on top

of the body (01) using a hoist. Align the cover
with the bonnet retaining studs.
13. Re-install the two 8 -10" (200-250 mm) long
3. Remove all remaining bonnet nuts (16) and
any two adjacent studs for valves with eight
studs or more (for valves with fewer than
eight studs, remove anyone stud). Slacken
eyebolts and lift with a hoist until the bonnet chain hoist to lower bonnet until it rests on
contacts the gasket and the bonnet studs have the stops in the body.
protruded the cover holes.
NOTE: If bonnet does not lower when hoist
14. Lubricate the threads of the bonnet studs (15) is slackened, tap on the eye bolts to free the
and nuts (16) and nut flats. Tighten finger tight. bonnet.
NOTE: If equiped with live load bonnet 4. Remove eyebolts and place one eyebolt in
(Belleville spring washers) ensure that the the tapped hole in the cover (50) (12" (300
spring washers are installed in the same
mm) and larger). Lift cover and remove.
order as noted during disassembly. Refer to
Fig. 4.5C & 0 (spring washer configuration) 5. Insert a drive pin into the holes provided in the
and Fig. 9. 1E top flange of the body. Tap lightly to remove
the four-segment gasket retainer (21).
15. Remove the eyebolts and replace with the
bonnet studs (15) and bonnet nuts (16) NOTE: If the valve has been in high pressure
service for a long period of time, it may be
16. Tighten the bonnet (02) by torquing
necessary to tap lightly on the gasket retainer
bonnet-cover nuts (16) uniformly. Perform inside the body first so that the drive pin will
this operation with great care to avoid cocking be able to push the gasket retainer out easily.
the bonnet (02) and damaging internal parts. Remove the two small portions of the four-
17. Torque bonnet-cover nuts in strict accordance segment retainer and then the larger portion.
with Section 4.5.1. Remove pressure seal spacer ring.
6. Place three 1" (25 mm) minimum shims on
9.3 TOTAL DISASSEMBLY the body (Fig. 9.3A). Replace the cover and
align holes so that the eyebolts can be
Follow warning instructions in Section 11/ before replaced in the bonnet.
beginning disassembly. As a general disassembly 7. Reattach hoist to eyebolts and raise bonnet

•
progresses, place matching marks on parts so that until it contacts the gasket. For valves with
(i. the same orientation of parts can be maintained fewer than eight studs, use two opposite nuts
at reassembly. to pull up gasket. For valves with eight studs
or more, use four nuts to pull up gasket.
CAUTION: Do not attempt to force out
NOTE: Nuts or screws should be turned
the pressure seal gasket by using a crane,
uniformly a fraction of a turn at a time
hoist, chain-block, etc. The gasket may because valve parts could be damaged
be tight inside the valve body and if by locking the pressure seal gasket ring.
pulled using a crane, jack, or other This uniform turning is important.
means, it may suddenly release causing
8. Lift the entire pressure seal enclosure assembly
personal injury and/or extensive damage.
out of the valve body. When putting parts aside
for inspection, it is very important that they be
placed carefully on a bed of rags or other soft
9.3.1 Body/Bonnet Disassembly
material to avoid damage of the finely
1. Remove two opposite bonnet retaining nuts machined gasket seating surfaces.
(16) and bonnet retaining studs (15) from
bonnet (02).

I \t
Screw two eyebolts twice the length of original
2. studs into the tapped holes in the bonnet (02).
Fastena chain hoist to eyebolts, pulling just
enough to eliminate any slack in the hoist.

79
IX SWING CHECK & TILTING DISC VALVES

9.3.2 Disc Disassembly

9.3.2.1Swing Check
1. After the entire pressure seal enclosure has
been removed, undo lock washers (60) and
hex bolts (56). The entire disc assembly can
now be removed from the valve body.
2. Velan has four major styles of swing checks.
a) Style I (Figs. 9.38 and 9.3C)
Hinge pin (54) can be pushed out of hanger
(51) and hanger bracket (48). Hanger will
disengage from hanger bracket bushing.
There are four bushings (55) in this style,
two bushings in the hanger and two in the
bracket.
b) Style II (Figs. 9.30 and 9.3E)
Push hinge pin (54) out of the hanger (51).
Remove two washers (57)from the pin.
Push bushing (55) out of hanger.
Figure 9.38 Swing check Style I
c) Style III (Figs. 9.3F and 9.3G)
Hinge pin (54) can be pushed out of the
hanger (51) and hanger ring (53). Hanger
will disengage from hanger ring. There PARTS DESCRIPTION
are four bushings (55) in this style, two 8 . Disc
bushings in the hangers and two in the 16A . Disc nut
60 . lock bracket
hanger ring.
48 - Hanger bracket
d) Style IV (Figs. 9.3H and 9.31) 51 - Hanger
Push hinge pin (54) out of hanger ring (53) 54 - Hanger pin
55 - Bushing
and hanger (51). remove spacer washer
56 - Hex. HD bolt
(57) push bushing (55) out of hanger. 57A - Disc washer
3. To remove disc (08) from hanger (51), remove 58 - Cotter pin
61 - Dowel pin
cotter pin (58) from disc nut (16A). Unscrew
disc and remove disc washer (57A) and disc
(08). Now all parts are ready for inspection
and repairs of disc, seat, bushing, etc.

Figure 9.3C Exploded view of swing check

valve - Style I

80 ~~
SWING CHECK & TILTING DISC VALVES IX

t ,

Figure 9.3D Swing check Style /I Figure 9.3F Swing check Style III

PARTS DESCRIPTION
8 _ Disc
16A _ Disc nut
51 _ Hanger
PARTS DESCRIPTION 53 _ Hanger ring
8 _ Disc 57 _ Spacer washer 54 _ Hanger pin
16A _ Disc nut 57A _ Disc nut washer 55 _ Bushing
51 _ Hanger 58 _ Cotter pin 56 _ Hex. HD bolt
54 _ Hanger pin 60 _ Tab washer 57A _ Disc washer
55 _ Bushing 58 _ Cotter pin
If 56 _ Hex. HD bolt 60 _ Tab washer

~
,~
~~

It
. Figure 9.3E Exploded view of swing check Figure 9_3G Exploded view of swing check
valve - Style /I valve - Style 1/1

81
IX SWING CHECK & TILTING DISC VALVES

9.3.2.2 lilting Disc

1. Before disassembling disc (08) Fig. 9.3J, match
mark adjustment pin with seat (09) (Fig. 9.31<).
Most pins have a vertical groove between
6 and 12 o'clock and a %" hole at the end at
12 o'clock, this indicates pin offset position
(Fig. 9.31<). After match marking offset
position, remove hex bolt (56), one per side.
2. Using a screw driver or any suitable tool, push
out the disc pin (54) towards the body wall,
one per side.

CAUTION: Before the last pin is pushed

out, hold disc unit securely with one hand or
chain hoist and push out the pin (54) with
the other hand. This will prevent the disc
from falling in and causing possible damage.

Figure 9.3H Swing check Style IV PARTS DESCRIPTION

· Disc
· Seat
PARTS DESCRIPTION · Disc pin
08 • Disc · Bushing
16A • Disc nut • Hex. head bolt
!washer combination · lock washer
51 • Hanger
53 • Hanger ring
54 • Hanger pin
55 • Bushing
56 • Hex. HD bolt
57
58
60
61

Figure 9.3J Exploded view of a tilting disc unit

12 o'clock

Figure 9.31 Exploded view of Swing check

6 o'clock

Figure 9.3K
3 o'clock
Discpin-seat match marked
,
valve - Style IV

82
SWING CHECK & TILTING DISC VALVES IX

After the pins have been pushed out, take the Although the surface has a smooth finish and
" 3. disc unit out of the valve body and place it in a is die-penetrant inspected, surface indications
secure area, caution should be taken not to can develop in service which can cause
damage valve, disc seating surface. subsequent leakage.
NOTE: Disc bushings are individually fitted and 2. Seal ring leakage
should be marked for left and right hand side. This may be caused by external flow on the
sealing edge of the ring.
3. Reusing the pressure seal ring
9.4 DETAILED MAINTENANCE Velan recommends that the pressure seal ring
not be reused. Spare rings should be kept on
9.4.1 Body/Bonnet (Gasket) Leakage hand before opening the valve. If the pressure
seal ring is removed from the body, it must be
carefully examined for imperfections and
I ., 9.4.1.1 General
score marks. These marks, usually made
To maintain the tightness of a factory-tested during the removal operation, may cause
pressure seal valve, it is essential to apply sufficient leaks if the ring is reused. The seal ring, made
bolt tension at all times by having the proper torque of soft iron (silver-plated) or graphite, must be
on the nuts or cap screws. The original torque handled with great care to prevent scoring of
might be lost due to vibration, relaxation of material internal and external surfaces.
caused by frequent temperature and pressure

,
fluctuations, or by creep in high temperature 9.4.2 Seat Leakage - Swing Check
applications. Joint bolt tension should be checked
at approximately one-year intervals and if 9.4.2.1 Swing Check Disc Repairs
necessary retighten in accordance with Section 2.9,
Recheck for Bolt Tightness. 1. Disassemble the valve as described in
Section 9.3, and inspect the disc and seat for
scratches, pitting marks or other damage.
9.4.1.2 Leakage of Body/Bonnet Joint
2. If the seating face of the disc is scratched, it
Tighten under line pressure the stud and nut to must be lapped. Slight pitting, grooving, or
values shown in Table 4.5A or 4.58 + 10%. Wait indentations no deeper than 0.005" (0.1 mm)

•
can be removed by lapping. If defects cannot

•
three to five minutes before determining if the
leakage has stopped. The parts could have be corrected by lapping, the disc can be
become loose during transportation or storage. ground and/or machined. Velan recommends
that no more than 0.031" (0.80 mm) be
If tightening does not stop the leakage, the pressure removed. After grinding is completed, lap
seal gasket is probably damaged and the valve the disc.
must be opened for examination. Such a leak can 3. For the lapping, a flat plate (preferably made
be caused by any of the following: of cast iron) should be used. An abrasive
lapping compound should be mixed together
1. Imperfect seal between bonnet and gasket
with olive oil and evenly distributed over the
An incomplete seal can be caused by corrosion
plate as shown in Fig. 9.4A. Only light, even
or dirt chips or other foreign matter pushed
pressure should be applied and the disc
between the seating surfaces of the body or
should be moved in a circular motion on
bonnet and the seating faces of the pressure
the plate. Lift the disc as often as possible to
seal gasket. An imperfect seal between the
prevent accumulation of particles in one area
seal ring and the inside contact surface of the
and to allow for proper distribution of the
body can be caused by an imperfect surface
lapping compound. The lapping plate should
caused by metal failure, sometimes after valve
be turned slightly every few strokes to

•
installation and use. All Velan bodies and
maintain a flat surface. The part should be
bonnets are of forged quality, eliminating the
lapped until seating faces are smooth.
possibility of surface porosity, and the contact
area of all pressure seal bodies has been 4. Thoroughly clean off the lapping compound
hardface deposited as an added precaution. with a suitable cleaning fluid such as acetone
or alcohol. Do not use solvents containing
chloride or fluoride.
83
IX SWING CHECK & TILTING DISC VALVES

9.4.3.2 lilting Disc Seat Repairs - General

If minor damage to seating surface is noted, it

should be lapped out by using original disc. Place
(smear) medium grit lapping compound on seat
and disc surface. Reinstall disc with bushings and
pins and move disc back and forth (open-close)
slightly while applying light pressure against seat.

If major seat damage is noted, it should be

repaired according to Section 5.2.3.3.1, Seat
Repairs, Gate & Parallel Slide Valve.
NOTE: Tilting disc seat angle is 22°. A cone
shaped disc or ring for hand or machine
lapping may have to be fabricated with same
seat angle.

9.5 ASSEMBLY
NOTE: Fitting of New Disc
When damage to the disc seating face cannot 9.5.1 Disc Assembly Fit-up
be removed by grinding or lapping, the disc
must be replaced. All new discs coming from This procedure is to be used when replacement of
the factory are already ground and should be disc assembly parts or rework is required. Use it •
lapped before installation. See installation after you have made sure that the body and disc
procedures in Section 9.5.1, Disc Assembly seats are clean, smooth, flat and free of any
Fit-up. seating surface damage.

9.4.2.2 Swing Check Seat Repairs 9.5.1.1 Swing Check Disc Unit

•
1. Preassemble disc unit (Fig. 9.5A), making sure
If repairs are required on the seat of a swing check that there is sufficient clearance between disc
valve, the procedure is the same as described in washer and hanger arm, disc post and arm
Section 5.2.3.3.1 - Seat Repairs (Gate and Parallel
Slide Valves). The only difference between these Hex.bolt Hangerpin
seats is the angle of the seat face. They can be
repaired with an automatic grinding or lapping
machine or by the manual method.

9.4.3 Seat Leakage - lilting Disc

Pin

9.4.3.1 lilting Disc Repairs - General Disc

nut
Seat
If minor damage to disc seating surface is noted, \1al~":'_-- Cotter
pin
it should be lapped out using a seat ring having
an angle of 22°. Place (smear) medium grit lapping II

,
\1.;1-----_ Disc nut
Body
compound on seat ring and disc surface and rock washer j
t
seat ring in an up and down motion, with light !
pressure applied against the disc.lf major repairs
become necessary, the disc should be repaired by
machining. No more than 0.015" (0.4 mm) should
be removed.
NOTE: Disc seating surface is of a Spherical
Figure 9.5A One type of Velandisc unit
Radius.
84
SWING CHECK & TILTING DISC VALVES IX

Hanger block
recess to be
measured

I Figure 9.5D Engagement in hanger block

Figure 9.58 Disc assembly clearances

bore (Fig. 9.58). Also ensure that hanger pin

rotates freely around Stellite bushings. The
bushings should fit comfortably into hanger

, arm and hanger block bushing recess.

A minimum of 0.010" (0.25 mm) bushing
engagement with recess is required
(engagement of less than 0.010" (0.25 mm)
is cause for rejection). To determine actual
engagement, follow these steps:
a) Measure both hanger arm bushing recesses
and record (Fig. 9.5C).
b) Insert a screwdriver between bushing and
Figure 9.5E Removal of hanger arm stopper
hanger arm recess, push everything to one
side, and measure the gap with a feeler
gauge. Subtract this gap from each of the recess, push outward and measure gap.
hanger arm recesses to get actual To get actual engagement, subtract this
engagement (Fig. 9.5C). gap from each of the hanger block recesses
c) For hanger block, do the same, except insert measured (Fig. 9.50).
a wedge-type object such as a screwdriver NOTE: Some hanger arms may have an
between the bushing and hanger block anti-rotation stopper. This stopper is used
with old style cast disc which has two small
pyramid-shaped stoppers. If the disc you are
replacing has a single stopper (new style), then
the hanger arm anti-rotation stopper is not
required. It must be ground off flush so that it
does not interfere with disc free movement
(Fig.9.5E)
9.5.1.2 Tilting Disc Unit (seeFig. 9.3J)

, 1.

2.
Install left and right side bushing (55), install
disc pins (54), push all the way towards body
wall (see Fig. 9.3J).
Carefully lower disc unit, align with bushings
(55) and push pins (54) inward. Insert hex bolt
(56) and lock washer (60) but do not tighten.
Figure 9.5C Hanger arm recess
85
IX SWING CHECK & TILTING DISC VALVES

the dowel pin location holes (only if original hang-

Match marked pin with match mark on seat
er block is used). If the hanger block is new, dowel
(see Fig. 9.3K) and verify gap at 3 o'clock using
pins are not required. To align the disc manually,
wire filler gauge.
lower the disc unit, release the disc gently against
NOTE: No less than 0.010" (0.250mm) gap the seat, insert the hanger block bolts and tighten
is allowed. For adjustment rotate the disc pin finger-tight. Back off bolts quarter turn, press disc
clockwise or counterclockwise using an "L" lightly against seat and retighten bolts finger-tight.
key as shown in Fig. 9.5F. With light pressure against disc, rotate disc slightly
back and forth. Take hold of disc post/disc nut area
and pull away from body seat. Undo hanger block
bolts and remove disc unit from valve body.

Examine disc seating area for contact.

1. If there is seating contact throughout the
whole seating circumference (360°), the disc is
well aligned with sufficient disc freedom. This
also indicates that the seating surfaces are
well mated and free of any damage.
2. If there is contact at the three or nine o'clock
position, the disc does not have sufficient
freedom of movement in the disc hanger arm
bore. The disc should be held, but not
constrained, by the hanger arm. The disc
should be free to find its own seat. This
Figure 9.5F Resetting of adjustment pins
freedom comes from the clearance between
using an "L" key the disc post 00 and the hanger arm bore 10,
NOTE: If new parts are used or if parts were and the gap between the hanger arm and the
not match marked ensure that maximum offset disc nut washer. Confirm that the clearances
position, usually marked with a %"(3 mm) are adequate (Fig. 9.58).
hole, is at approximately 12 o'clock position. 3. If there is contact at the 12 o'clock position
The largest gap measured at 6 o'clock means (see Fig. 9.5G), the disc needs to be lifted by
maximum offset at 12 o'clock, this type of machining. Material must be removed from
adjustment is preferred. No less than 0.010"
(0.25 mm) gap is allowed at 3 o'clock position.
3. With the disc pins (54) in place, tighten hex H.inge
~---pln
bolts (56), one per side. Torque to values
shown in Table 4.5A and secure with lock /lHange,
washer (60).
Disc
9.5.2. Bearing Blue or Developer Test S nut

9.5.2.1 Swing Check (Removal of disc is required)

To perform a bearing blue or developer test the

disc unit must be preassernbled as described in Disc
Section 9.5.1, Disc Assembly Fit-up. First, smear
or spray a light coating of bearing blue or dye
developer over the disc seating circumference.
With one hand, hold the disc at its post or disc nut
area. With the other hand, hold the hanger block
in place. Lower the whole disc unit into the valve
body and place the hanger block so that it matches Figure 9.5G 12 o'clock contact

86
SWING CHECK & TILTING DISC VALVES IX

the top of the disc post and base of the post,

as shown in Fig. 9.5H.
Area to be machined
NOTE: This condition is rare for a valve with
its original parts. It sometimes occurs when
new seating surfaces have been added, when
a new disc has been installed, or if a hanger
arm has been replaced or bent (if bent, the JIC"
hanger arm should be replaced).
12 2 2 212 2 2 a==:;:::+ =
I t
Washer

F\) Figure 9.5J Machining of hanger arm

9.5.2.2 Tilting Disc

Prior to reassembly, apply slight coating of bearing

blue on valve seat surface. Reassemble per Section
9.5.1.2 - steps 1 and 2, and press disc against seat.
Disassemble and verify for 100%contact.
Figure 9.5H Material removal from disc post
9.5.3 Paper or Light Test

a '. 4.
If there is contact at six o'clock (see Fig. 9.5/), the
disc is too high in the hanger arm, or the seats
are too low. This sometimes happens after
9.5.3.1 Swing Check - (Removalof disc is not required)

extensive lapping. To correct the problem, the Paper test

disc must be lowered. The top of the hanger
arm should be machined and a washer of equal With the disc unit assembled, clean, dry and
thickness "C" must be added to the base of the installed in the valve, conduct a paper test (similar
disc post, as shown in Fig. 9.5J. This will lower to the bearing blue and developer test). The paper
or "drop" the disc. should be 0.001 to 0.002" (0.025to 0.050 mm) thick,
1" (25 mm) wide and about 8" (200 mm) long. Lift
the disc off the seat enough to put the paper
H,inge between the two seats and gently lower the disc.
S pm Pull the paper out with just enough force so that the
S Hanger paper does not rip. Do this test around the disc,
taking special note at the top (12 o'clock) position,
at the bottom (six o'clock) position, and at both
S o·ISC sides (three and nine o'clock). Make a record of
S nut where the paper holds and where the paper pulls
without ripping.
1. If paper pulls at three o'clock or nine o'clock
position, the disc cannot move enough in the
disc hanger arm bore. The disc should be free
to find its own seat. This freedom comes from
the clearance between the disc post 00 and

•
the hanger arm ID, and the gap between the
hanger arm and the disc nut washer. Confirm
that the clearances are adequate (Fig. 9.58).

Figure 9.51 6 o'clock contact

~&b 87
IX SWING CHECK & TILTING DISC VALVES

2. If the paper pulls at the 12 o'clock position 9.5.4 Internal and Mid-Section Assembly - Swing
(contact @ 6 o'clock), see Fig. 9.5/, the disc is Check Valve
too high in the hanger arm, or the seats are NOTE: If disc and/or disc nut are new, cotter
too low. This sometimes happens after exten- pin hole may not have been pre-drilled. In this
sive lapping. To correct the problem, the disc case drilling is to be done at site before
must be lowered. The top of the hanger arm reassembly.
should be machined and a washer of equal
thickness "C" must be added to the base of 1. Mount disc (8) on hanger (51), place disc nut
the disc post, as shown in Fig. 9.5J. This will washer (57A),tighten disc nut (16a)and lock in
place with cotter pin (58). Checkif disc can
lower or "drop" the disc.
rotate freely on hanger.
3. If the paper pulls at the six o'clock position
(contact@ 12 o'clock), see Fig. 9.5G, the disc NOTE: Disc nut and disc nut washer may be
needs to be lifted by machining. Material must supplied as combination (one piece).
be removed from the top of the disc post and 2. Depending on the swing check style proceed as
base of the post, as shown in Fig. 9.5H. follows:
NOTE: If paper cannot be used, the same test a) Style I (Figs. 9.38 and 9.3C)
can be done using shim stock material. Place two bushings (55) in hanger and two
in hanger bracket (48). Insert hinge pin (54)
into the hanger (51) and push pin through
Light test
the hanger bracket into the opposite side of
Use a small flash light and position it on the the hanger.
up stream side with the light facing the disc. b) Style II (Figs. 9.30 and 9.3E)
Observe any light indication when disc is closed. Push bushing (55) into hanger (51) line up •
Record the position of light (gap) and then the hanger and washers (57) with hanger
proceed with repairs as for paper test. ring (53) and insert hinge pin (54) into
bushing. Place one spacer washer (57) on
each side of hanger pin.
9.5.3.2 lilting Disc
e) Style III (Figs. 9.3F and 9.3G)
Place two bushings (55) in hanger and two
Light test bushings in hanger ring (53). Insert the
hinge pin (54) into the hanger (51) and • ,
Prior to reassembly, insert a flash light,
push pin through the hanger ring to the ,.
reassemble per Section 9.5.1.2 - steps 1 and 2,
and check for light indication. If light is noted, opposite side of the hanger.
rotate both disc pins clockwise or counter- d) Style IV (Figs. 9.3H and 9.31)
clockwise as necessary until light indication Push the bushing (55) into the hanger (51)
disappears. Match mark disc pins and disassem- and insert the hinge pin (54) into the hang-
ble. Remove flash light and reassemble per er ring (53). Push pin through the bushing
Section 9.5.1.2 - steps 1 through 4. to the opposite side of the hanger ring.
NOTE: Alternate test:
Feeler gauge using 0.001" (0.025mm) feeler
gauge shim stock, check between the disc
and seat all around 360 degrees seating
circumference, If feeler gauge enters between
seats, rotate both disc pins clockwise or
counter-clock as necessary until feeler gauge
no longer penetrates between seats. The disc
is now properly aligned with 360 degrees
circumferential contact.

88
y~
•
\
SWING CHECK & TILTING DISC VALVES IX

3. Place the entire assembly carefully back in 9.5.5 Body-Bonnet and Cover Assembly Swing
the body. For Style I (Fig. 9.3B and Fig. 9.3C) Check & Tilting Disc
with original hanger bracket and body seat.
1. Install new pressure seal gasket (19) and
Ensure proper disc alignment by inserting
spacer ring (20) on bonnet (02).
dowel pins (61) in their respective holes in
hanger bracket (48) and top of body seat, 2. Install cover (50) over studs and on bonnet.
making sure that the hanger pin can move 3. Remove two opposite studs and replace with
freely in an axial direction. 8" (200 mm) and 10" (250 mm) long eyebolts.
NOTE: Alignment with dowel pins can only 4. Place bar through eyebolts and suspend the
be achieved using original hanger bracket and cover-bonnet assembly on hoist.
body seat. If the hanger bracket or body seat
5. Lower the entire bonnet assembly into the
is being replaced DO NOT USE DOWEL PINS
valve body, making sure the concentricity and
FORALIGNMENT. Use following manual
alignment of all parts are maintained.
alignment method which is applicable to
all swing check valves without dowel pins: 6. Remove the eyebolts and lift cover (50) with a
Follow steps 1,2 and 3 A, B, C or D. chain hoist, install the gasket retainer ring (21)
Insert lock bracket or tab washer (60) and in the groove in the body (01)
hand tighten hex HD bolts (56) then back off 7. Lower the cover (50) reinstall the eyebolts in
half to one turn, with one hand over center of the bonnet, with a chain hoist and a sling.
disc, press against the body seat and with the Pull up the bonnet against the gasket retaining
other hand, tighten down hex bolts. Complete ring.
tightening in accordance with Section 5.3
8. Lubricate the threads of the bonnet studs and
Torque Values -Yoke / Bonnet Bolting, Table
nuts and nut flats and tighten finger tight.

•
5.3A Torque Values for yoke / actuator /
bonnet bolting and continue steps 4 and 5. 9. Remove the eyebolts and install the last two
bonnet-cover studs (15) and bonnet-cover nuts
(16)
NOTE: If the valve is equiped with live load

I.
bonnet (Belleville spring washers) ensure that
the spring washers are installed in the same
order as noted during disassembly, refer to
Fig. 4.5C and 4.50 on page 18 for "spring
washer configuration"
10. Tighten the bonnet (02) by torquing bonnet-
cover nut uniformly. Perform this operation
with great care to avoid cocking the bonnet
and damaging internal parts.
11. Torque bonnet-cover nuts (16) in strict
accordance with Section 4.5.1.

~.
89
X APPENDIX

10.1 PROCEDURE FOR REMOVING 10.1.-1 Style I (Fig. 10.1A)

MANUAL GEAR ACTUATOR 1. Valves with Style 1 manual gear actuators
are equipped with a self-contained thrust unit.
Velan valves can be equipped with a variety of This actuator can be removed under line
manual gear actuators. Actuators of this type come pressure.
in two main styles: one for applications where only
2. Remove housing actuator bolting (178).
rotary torque is required, and one for applications
requiring both rotary torque and linear thrust. 3. Using a hoist, raise the actuator (32) above
the stem (4) and stem nut (88).
Generally, all pressure must be relieved from both 4. To repair the actuator, refer to the manufactur-
sides of the valve before removal of the manual er's instruction manual. If there is further work
gear actuator. Exceptions to this rule include valves to do on this valve, refer to the appropriate
which have a self-contained unit. section of this manual.
IMPORTANT: Determine the actuator style 5. The disassembly of the self-contained thrust
that is mounted on the valve you are servicing. unit follows the same procedure as described
If it is not possible to determine the style of in Disassembly Valve Top Works.
actuator, refer to the actuator manufacturer's
maintenance and instruction manual or
contact your local Velan representative for
more technical assistance.

•
PART DESCRIPTION
3 - Yoke
4 - Stem
17A - Yoke/housing cap screw
17B - Yoke/adaptor cap screw
28 - Yoke/housing cover
29A - Bearing
32 - Gear actuator
34 - Grease fitting
88 - Stem nut
113 - Stem nut gear driver

Figure 10.1A Manual gear actuator-Style 1

90
•
APPENDIX X

• ASSEMBLY EXPLODED VIEW

-.~-.--
---l-----·
i
PART DESCRIPTION
3 - Yoke

I) 4 - Stem
178 - Yoke/actuator
cap screw
32 - Gear actuator

•
NOTE:Applications where both rotary torque and linear thrust are required .

Figure 10.18 Manual gear actuator-Style 2

10.1.2 Style 2 (Fig. 10.18) 6. To repair the actuator, refer to the manufactur-

~.
er's instruction manual. If there is further work
1. Valves with a Style 2 manual gear actuator are to be done on the valve, refer to the appropri-
equipped with a self-contained thrust unit which ate section of this manual.

• will be removed with the actuator. Therefore the

actuator cannot be removed under line pressure.
The pressure must be relieved.
NOTE: In case the valve can be fully open, then
CAUTION: When reinstalling actuator,
the valve should be in a slightly off-seated
position (main seat or backseat) for
the actuator can be removed underline pressure. centering purposes.
Follow steps 3, 4, 5 and 6 below.
2. The valve should be in a partially open position. IMPORTANT: Velan does not recommend
interchanging of actuator parts as this may
3. Make sure that the packing flange nuts cause parts to be misfitted that could result in
are tight. actuator damage making the valve inoperable.
4. Remove the yoke-actuator bolting (178). If parts must be interchanged contact Velan
5. Turn the actuator handwheel clockwise. This Customer Service Department for instruction.
will cause the actuator (32) to rise and unthread
from the valve stem. As this takes place, the
weight of the actuator should be supported by
a hoist to prevent damage to the stem thread or
any internal part of the valve.

t •
91
X APPENDIX

10.2 PROCEDURE FOR REMOVING CAUTION:

MOTOR ACTUATOR 1. If the valve packing material is changed
Velan valves can be equipped with a variety of
for any reason, the torque switch setting
electrical motor actuators. Motor actuators are may have to be changed in this case
mounted through two different methods. Some contact Velan customer service Dept.
units are attached directly to the yoke (Fig. 10.2A), 2. Upon reassembly of a valve equipped
and some are attached to an adaptor plate and with an electro-mechanical actuator, the
then to the valve yoke (Fig. 10.28). Both methods open and close limit switches must be
have the same removal procedure.
reset. Please refer to the maintenance
and instruction manual provided by the
actuator manufacturer for appropriate
instructions.
IMPORTANT: Velan recommends to
reset open limit switch as a rule of
thumb 1/4" (6 mm) off back seated
position. For torque seated valves only,
the close limit switch should be adjusted
at approximately 95% of closed valve
travel, this is to allow sufficient torque
switch by-pass during unseating.
3. When checking for proper rotation of
Figure 10.2A Motor actuator- Direct attament
the electrical actuator, make sur.edthatk •
the valve is in approximately rru -stro e .'
IMPORTANT: For torque seated valves, the position. If the three-phase wiring
torque switch of the motor-actuated valve is
connection isincorrect, the valve will
set during factory assembly to close the valve
close when the open button is pressed
against the specified differential pressure
and requires the same special attention and the close torque switch will not
for resetting. function, which could damage the valve.
WARNING: Should it become necessary to
If the valve does not travel in the correct t
direction, then simply interchange any
change the torque switch setting for any
two of the three power connections.
reason, contact your Velan Customer Service
Manager to obtain a correct new setting from 4. When checking for full stroke of the
the factory. valve without pressure in the line, the
closing torque switch should be set to
its minimum value which will close the
valve until all testing is finished. The
torque switch should then be reset to
its recommended value.

Referto Fig. 1O.2Cand Fig. 10.20

NOTE: If the valve is in full open position,
the motor actuator and bevelgear can be
removed under line pressure, otherwise.
1. All pressure must be relieved from both
sides of the valve before removing the motor •
Figure 10.28 Motor actuator - Adaptor plate actuator and bevelgear.
attachment (Assembly) 2. The valve should be in a partially open position.

92
APPENDIX X

• 3.

4.
5.
Disconnect the electrical wiring from
the actuator.
Tighten the packing flange nuts.
Remove all actuator bolting (17C)from the
7. Turn the actuator handwheel clockwise to
close the valve. This will cause the actuator
to rise and unthread itself from the valve stem.
As this takes place, the weight of the actuator
should be supported by a hoist to prevent
underside of the yoke flange. damage to the stem or to the internal parts
NOTE: If removing the motor actuator of the valve.
with bevelgear Fig. 10.20, remove hex 8. If further disassembly of the actuator is
bolts (17) push out the motor actuator (32) required, refer to the maintenance manual
from bevelgear keyed stem (34). If removing provided by the actuator manufacturer.
bevelgear, remove cap screws (17C),
9. If there is further work to be performed on the
rotate bevelgear clockwise this will cause
valve, refer to the proper valve disassembly
the bevelgear to unthread from the stem.
and maintenance section in this manual.
• 6. All electrical actuators have an automatic
hand-wheel declutching arrangement. In
CAUTION: When reinstalling actuator,
most cases, move the lever from the motor
the valve should be in the slightly off-
operation position to the hand operation
position (manual mode). seated position (main seat or backseat)
for centering purposes.
NOTE:_Do not try to force declutch lever into
an operation position.

••
, @
®
@ 03 - Yoke
04 - Stem
@ 15 - Adaptor/actuator
stud
@ 16 - Adaptor/actuator
nut
@ HC -Yoke/adaptor
cap screw
03 - Yoke 32 - Motor actuator
@----- 32 - Motor actuator
37 - Adaptor plate 04 - Stem
17 - Bevelgear/actuator hexbolt
33
34
-
-
Bevelgear actuator
Keyed stem
17C -Yoke/bevelgear cap screw 50 - Stem protector

Figure 10.2C Motor actuator- Adaptor plate Figure 10.2D Bevelgear actuator
attachment (Exploded view) (Exploded view)

,•
93
X APPENDIX

10.3 PROCEDURE FOR MOTOR HYDRAULIC

OR PNEUMATIC ACTUATORS (Fig. 1O.3A)
PART DESCRIPTION
The following instructions will give you a general 3 . Yoke
guide for removal and reinstallation of a hydraulic 4 . Stem
or pneumatic actuator. All hydraulic or pneumatic 178 . Yoke/actuator.
actuators have a connection between the valve cap screw
stem and the stem of the actuator. All these 32 . Actuator
connections are formed by some type of coupling. 35 - Coupling
set screw
Fig. 1O.3Aillustrates some examples of coupling
97 - Coupling
used on Velan valves. As a rule, examine this
connection first to understand how the coupling
works.

4 • Stem
48 - Actuator stem
16 - Jam nut
97 - Coupling

Figure 10.38 Removal of actuators

Removal of Actuators (Fig. 10.38)

•
1. All pressure must be relieved from both sides
of the valve before removal of actuator.
2. All air pressure must be relieved from actuator'
before disassembly.
Figure 10.3A Examples of coupling
3. Remove yoke-actuator bolting (17B).
NOTE: In case of fail close actuator type (air
fail spring to close). Before air is relieved
replace two capscrew (17B)one opposite the
other with longer (twice the length) studs or
threaded rod, relieve air and gradually release
spring tension by backing off stud nuts.
4. Loosen coupling (97).

PRECAUTION: Examine coupling (97)

for set screw (35) or any locking device
before loosening it.

NOTE: On some actuators, it is necessary

•
to rotate the actuator stem to remove this
connection.

94
APPENDIX X

• 5. When the stem threads are disengaged, lift

the actuator (32) clear of the yoke and place it
down on a clean area. If further disassembly
10.4 SPARE PARTS
All parts on any valve can be ordered, but Velan
on the actuator is required, refer to the does not recommend changing all parts in the
manufacturer's maintenance and instruction field (e.g. body seat, bonnet backseat, wedge
manual. guides, etc.).
6. If there is further work to be performed on the
valve, refer to the proper valve disassembly Changing these parts may require special fitting.
section in this manual. In these cases, it is best to get in touch with your
local Velan representative who will help you

•
CAUTION: When reinstalling actuator, determine the way to restore your valve with
the valve should be slightly off seated a minimum of time and expense.
position (main seat or backseat> for
centering purposes. When ordering spare parts, correctly determine
which parts are required. After this is done,
present Velan with some of the following
information:
1. Velan order number.
2. Velan item number (if more than one item).
3. Velan figure number and drawing number

•
(usually found on the valve nameplate) .
OR in absence of the above:
1. Customer order number.
2. Customer item number.

~.
3. Valve size, type, pressure class and
drawing number.

,
i
I
.~
,
• >il! 95
X APPENDIX

10.5 SPECIAL TOOLS FOR VALVE ASSEMBLY

AND DISASSEMBLY

Figure 10.58 Flexible packing extractor

cork screw type for all braided
type packing rings.

Figure 10.5A HC" type saw for cutting and

removal of all graphite ribbon
packing rings

Figure 10.5C Crawfoot wrench for torquing

pressure seal valves 2 - 2 Y2"
(50-65 mm)

96
•
APPENDIX X

I•
used for 3-4" (75-100 mm) valves

I~
1
I
4

/
! :
-.! .:»
--:,
-- ~-..,
I
I
'"
11)
I
I
used for 6" (150 mm) valves
Figure 10.5D Ball type allen sockets for
torquing pressure seal valves :,
L __ ~ :, -' /'
3", 4", and 6" r -1--1

1
~-l-~
(75 mm, 700 mm and 750mm)
:
I
I

I- s

• Figure 10.5F Allen socket wrench for

pressure seal valves
3 - 6" (75 - 150 mm)

Figure 10.5E Standard 72 point sockets for

torquing pressure seal valves
6" and up (750 mm and up)

97
':..
X APPENDIX ~

-4 f
'1

"
snapon rachettype:orque7h

--t-- --
V2 - %" (15-20 mm) adaptor I I

-........ ~'S.l~\

incline rachet - __ .......

.~
Figure 10.5G Ratchet type adaptor, ratchet wrench for

•
torquing hard to accesspressure seal
bolts, for pressure seal valves
8" and up (200 mm and up)

I
j

Figure 10.5H Velan disc clamp for

disc removal and reassembly
of parallel slide valves

98 v11
.'
TERMS AND CONDITIONS OF SALE

I, o CONTRACT: Orders are subject to acceptance by

the Velan Companies hereinafter referred to as the
seller. No terms or conditions of Purchaser's order
contrary to the Seller's terms and condition shall
proven defective, or (iii) in discharge of Seller's
maximum liability herewith, refunding all monies
paid by Purchaser to Seller for the Product and, at
discretion of Seller, having the product removed
be binding upon the Seller unless specifically and returned to Seller at Purchaser's expense. All
agreed to by the Seller in writing. transportation charges relative to corrective work,
MINIMUM ORDER CHARGE: $500.00 net. defective parts or replacement parts shall be borne
by Purchaser. Purchaser shall give Seller immediate
PRICES: All quoted prices are subject to change by
notice upon discovery of any defect. The undertak-
the seller without prior notice and, unless other-
ing of repairs or replacements by Purchaser or its
wise stipulated by Seller, are understood to be

f
i
F.O.B. Seller's plant, with delivery to carrier consti-
tuting delivery to purchaser. Right to possession of
the material to secure the payment of the purchase
agents without Seller's written consent shall relieve
seller of all responsibility herewith.
Finished materials and accessories purchased from
price shall remain in Seller until all payments other manufacturers are warranted only to the
• therefore shall have been fully made. For the pro- extent of the manufacturer's warranty to Seller.
. tection of the Purchaser and the Seller, verbal cus- Any alteration in material or design of Seller'S prod-
tomer orders must be confirmed by a formal writ- uct or component parts thereof by Purchaser or oth-
ten purchase order. If a written purchase order is ers without written authorization by Seller voids all
not received within ten days or a verbal order, obligations of Seller regarding the product and any
product descriptions, quantities, specifications, associated warranty herein stated or implied.
etc., as set forth in Seller's acknowledgement and
invoice shall be conclusive and binding on both Seller's sole liability shall be exclusively as set
parties. Any order that is shipped before receipt of forth herein, and Seller shall not be liable for any
confirmation which might have been entered incor- incidental or consequential damages due to its
rectly and would require remedial action would be breach of any warranty herein contained, or other-
for the Purchaser's account. wise. Without limitation to the foregoing, in no
event shall Seller be liable for the loss of use of
• TAXES: All prices are exclusive of taxes. Sales,
the product or of any other product, process,
use and other taxes, by whomsoever levied, are to
plant, equipment, or facilities of the Purchaser or
be paid by the Purchaser, and unless invoiced, are
end-user whether partially or wholly due to
to be paid by the Purchaser directly to the appro-
defects in material and/or workmanship and/or
priate governmental agency.
design of Seller's product, and in no event shall
DELIVERY: Delivery or shipment specified is Seller be liable for removal of appurtenances or
Seller'S best estimate and Seller shall not be liable incidentals such as connections, pipe work and
for delay in deliveries resulting from any cause similar items of obstruction or for any cost
whatsoever. Failure to ship on or near the estimat- brought about by the necessity of removing the
ed date shall not entitle Purchaser to cancel his product from its point of installation.
order without charge.
Seller makes no warranty of any kind whatsoever,
RETURN OF MATERIALS: Materials may be expressed or implied, other then is specifically stat-
returned only with prior written agreement of Seller. ed herein; and there are no warranties of mer-
CANCELLATION: Cancellation of orders may be chantability and/or fitness for a particular purpose
made only with the Seller's written consent and which exceed the obligations and warranties specifi-
Purchaser shall be subject to cancellation charges. cally stated herein.
PRODUCT WARRANTY: Seller warrants the equip- Parts furnished without charge as replacements
ment of its own manufacture to be free of defects for original parts under warranty are warranted for
in material and workmanship, under normal use that period of time during which the original parts
and proper operation for a period of one year from warranty is effective.
the date of shipment from Seller's plant. Seller's
ALL SHIPMENTS WILL BE F.O.B. PLANT LOCATION.
obligation under warranty shall be strictly limited,
at Seller's option, to: (i) furnishing replacement SHIPMENTS WILL BE MADE VIA MOST ECONOMI-

•
parts for or repairing without charge to Purchaser, CAL CARRIERS UNLESS OTHERWISE REQUEST-
F.O.B.Seller'S plant or (ii) issuing written authoriza- ED.TERMS: NET 30 DA YS FROM DA TE OF INVOICE:
tion for Purchaser or others to replace or repair 10% PER MONTH OF ALL OVERDUE ACCOUNTS,
.~. without charge to Purchaser, at costs comparable to ALL TAXES EXTRA. PRICESSUBJECT TO CHANGE
Seller'S normal manufacturing costs those parts WITHOUT NOTICE.

99
--
MANUFACTURING
- - - ---......,,- ~- ~--- .
PROGRAM
'/.j~ll~~r<!)~fIJtjf.!il!q
-._-_. --- _. - ~-"--" ~', -;11_"," '''1 - ~ --- ;.ri~~~;~~I;':-·--:-·--·-)W-~m;:l(i.t~"--l
, \""
~'" -
{
- ; . "....i. _.JU .... JI ''c_ : ,. ".,};Jb);:J :,:~.·L t '. ,~ttit~)",~1.ml'JD
.cJ

Forged steel gate, globe and check valves X-2 8-50 ASME 150-1500 API 602, 606
ASME B16.34
Forged steel Y-pattern globe valves X-4 8-100 ASME 900-4500 ASME B16.34
Cast carbon and allo1 steel
gate, globe and chec valves 2-48 50-1200 ASME 150-1500 API 600

Cast stainless steel gate, globe and check valves X-24 15-600 ASME 150-300 API 603
ASME B16.34
Forged pressure seal and bolted body cover ASME PS 600 - 4500
gate, globe and check valves, Y-pattern 2-24 50-600 BB 600-1500 ASME B16.34
Industrial ball valves! Ball valves for slurry ASME 150-600
Metal-seated ball valves X-24 8-600 1000-2000 WOG ASME B16.34
All stainless steel knife aate valves
bolted body cover & bo y coverless
2-36 50-S00 150 psi TAPPI TIS 405-8
Split-body tilting disc check valves SP-81
Forged tilting disc check valves 2-24 50-600 ASME 150-2500 ASME B16.34
Bellows seal valves Globe: X-12 15-300 ASME 150-2500 ASME B16.34
Gate: X-12 15-300

Cryogenic valves Globe: X-16 15-400

Gate: X-48 15-1200 ASME 150-2500 ASME B16.34

SALES OFFICES MANUFACTURING PLANTS

U.S.A. CANADA EUROPE INDIA U.S.A. CANADA
Bill Hannon/ Don Bowers Charles Pogue/ Paul Dion/ John Smith/Brian Hall S.Giridhar VELAN VALVE VELAN INC.

•
18Avenue C B. Lawson / T. Harfield Jacques Godbout/ VELANENGINEERING Block A-I, Flat 604 CORPORATION 2125Ward Avenue
Griswold Industrial Park 730N. Post OakRoad Woody Bowler CO.LTD. GlaxoApartments 18Avenue C Montreal. QC H4M 1T6
Williston, VT 05495-9798 Suite 311 2125Ward Avenue CambridgeRd., Mayur Vihar-PH-l Griswold Industrial Park Tel: (514)746-7743
Tel: (8021864-3350 Houston,TX 77024 Montreal, nc H4M 1T6 Whetstone Delhi-ll0091 Williston, VT 05495-9798 Fax:(514)748-8635
Fax:(8021865-3030 Tel: (7131682-1084 Tel: (5141748-7743 Leicester LE86LH TeVFax:91-11-271-2196 Tel: (8021863-2562 VELAN INC.
Fax:(7131682-6071 Fax:(5141748-8635 England Fax:91-11-225-8799
RonaldJ. Harrington Fax:(802)862-4014 550McArthur Ave.
Tel: 44-6-275-0206
43 Wyckoff Avenue Christopher G.Hiett George S. Lysakowski
Fax:44-6-275-0224
CHINA QUALITYASSURED Montreal, QC H4TlX8
Waldwick, NJ 21931HarborbreezeLane 871Kowal Drive Room4003of No. 13 PRODUCTSINC Tel: (514)748-7743
07463-1721 Huntington Beach, Mississauga, ON Gordon Hogben Xiao-Ying Road 2601Monarch Street Fax:(514)341-3032
Tel: (201)670-0995 CA 92646 L5H3T3 10ReynoldsWay ChaoYang District Alameda, CA 94501-5002
Fax:(201)670-6810 Tel: (7141965-6277 Tel: (9051278-7522 Croydon, CRO5JW Beijing 100101 Tel: (510)749-3900 VELAN INC.
Fax:(7141965-6737 Fax:(9051278-8155 England Tel: 86-10-64968995 Fax:(510)749-3850 1010Cowie Street
Paul R.Lee Fax:86-10-64968997 Granby,QC J2J 1E7
John Flynn Bill Patrick Tel: 44-181-680-7409 FRANCE Tel: (450)378-2305
208Lindbergh Avenue
289Antioch Road 8825,51"Avenue Fax:44-181-760-1968 JAPAN ALSTOM VELAN Fax:(450)378-6865
Wilmington, DE
19804-3316 Lake Lure, NC28746 Edmonton,AB T6E5HI Tak Sakamoto 90,rue ChallemelLacour
Tel: (828)625-9441 Tel: (7801465-1122 Jacques Chanols 4-31-3Kamimeguro, 69367LyonCedex7 PROQUIP
Tel: (302)994-1176
Fax:(828)625-9437 Fax:(780)465-0403 ALSTOM VELAN Meguro-ku Tel: (33)4 78616700 835Fourth Line
Fax:(3021994-6156
229rue La Fontaine Tokyo 153-0051 Fax:(33)4 7872 1218 Oakville,ON L6L5B8
Joe Denny Leo Shewchuk 94134Fontenay Tel: (905)842-1721
Michael Midgley 1100,5405"Avenue Tel: 81-3-3792-1891
3160Vera Valley Drive
1638Estate Circle SousBois Cedex Fax:81-3-3792-1891 ENGLAND Fax:(905)849-0923
Naperville, Il60565 Calgary, AB T2POM2 France VELANENGINEERING
Franklin, TN 37064 Tel: (403)232-6482 CO.LTO. KOREA
Tel: (630)579-1833 Tel: 33(1) 43 946722-21 MIDDLE EAST
Tel: (TBAI Fax:(403)213-8547 CambridgeRd., VELAN LTO.
Fax:(630)579-1834 Fax:33 (1)43 9419 61 Cherif Demian
Fax:(TBA) B 608-7Panwollnd.
Golden SandsBldg. #10 Whetstone
David Brodnax Leicester LE86LH Estate
Larry A. Woodworth 503ComancheTrail MEXICO, Manfred Hanke Suite 307,Dubai U.A.E.
1343Paddock Place VELANGmbH P.O.Box 9168 Tel: 44-6-275-0206 P.O.Box 12 '-"
West Monroe,LA 71291 CENTRAL Ansan City, Kyunggi-do
BARTlETT,ll 60103 Daimlerstrasse 8 Tel: 971-4-599-000 Fax:44-6-275-0224
Tel.: (318)396-7517 & SOUTH Tel: (82)345-491-2811
Tel: (6301736-9395 Fax:(318)396-4995 AMERICA 47877Willich Fax:971-4-552-265 PORTUGAL
Fax:(630)736-9397 Germany Cell:971-50-458-1843 Fax:(82)345-491-2813
Sergio Pensotti VELAN VALVULAS
Frank Keegan
Unit 14,
VELAN VALVECORP. Tel: (49)2154/427001-04 SINGAPORE INDUSTRIAlS, LOA. TAIWAN
Tony Boland Fax: (49)2154/41695 Av. Ary dos Santos
730N. Post OakRoad VELAN-VALVAC
45W. Franklin Street 9007Highland Road GaryTan
Suite 311 Lisbon-167SOdivelas P.O.Box 2020
Bellbrook, OH 45305 Baton Rouge,LA 70810 NO.4 Pioneer Place
Houston,TX 77024 Tel: (351-1)934-7800 Taichung, Taiwan, R.O.C.
Tel: (937)848-2011 Tel: (225)767-7965 Singapore 627893
Tel: (713)682-1837 Fax:(351-1)934-7809 Tel: (04)2792649
Fax:(937)848-2144 Fax:(225)767-8160 Tel: (65)862-0572
Fax:(713)682·6071 Fax:(886)42750855
Fax:(651862-0573

Velan's valve distributors are located worldwide. GENERAL INFORMATION

Note: Although every attempt has been made to ensure that the information contained in this manual is correct, Tel: (514)748-7743
Velan reserves the right to change designs or, materials or specifications without notice. Please get in touch Fax: (514) 748-8635
with your local Velan representative for more information. Web: http://www.velan.com
PRINTED IN CANADA VEL-FPSM-99
/17
VOLUME-12 PIPING, VALVES AND ACCESSORIES Chapter-3

3.7 VACUUM BREAKER VALVE

.::::

!
I! -T

~.
(
1/
-
® Contents 15/37
INSTRUCTION MANUAL
FOR
INSTALLATION, OPERATION AND MAINTENANCE
UTE VALVES

'I"
...
UTSUE VALVE CO_" LTD_
INSTRUCTION MANUAL
FOR
INSTALLATION. OPERATION AND MAINTENANCE
OF
UTE VALVES

BEFORE YOU DO ANYTHING

Before you do anything, we recommend you read
this Manual a few times, and keep it close at hand
where you can refer to it at a moment's notice.
Before you start any adjustment or repair work, be
sure to check the marker plate carefully and confirm
the pressure rating, type, structure, etc. in the draw-
ings presented by UTE and/or in the illustrations in
this Manual. Then proceed with the work in the order
described in this Manual. .

UTSUE VALVE CO., LTD.

He•• omu
&: PI.. , 2 - 1- 1 3 Kit am u r a. Ta I • h Q - k u I
O.aka, 661-0032, Japan
TELEPHONE NO. 08(8662)31~1
FAX NO. 08(8651)3246

This instruction manual may not be copied without permission.

PRECAUTIONS FOR SAFETY USAGE OF VALVE

This leaflet contains important instructions to handle valve safely.

Do not to attempt to handle valve without reading this booklet thoroughly.
. The maintenance of valve must be carried out with well-trained experts.

Transportation and Storage

ILf51 CAUTIoo I
Precaution for falling down
1. When hanging a valve to move, make sure the weight of the valve and keep off under the
valve.
2. When hanging a motor operated valve, be sure not to hang by the hand-wheel, gland!
stem nor actuator ..
3. All valves should be stored in a clean, dry and well-protected warehouse.
4. Valves in a carton box or crate must be stacked orderly.

Installation .
I.&;; C.\UT 100 I Precaution for falling down
1. When hanging a valve to mount, make sure the weight of the valve and keep off under
the
valve.
2. When hanging a motor operated valve, be sure not to hang by the hand-wheel, gland,
stem nor actuator ..
3. When installing, be sure to keep surroundings safe and to avoid working at a dangerous
place.
4. Do not use a hand-wheel of the valve as a scaffold because a hand-wheel shall rotate.

lit CAUT100 I Precaution for damaging valve

1. Do not use a hand-wheel of the valve as a scaffold. Valve may be damaged.
2. Do not lag a valve gland. Lagging may shorten life of gla,ndpacking.
3. When changing the direction of mountingmotor actuator, be sure that a well-trained
operator must do and adiust limit switches.

1& CAUTIoo I Hydro- pressure test of the plant line

Precaution for valve damage by hydro-pressure test
1. The pressure of hydro-pressure at site test should be within the pressure of

P 1/3
hydro-pressure test at factory.
2. When using as a hydro-pressure stop valve, be sure that the pressure should be within
the seat leakage test pressure.
3. In case of leakage from gland or gasket at hydro-pressure test; be sure to refasten
If the leakage does not stop, call UTSUE VALVE Co., LTD. for help.

4. When a seat leakage of a gate valve with an adjustment nut (usually called as
"stopper") at the top of the stem does not stop, refasten after removing a split pin to
unfasten the adjustment nut. After the test move the adjustment nut to the original
position and fix with the split pin.

During operation
ILh CAUl JON I Precaution for damaging plant line
1. Tum a hand-wheel clockwise to close the valve and tum counter-clockwise to open.
Make sure the opening position of the valve before operation.
2. Be sure to refasten gland packing before starting operation of the plant. As to motor
operated valve, confirm the operation with motor after refastening gland packing.
3. In case of gland leakage, be sure to refasten immediately. If refastening is not done
immediately. leakage shall grow and shall result in plant shut down.

ILh CAUTION I Precaution for damaging valve

1. Clean and apply grease to stem before starting operation then on every three months
basis
Also, apply grease to grease nipple on every three months basis ..
2. Valve should be used at either full-open or full-close position except for needle globe
valve. Using valve at an intermediate may lead to malfunctioning of the valve.
3. As to gate valve with manual operation, make sure to return a hand-wheel by 1/4 or
112 rounds (1.5 to 4.5 rounds to a gear operated valve) to the opposite direction after
opening at the full open position. To neglect this operation may lead to the problem
that the valve shall not open nest time. '.
4. As to gate valve and globe valve with manual operation, make sure to return a
hand-wheel by 1/4 to 112 rounds (1.5 to 4.5 rounds to a gear operated valve) to the
opposite direction after opening at full open position.
To neglect this operation may lead to malfunctioning of the valve.

P2/3
During operation
~liS CAUTIOO I Precaution for hurting working people
1. Do not change gland packing or refasten utilizing back seat during operation.
It may cause to the fluid out of the gland to hurt working people.
2. Be sure to never touch a valve empty-handed over 40 degrees centigrade outside surface
of the valve. When it is necessary to touch, be sure to wear anti-high temperature gloves
to prevent from a bum. I~may cause to have a burn.

During maintenance
1l1S CAUTION I Precaution on hurting working people

I. Before starting maintenance, make sure that there is no inside pressure of the line
and the temperature of the outside surface of the valve is below 40 degrees
centigrade.
. 2. As to motor-operated valve, be sure to start maintenance after the power is off.
3. Trained expert must do the job.

P 3/3
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Section V Repair ---------------39 26 Cross-Section of Swing Check Valve,

1. Repair of Valve Body or Bonnet 39 PressureSeal CoverType - Style 20-------18
2. Repair of Seat of Gate Valve and Swing 39 27 Motor Operated Gate Valve 19
Check Valve 39 28 Single Flange Connection Type - Gate
3. Repair of Seat of Globe Valve 40 ,Valve 20
4. Repair of Sealing Area of Body 29 Double Flange Connection Type - Gate
(PressureSeal Type)-------------41 Valve 20
5. Repair of Stem and Yoke Bushing 30 Motor Operated Globe Valve---------21
(or Yoke Sleeve) 41 31 Special Bonnet or Yoke Type - Globe
Section VI Spare Parts----,---------_-43 Valve 22
1. Gate and Globe Valve 43 32 Double Flange Connection Type - Globe
2. Swing Check Valve 44 Valve 22
3. Special Parts and Tools 44 33 FlexibleDisc- Gate Valve----------27
34 Hammer Blow Handwheel - Globe Valve 27
35-a Removalof Packing 29
LIST OF ILLUSTRATIONS 35-b PackingToolkit 29
35-<: PackingTools 29
Figure No. Title 36 Fitting Method for New Packing 30
1 Factors for ReliableValvingService-------1 37 Gland for PackingFitting 30
2·a Headed Bolt 2 38 PackingFitting Staggered 30
2-b Stud Bolt 2 39-a Disassemblyof Valve- UTE Product 31
2-<: Bolting Bolt 2 39·b Disassemblyof Valve- UTE Product 31

",
3-a Pressure'SealStructure 2 39-<: Disassemblyof Valve- UTE Product 31
3-b Pressure Seal Structure for CDF Valve 2 40 Bolt TighteningSequence 32
3-<: PressureSeal Structure for 4" and Smaller 41 Knockout Hole in the Body 33
~~ 2 42 Take-out Hole in the Retainer 34
4-a Seat 0" Gate Valve and Swing Check 43 Seat Lapping Jigs - Gate Valve and
V~~ 3 SwingCheck Valve 40
4-b- Seat of Globe Valve 3 44 Conical Seat Lapping Jigs - Globe Valve-----40
5 Cup Square Neck Bolt 5 45 Flat Seat LappingJigs - Globe Valve 41
6 U-Ring (DiscGuide Rail) - Gate Valve 5
7 Cross-Section of Gate Valve, Bolted
Bonnet Type - Style 1 6 LIST OF TABLES
8 Cross-Section of Gate Valve, Bolted
Bonnet Type - Style 2 6 Table No. Title
9 Cross-Section of Gate Valve, Bolted 1. ClassifiedUTE Standard Valve 4
Bonnet Type - Style 3 7 2. Name of Parts for Style 1,2,3,4,5 & 6-
10 Cross-Section of Gate Valve, Bolted Gate Valve 8
Bonnet Type - Style 4 7. 3. Name of Parts for Style 7, 8 & Fig. 15 -
11 Cross-Section of Gate Valve, Bolted Gate Valve 10
Bonnet Type - Style 5 8 4. Nameof Parts for Style 9 - Gate Valve 11
12 Cross-Sectionof GearedOperationType ..:.. 5. Name of Parts for Style 10, 11 & 12 -
Style 6 8 Globe Valve 13
13 Cross-Sectionof Gate Valve, PressureSeal 6. Name of Parts for Style 13, 14 & .15 -
Bonnet Type - Style 7 9 GlobeValve 16
14 Cross-Sectionof Gate Valve,PressureSeal 7. Name of Parts for Style 17, 18 & 19 -
Bonnet Type - Style 8 10 SwingCheck Valve 18
15 Geared Operation Apparatus---------l0 8_ Name of Parts for Style 20 - SwingCheck
16 Cross-Sectionof Gate Valve,PressureSeal Valve 18
Bonnet Type - Style 9 11 9. Nameof Parts for Fig. 27, Fig. 28 & Fig. 29
17 Cross-Section of Globe Valve, Bolted Motor Operated Gate Valve 20
Bonnet Type - Style 10 12 10. Nameof Parts for Fig. 30, Fig.31 & Fig. 32
18 Cross-Section of Globe Valve, Bolted Motor Operated Globe Valve 22
Bonnet Type - Style 11 12 11. Ratingof Heaters 23
19 Cross-Section of Globe Valve, Bolted 12. Range of UsableHammer BlowHandwheel-----27
Bonnet Type - Style 12 13 13. UsableRangeof Handwheel 28
.20 Cross-Section of Globe Valve, Pressure 14. Bodv-BonnetBolt Torques 31
Seal BonnetType-Style 13---------14
21 Cross-Section of Globe Valve, Pressure
Seal Bonnet Type - Style 14 15
22 Cross-Section of Globe Valve, Pressure
Seal Bonnet Type - Style 15---------16
23 Cross-Section of Swing Check Valve,
Bolted CoverType - Style 17---------17
24 Cross-Section of Swing Check Valve,
Bolted CoverType -Style 1B---------17
25 Cross-Section of Swing Check Valve,
Bolted Cover Type - Style 19---------18

iii

\..
-_'"
FOREWORD
Since its .founding in 1931, Utsue Valve Co., Ltd. (UTE) has
been manufacturing high quality valves while devoting constant
attention to research for design and technology. In order to
assure re!iable performance, every single UTE valve is manu-
factured, inspected and then shipped under a stringent Quality
Program. .
This manual has been prepared to help you to obtain the most
satisfactory service from your UTE valves. It gives you helpful
sU\IDestions for receivinq, storing, installing, operating and
maintaining of these valves. The contents include discussions
enabling you to become familiar with design features and
proper use of supplied valves.

January 1. 1978
------------------- ---_.

iv
SECTION I INTRODUCTION

1. General

Despite the strict Quality Control Programs·atthe factory, it is 1. Product Quality

often unavoidable that some valve, after a certain period of 2. Correct Selection of Individual Valve
time, may need repair. On the occasion of repair, the step-bv- 3. Correct Installation
step procedures for disassemblyand reassemblyin this Manual 4. Correct Usage
will help you to recondition the valve with minimum of time
and labor.
In order to enable the valve to work for any servicenormally The following illustration shows these factors, including the
and reliably, the following four factors must be assured: important points in eachcase.

UTE QUALITY PRODUCTS

COI}.RECT SELECTION
• Research and development
~ Service conditions
• Design and engineering
• • Fluid • Pressure
• Temperature and heat cycle • Material sourcing
• Shop quality control
• Serl(ice period ..
• Final testing and inspection
• Ambient temperature and
atmosphere • Quality assurance
• Seismic and other
natural conditions

CORRECT INSTALLATION CORRECT USAGE

• Receiving inspection • Correct operation
• Correct storage • Preventive maintenance
• Proper handling • Periodical inspection
• Correct valve connection to • Periodical lubrication
piping • Correct disassembly and
• Preliminary valve operation reassembly
testing • Repair

Fig. 1 Factors for Reliable Valviog Service

,<:I
, .'J
2. UTE Standard Valve

Our Standard valves can be basically divided into three major

groups: Gate, Globe and Check Valve. Materials may be selected
according to the kind of fluid, service temperature and pressure.
(Typically carbon steel, chromium molybdenum steel and
stainless steel are used.)
This Manual has been prepared for UTE 2-1/2" and larger
valves. Regarding 2" and smaller valves, refer to "Instruction
Manual for UTE Forged 2" and Smaller Valve."

3. Seal Structure of Body and Bonnet

3-1 Bolted Bo,:,net Type

Classes under SOO Gate, Globe and Check Valve, and also
Class 900 Globe VaLve under S" are in bolted bonnet joint.
Bolts used in the globe valve, swing check valve and relatively
small size gate valve (up to 4") are either headed bolts or Fig.3-a Pressure Seal Structure
bonnet-stud bolts. Valves other than the above have stud bolts Clamp Bolt
or bblting bolts. See Fig. 2-a, Fig. 2-b and Fig. 2·c respectively. CI~p. - --~::-,

'/

"

. . .'
Fig.2·a Fig.2-b Fig.2·c .Adapter
Headed Bolt Stud Bolt Bolting Bolt Seal Ring
• • ro-- i
Stellite Faced

.v
3-2 Pressure Seal Bonnet Type [
____ .... t,,: ':'. ..: .; _ _ --.
Other higher-class valves are pressure seal types. Their design
Fig.3-b Pressure Seal Structure (CDF Valve)
structure is shown in Fig. 3-a, Fig. 3-b and Fig. 3-c. In this
construction, a wedge-shaped seal ring is used and is self-
sealed by fluid pressure. Fluid pressure forces the bonnet against I
,I
the smaller contacting area of the wedge-shaped seal ring. I
But the seal ring is prevented from being pushed by the
adapter ring, and the retainer ring that is fixed in the body
groove. As internal fluid pressure increasingly rises, the self-
!,
sealing force of the seal ring subsequently increases. !,
In 4" and smaller valves, the threaded one-piece yoke works
as the segmented retainer. Tightening nuts in this design are
adopted in lieu of the bonnet lifting studs.

--t+--! Bonnet

-Stellite Faced
I

- ,

Fig.3-c Pressure Seal Structure (4" or smaller)

4. Seat Arrangement
SealWeld Stellite No.6
All UTE valves (gate, globe and check) have integral hard
surfaced seats. They are "welded-in" type and an integral
part of the body. Since the seats are not "renewable" type,
they can be removed by grinding off the welds. Unless other-
wise specified, Stellite No.6 should be used as standard material
for hard surfacing of the seat. The seat ring of the same
material as body, stellite-faced on its base material, is put into
the body. It is seal-welded as shown in Fig. 4·a in case of gate (al ConicalSeat (blFlat Seat
valve and swing check valve, or is directly stellite-faced on the
body as in Fig. 4·b in case of globe valve. Fig.4·a Seat of Gate Valve Fig. 4·b Seat of Globe Valve
and Swing Check Valve

5. UTE Valve TYl1eNumber

The valve type numbers explained below are designed to cover

essential features of a UTE product. When you wish to purchase
a new spare valve or part, be sure to refer to the type number
so that we can efficiently process your purchase order.
What the Type Numbers Mean
The type numbers used on UTE products are made up of the
letter "U" followed by six numerals.
These numerals have the following significance:

U 1 1 2 0 02
Valve Size 2Y> 3 4 5 6 8 10 12 .
(Inches) -,- I -. -. -r -r --r -.-
'-- 02 03 04 05 06 08 10 }2 .

...Valve End BUTT WELD ANSIFLG JIS FLG RJ FLG

2 3 4
Valve Class (Nominal Pressure PSI)
75 150 300 400" 600 900 1500 2000 2500
T -,--r -,-T
123456789
-r -r -r"-r
GATE LIFT SWING SWING CHECK
Valve Type OS & Y ISS GLOBE ANGLE CHECK CHECK FOR STEAM EXT.
--r -y--r
1 2 3 4 5 6 7

NOTE: A zero appearing in the above sample numberingwill be"

replaced by a number indicatingwhich of the four available
types of valveend is used.
6. Classified UTE Standard Valve

For your quick reference, information presented above is left column of the table.Jn next paragraph, eachdssiqn stylewill
summarized in Table 1, Valves having the same design (can- be illustrated by both a cross-section and a descriptive figure.
structionl are represented by a style number at the extreme
Table 1 Classified UTE Standard Valves
Design
Type of Type of Valve Size UTE Type No. Remarks
Style Class
Valve Seal
No.
150 2·1/2" - 4" Ul12002,Ul12003,Ul12004 B
300 2-1/2"- 4" U113002, U113003, U113004 B
Bolted U114002, Ul14003,
1 Gate B
Bonnet 400 2·1/2"- 6"
U114004, U114005, Ul14006
600 2-1/2"- 4" Ul15002, U115003, Ul15004 B except Ul15004
Bolted U112014, U112016, U112018
2 Gate 150 14" - 24"
Bonnet U112020,Ul12022,U112024 C I&.
U113014, U113016, U113018
300 14" - 24" C except Ul13014
U113020, Ul13022, U113024
U11400a, U114010, U114012
400 a" - 24" U114014, U114016, U11401a
C
Bolted U114020,U114022,U114024
3 Gate
Bonnet U115005,U115006,U11500a
U115010
600 5" - 24" Ul15012, Ul15014, U115016
U11501a, U115020, U115022 C
Ul15024
4 Gate Bolted D
150 a" - 12" U21200a, U212010, U212012
Bonnet
150 5"- 6" U212005, U212006 D
5 Gate Baaed
Bonnet 5" - 12"- U213005,U213006
300 0
U21300a,U213010,U213012
Pressure 900 2-1/2" - 4" Ul16002, U116003, U116004
7 ·Gate Seal 1500 2-1/2" - 4" Ul17002, Ul17003, U117004
Bonnet '2500 2-1/2"- 4" Ul19002, U119002, U119002
Ul1600S, U116006, U11600a
900 5" - 16" U116010, Ul16012, Ul16014
C
U116016
Pressure U11700S, U117006
8 Gate Seal 1500 5" -16"- Ul17008, U117010, U117012
Bonnet C
U117014, U117016
U11900S
2500 5" -10"
Ul19006, U119008, U119010 C
Ul17006, U117008, Ul17010
Pressure 1500 6" - .16"
Ul17012, U117014, Ul17016
9 Gate Seal E
Bonnet U119006, U119008, U119010
2500 6" - t6"
Ul19012, Ul19014, U119016
U132002,U132003,U132004 A
lS0 2-1/2" - 16" U13200S,U132006,U132008
U132010,U132012,U132014 F
U132016
Bolted U133002,U133003,U133004 A
10 Globe
Bonnet 300 2-1/2" - 12" U13300S,U133006
U133008,U133010,U133012 F
U134002,U134003,U134004
400 2-1/2" - 10" Ul3400S
U134006,U134008,U134010 F
Bolted 600 2-1/2'~,3" U13S002,U135003
11 Globe
Bonnet 900 2-1/2",3" U136002, U136003 F

e
Design
Type of Type of UTE Type No. Remarks
Style Class Valve Size
Valve Seal
No.
U135004,U135005, U135006
Bolted 600 4" - 12"
12 Globe U13500S,U135010,U135012
Bonnet
900 4" - 6" U136004,U136005,U136006
Pressure 1500 2-1/2",3" U137002,U137003
13 Globe Seal
Bonnet 2500 2-1/2",3" U139002,U139003
Pressure 1500 4",5" U137004,U137005
14 Globe Seal
Bonnet 2500 4",5" U139004,U139005
-_ ...-._- .._- ----.
900 S",10" U336008,U336010
Pressure U137006
15 Globe Seal 1500 6·', S" U13700S
Bonnet C
2500 6", S" U139006,U13900a C
Swing Bolted 150 2-1/2"- 4" U162002,U162003,U162004
17
Check Cover 300 2-112" - 4" U163002,U163003,U163004
150 S" _ a" U262005,U262006,U26200a
300 5"- a" U263005,U263006,U263008
la Swing Bolted U264002,U264003,U264004
Check Cover 400 2-1/2"- 6" U264005,U264006
600 2-1/2"- 6" U265002,U265003,U265004
U265005,U265006
150 10" - 14" U162010,U162012,U162014
300 10" - 14" U163010,U163012,U163014
19 Swing Bolted
Check Cover 400 S" - 14" U16400S,U164010,U164012
U164014
600 S" - 12" U16500a,U165010, U165012
U166002,U166003,U166004
900 2-1/2"- 10" U166005,U166006,U166008
U166010
Swing Pressure U167002,U167003,U167004
20 Check Seal 1500 2-1/2"- 10" U167005,U167006,U16700a
Cover U167010
U169002,U169003,U169004
2500 2-1/2"- 10" U169005,U169006,U169008
U169010

NOTE: The above individual initial at "Remarks" column indicates

the following meanings: .
A . • . Headed bolt is used for bonnet.
S • •• Solid disc is used (The flexible disc is usually used
lor a gate valve. See page 27.1
C . . . Geared operation is applicable. This attachment is
classi lied into Style 6 illustrated in Fig. 12 on
page 8
o ... This type indicates EXCO·Valves. Features 01
EXCO·C type are as follows:
1) Headed bolt is used lor bonnet and flange connec-
tion. There are screw holes in the body flange.
21 Gland bolt is cup square neck bolt. See Fig. 5.
3) For guide of the disc, U·ring fixed in the groove
of the body is used. Sea Fig. 6.
E Closed Oia Forged (eOF) body is designed in
this stYle.
F Hammer blow handwheel is used.

Fig.5 Cup SquareNeck Bolt Fig.6 U·Ring

e
7. Design Styles of UTE Standard Valve

Design styles of UTE standard valves (Style 1 to Style 20)

are illustrated in the following Fig, 7 to Fig. 26.

7·1 Gate Valve

7·1·1 Bolted Bonnet Type, Style 1,2,3,4,5 and 6.

This type is illustrated in the following Fig. 7, 8, 9,10,11 and 12.

Fig. 7 Style 1 Fig. 8 Style 2

See Table 2 for part names

Fig. 9 Style 3 Fig. 10 Style 4

See Table 2 for part names

,
I I

Fig. 11 Style 5 Fig. 12 Style 6

Table 2. Name of Parts (Style 1,2,3,4,5, and 6)
1 Body 21 Key
2 Bonnet 22 Handwheel Nut
3 Disc 23 Adjusting Nut
4 Yoke 27 Split Pin
5 Handwheel 30 Set Screw
Yoke Flange or 31 Washer
6 Yoke Nut
7 Seat Ring 32 Washer
8 Stem 34 Bevel Gear
9 Bonnet Bushing 35 Pinion
10 Packing Stop Ring 37 Thrust Ball Bearing
11 Lantern Ring 38 Grease Nipple
12 Gland Ring 39 Packing
13 Yoke Sleeve 40 Gasket
14 Gland Flange 41 Spindle
15 Bonnet Bolt and Nut 42 Marker Plate
16 Gland Bolt and Nut 52 Hexagonal Nut
17 Yoke Bolt and Nut 53 S~:it Pin
18 Hexagonal Bolt 54 Gear Cover
19 Pin 80 Disc Guide
20 Taper Pin
7·1·2 Pressure Seal Bonnet Type, Style 7,8 and 9
This type is illustrated in the following Fig. 13, 14 and 15.

Fig. 13 Style 7

See Table 3 for part names

o
I

Fig. 14 Style 8

Table 3. Name of Parts

(Style 7, Style 8 and Geared Operation)
1 Body 37 Thrust Ball Bearing
2 Bonnet 38 Grease Nipple
3 Disc: 39 Packing
4 Yoke 42 Marker Plate
5 Handwheel 44 Stem Cover
7 Seat Ring 54 Gear Cover
8 Stem 69 Seal Ring
10 Packing Stop Ring 71 Adjusting Nut
12 Gland Ring 73 Retainer
13 Yoke Sleeve 74 Bonnet Clamp
14 Gland Flanqe 76 Gland Bolt Clamp
16 Gland Bolt and Nut 77 Stud Bolt and Nut
19 Pin 78 Adapter RinQ
21 Key 79 Bolt and Nut
27 Split Pin 84 Indicator
30 Set Screw 85 Yoke Fixing Plate
31 Washer 86 Hexaconal Nut
34 Bevel Gear 87 Yoke Bolt and Nut
Fig. 15 Geared Operation 35 Pinion 90 -Nut
Fig. 16 Style 9

Table 4. Name of Parts (Style 9)

1 Body 39 Packing
2 Bonnet 40 Seal Ring
3 Disc 41 Pinion Shaft
4 Yoke 42·1 Marker Plate
5 Handwheel 44' Stem Cover
7 Seat Ring 45 Collar
8 Stem 47 Snap Ring
10 Packin~ Stop Ring 52 Hexagonal Nut
12 Gland Ring 53 Split Pin
13 Yoke Sleeve 54 Gear Cover
14 Gland Flange 73 Retainer
Yoke Clamp Bolt Bonnet Clamp
15 74
and Nut
16 Gland Bolt Yoke Clamp
74·1
21 Key 75Disc Guide Pin
23 Adjusting Nut Gland Bolt Clamp
76
Bonnet Stud and
27 Split Pin 77 Hexaoonal Nuts
29 By-pass Valve 78 Adapter Ring
30 Set Screw 79 Bolt and Hexagonal Nut
34 Bevel Gear 80 Disc Guide
35 Pinion 82 Sleeve Nut
36 Pipe 83 Set Bolt
37 Thrust Ball Bearing 84 Indicator
38 Grease Nipple 96 Bush
7·2 Globe Valve

7·2·1 Bolted Bonnet Type, Style 10, 11 and 12

This type is illustrated in the following Fig. 17, 18 and 19.

Fig. 17 Style 10 Fig. 1.8 Style 11

See Table 5 for part names

Fig. 19 Style 12

Table 5. Name of Parts (Style x 10, 11 and 12)

1 Body 18 Stem Stopper
2 Bonnet 19 Pin
3 Disc 20 Bolt
4 Yoke 22 Hexagonal Nut
5 Handwheel 23 Clutch
6 Disc Nut 26 Handwheel Plate
8 Stem 27 Split Pin
9 Bonnet Bushing 28 Key
10 Packing Stop Ring 30 Set Screw
12 Gland Ring 31 Washer
Yoke Bushing
37 Thrust Ball Bearing
13 (Style 10 and 11)
Yoke Sleeve (Style 121 38 Grease Nipple
14 Gland Flange 39 Packing
15 Bonnet Bolt and Nut 40 Gasket
16 Gland Bolt and Nut 42 Marker Plate
17 Stem Pad 83 Bolt
7·2·2 Pressure Seal Bonnet Type, Style 13,14 and 15

This type is illustrated in the following Fig. 20, 21 and 22.

Fig. 20 Style 13

See Table 6 for part names

®-
!b ZO
@
~
@j----

" @
qO,

Fig. 21 Style 14

See Table 6 for part names

Fig. 22 Style 15

Table 6. Name of Parts (Style 13, 14 and 15)

1 Body 23 Clutch
2 Bonnet 26 Handwheel Plate
3 Disc 27 Split Pin
4 Yoke 28 Key
5 Handwheel 30 Set Screw
6 Disc Nut 31 Washer
8 Stem 37 Thrust Ball Bearing
10 Packing Stop Ring 38 Grease Nipple
12 Gland Ring 39 Packing
Yoke Bushing (Style 13) 40 Seal Ring
13 Yoke Sleeve
73 Retainer
(Style 14 and 15)
14 Gland Flange 74 Bonnet Clamp
15 Yoke Bolt and Nut 76 Gland Bolt Clamp
16 Gland Bolt and Nut 77 Washer
17 Stem Pad 78 Adapter Ring
18 Stem Stopper 79 Bolt and Nut
19 Pin 85 Yoke Stopper
20 Bolt 86 Set Bolt
21 Key 90 Nut
22 Handwheel Nut 90-1 Hex. Bolt
8·2 Globe Valve
The motor operated globe valve is illustrated in Fig. 30.
Fig. 30 and Fig. 32 show how to mount the operator .unit on
the valve by a single flange and a double flange respectively.
In case of Class 150, 10" and larger, as well as Class 300,
S" and larger, the operator unit should be mounted on the
specially made bonnet or yoke extension as shown in Fig. 31.

Fig. 30 Motor Operated Globe Valve

See Table 10 for part names

Fig. 31. Special Bonnet or Yoke Type Fig. 32 Double Flange Connection Type

Table 10. Name of Parts (Fig. 30, 31 and 32)

1 Body 68 Upper Flange
2 Bonnet 69 Lower Flange
8 Stem 87 Motor
Hexagonal Cap Screw
13 Yoke Bushing 92 Bolt
38 Grease Nipple 93 Hexagonal Bolt
67 Control Unit 93·1 Spring Washer
1. Receiving Inspection and Storage

!6CAUTION]
1·1 Matters Related to Quality Assurance Documentation 1·5 Space Heaters for Motors
The LimiTorque and Rotork operators are not weatherproof
If customers purchased valves produced under our Quality until properly installed. If the unit is to be stored in a damp
Assurance Program, check the package of documents to see place before installation, a space heater should be used until
whether they match purchase order and instructions or not.
the unit has been installed in its proper place so it can be
kept dry. The following table 11 shows the rating of heaters
1·2 Receiving Report to be used for various voltages.
(For more detailed information, see the marker plate at Drive
When the package arrives on location, check and issue a Section or Instruction Manual of Motor Actuator.)
report whether the valves have been damaged during trans-
portation or whether there are signs of damage. Table 11. Rating of Heaters
If it is judged that the damage is serious enough to affect the
function and installation of the valves, send us a report stating Heater Resistance
Voltage (V) Watts (W)
(Ohms)
the exact conditions so that we can apply the proper treatment
( . repairs without delay. 100- 125 20 900
LimiTorque 200 - 240 20 3500
400 - 460 20 12000
.1·3Storage 100 10 1000
200 10 5000
Rotork
1·3·1 The valves should be kept crated until immediately 400 10 20000
before installation and stored in a suitable place to prevent 120 15 2000
contamination by weather, dirt, moisture, etc.

1·3·2 Special attention should be paid to the life of the seal

material in the valve. In case the storage period of delivered
valves is expected to last more than 2 years, seals and packing
rings should be renewed before valve installation.

1·3·3 Stainless steel valves must all be stored indoors. They

must be stored apart from carbon steel and nonferrous valves
where there is a clear boundary line. In addition, the crate
must be wrapped in a polyethylene sheet and kept as clean
as possible when purchased.

( 'I. Precaution on Storage before Piping 1& CAUHOOI

'rlOished products are protected by the prescribed packing
after final inspection and then shipped. Be especially careful
that no foreign matter gets inside whim transporting them
after they have been unpacked, and avoid placing them out·
doors or where there is a lot of dirt. Even fine sand will cause
damage to the seat and flange surfaces.
When storing for a long time, remove dirt from the surfaces
and put a suitable oil on the surfaces to prevent rusting. Pay
special attention to choosing a damp-free, well ventilated
space for long period storage. Don't put them directly on a
dirt or concrete floor. An effective way to prevent moisture is
to put the valves on top of sleepers, blocks, etc. Pay special
attention to these instructions with stainless steel valves.
Namely, use sleepers as storage platform, i.e. wooden or stain.
less steel plates where there is direct contact. Take the proper
steps so the valves don't directly touch metal with a low
melting point (lead, zinc, tin, etc.) and other nonferrous
metals. Be sure to clean the inside of the valves with a dry
cloth before installation.
2. Handling and Preparation for Installation 3. Installation

2·' End Protectors 1& CAUTIONI 3·' Before Installation

Remove the end protectors from the valves, and examine to Before installation check once again whether or not the
see if there is damage to the ends and if they are clean. When position of the valve matches the piping layout drawings.
removing the protectors, check if there is any visible foreign
matter inside the valve and if there is, remove it completely. 3·2 Providing Sufficient Space
On weld-end valves, clean the weld end preparation with a
suitable solvent such as acetone or its equivalent. It is important to provide sufficient space for inserting
(Do not use chloride or fluoride·containing solvents.) and removing packing material and for disassembling and reas-
sembling the valve itself. Long term leak-free service of a valve
depends on proper maintenance service.
2·2 Transporting and Lifting
3·3 Installing Position to Piping
2·2·' When lifting large valves for transport, pass a wire
around the cover or yoke in such a way as not to touch the
( nandwheel and adjust it so the entire valve can be lifted as
Stop valves (globe, angle) and gate valves should be installed
vertically for horizontal piping. It is known that valve stems
vertically as possible to the place where it is to be finally oriented vertically give much better performance as compared
installed. Under no circumstances should you put the wire on with valve stems oriented horizontally or at an ·angle between
the handwheel or electric drive to lift it that way. 1& DANGER I 0° and 90°. Valve stem leakage is likely to occur much more
With swing check valves, use the hoist bolt incorporated in frequently if valve stems are other than vertical.
the top of the cover. ~ Pay attention to the following valves because the installing
2·2·2 Use stainless steel wire cable or hemp rope when hoisting position affects their function.
stainless steel valves. Ordinary carbon steel wire should not be
used. 1 It CAUTION I 3·3·' Check Valves
When raising and lowering during transport, be careful that the
1) Lift Check Valve
valve doesn't come in contact with carbon steel material on
Install the valve disc guide vertically for horizontal piping.
the loading platform, etc. But protect it with sleepers or a
2) Stop Check Valve .
sheet. IitCAUTION I Install the valve stem vertically for horizontal piping.
3) Swing Check Valve -
2.3 Special Instructions for Flow Directional Piping and Valve The cover should be on top for horizontal piping but upward
Connection flow is also possible with vertical piping. However, there is
also a difference in performance depending on the pressure
Special attention must be paid to the direction' of flow when difference before and after the valve and on the installing toea-
connecting these to the piping, as the marking on the valve
tion. For critical service valves such as extraction check valves,
body indicates. we take special considerations in manufacturing and handling.
State your specifications clearly when you order these valves.
2·3·' Gate Valves
order these valves.
Unless otherwise specified, either end of the valve can be the
inlet. In other words, with this valve the flow can be from
3·3·2 Motor Operated Valves
either direction. Motor operated valves.should be installed vertically for hori-
zontal piping. It is known that valve stems oriented vertically
2·3·2 Globe Valves ILh CAUTIONI give much better performance as compared with valve stems
The inlet for fluid is usually located below the valve disc.
oriented horizontally or at an angle between 0° and 90°.
Special care must be paid to this point when installing to avoid
Valve stem leakage is likely to occur much more frequently
wrong installation. The globe valve is used for intermediate
if valve stems are other than vertical.
opening and at this position there is sometimes wear, vibration,
noise, etc. If these phenomena continue, the result will be
major damage to the valve stem, disc, etc. So we ask you to
report these phenomena to us as soon as they occur, so that 3·4Installation during Piping
we can provide proper treatment.
3·4·' Valve Check
2·3·3 Swing Check Valves
Since the valves. are finished to meet plpang specifications
The valves can only be installed with the inlet located below when installing, check the markings (pressure, bore, flo'/l
the disc. Pay careful attention to this principle during installa- direction, valve number, etc.) on the body surface and als(
tion. the name plate on top of the handle.
3-4-2 Precautions about Joints during Installation f]
1) Valves with Flanges Special care must be paid to the temperature distribution in
When the valves are connected to pipe with flanges, tighten the welding area. The same applies to stress relieving after
the bolts alternately on opposite corners so the gasket will be welding. Uneven distribution of temperature in the welding
tightened evenly. area will deform the seat and cause leakage.
g)
2) Valves with Welding Ends I&. CAUTIOO I
We will give our recommendations, if requested; however, the
a) responsibility for welding valves rests with the user.
Welding and stress-relieving should be done on the assembled
valve, and the valve shouldn't be closed but slightly open with 3-4-3 Other precautions
the disc and seat lightly touching. (It is not recommended to Lagging is necessary for valve bodies and bonnets of valves
weld valves with tlre bonnet and internal parts disassembled used for high temperature service. Never provide this measure
from the body.) For partial stress-relieving, heat the necessary on the stuffing box on top of the bonnet, but cool it naturally.
range of area of welds between pipe and welding-end valves.
Don't add excessive heat to the valve body and seat. Be very
careful with the rate of cooling. When welding many valves, 3-5 Motor Operated Valves
elbows, reducers, etc. in a loop, the piping must have a flexible After the valve has been installed in the piping line and when
, ·'cture. the welding and heat treatment of the end are finished, the
\ motor can be wired and connected to the power line. When
b) wiring the motor, follow the wiring diagram that was supplied
Basically the valves are designed to withstand the effect of with the motor.
heat during welding but they must be welded in accordance
with the ASME Boiler and Pressure Vessel Code Section
III, the Code for Pressure Piping ANSI B31.1 and other appli- 3-6 Checking of Limit Switches
cable standards, and the welding must be performed by
Before operating a motorized valve with motor, first inspect
technically qualified welders.
the setting of the limit switches. 1& CAUTION I .
Welding procedure specifications depend upon material to be
Disconnect the control and power circuits when inspecting
welded, welding classification, position, etc. Please refer to
the limit switches. ILK DANGER I
individual manuals. In which welding rods, preheating, post For details, refer to the Instruction Manual for the operator.
heating, electric current, polarity, etc. are specified. Welding
procedure should be first tested and checked. After finishing
the above preliminary arrangements, start the actual welding.
After the welding is finished remove slag, 'spatter, backing ring,
etc. and take special care that no foreign matter gets in the
valve.

c)
When welding BW (butt-weld) valves, be careful not to deposit
( ) much welding metal in the fillet welds. Excessive welding
may distort the valve body and may affect the tightness of
sealing between body and bonnet. In addition, maintain at
least a 1/16" clearance between pipe end and valve body or
valve ends on socketweld valves,

d)
On valve bodies of austenitic stainless steels such as 304 or 316
type, pay attention to the following points to prevent sensitiza-
tion when welding.
* Temperature in the heat-affected welding area should not
exceed 4 30" C for more than a maximum of 7 minutes.
* After the first welding pass, the temperature of the weld
metal should drop to 180°C before the next pass is made.

e)
Special care must be taken when welding valves with soft and
resilient material such as Teflon for the valve seat and packing
ring. This kind of material is affected at high temperatures
and is damaged by excessive heat.
WELL BEGUN IS HALF DONE.
(

•
SECTION III OPERATION
AND PREVENTIVE MAINTENANCE
1. Opening and Closing Opening and closing by this structure is possible with smaller
torque than that needed with ordinary solid disc.
In addition, there is an adjusting nut as a stopper on top of
all stems, so you don't tighten too much when closing valves
1·1 Periodical Inspection of Valves 1 LiS CAUTION I with this structure. Therefore, when closing the valve, stop it
slightly before the stopper and when 'it lightly touches, then
It is important to have periodical inspection of valves during turn the handwheel 1/4 or 1/2 turn backwards.
operations, and close attention is to be paid in order to avoid Use the valve fully open as much as possible when opening it.
eventual development of trouble. Some valves are not operated When using the valves slightly or half opened, be careful
as frequently as others, and they may be kept open or closed because the high velocity of the fluid may cause the disc to
for a long period of time. However, they should be inspected . vibrate and the sealinq part to erode.
at least once a month, for proper maintenance service. If you take off the handwheel from valves ofStyle-l, 7 and 8
in Section 1-7 while the valve is open and the stem is moved
1-2 Manually Operated Valve vertically, be careful so that the stem, disc, etc. do not fall
inside.
Unless otherwise specified, valves close when the handwheel is
turned clockwise.
1-2-2 Globe Valve
.1 Wedge Gate Valves '1 LiS CAUTION I
"-1 , When tightening, sufficient force 'must be applied to the
" .e valves, except at extremely low pressure, use the pressure handwheel to maintain the seat tightness, but don't overtighten
of the fluid to press and seal the disc tightly to the seat of the with a large auxiliary lever, etc. In addition, a large closing
outlet side of the body. This means that, just as with stop force is needed for large size and high pressure valves, so they
valves, no large force is required for tightening. are equipped with hammer blow handwheels. See Fig. 34.
If the valve is tightened too tight with excessive torque, the The usable ranges with valve size of the handwheel are shown
valve stem will expand at high temperatures, press the disc in the following Table 12.
into the seat and make opening difficult. Therefore, the usual
way is to turn the handwheel (approx. 1/4 - 1/2 turn) in
reverse and keep it there until there is no gap in the disc and
stem T-head.
We took into consideration leaks and the above mentioned
points such as heat, distortion, etc. caused by deformation of
the body and used a flexible structure except for small size
valves (4" and smaller). Fig. 33 illustrates a flexible disc.

Fig. 34 Hammer Blow Handwheel

( Table 12.
2500

This handwheel is built to tighten by means of inertia from

blows and a small force creates a large tightening force, so be
careful that you don't tighten more than necessary.
When closing the valve, you can't close it completely if scale,
dust, etc. from the fluid get into the seat. At such times, don't
force the valve but open it again a little, remove the foreign
matter and tighten it again.
Fig. 33 Flexible Disc Standard stop valves should be used slightly back seated and
fully opened but a certain extent of flow control is possible.
However, if they are used slightly open when there is a high
pressure difference between inlet and outlet of flow path,
the seat will be eroded by the high velocity of the fluid, so
when flow control is needed use a needle disc valve or flow
control valve that has the right structure.
1-3 Motor Operated Valves 1& CAUTIOO I 6) After the torque switches of the gate valves and globe
valves (opening only) have been operated. the switches must
Pay attention to the following precautions when operating be readjusted. Adjust them according to the instructions
motorized valves. (Refer to Operator Instruction Manual of in the Operator Manual.
usual method.) 7) When returning the switch compartment cover. fasten the
1) Inspect for dust or foreign matter in the threads or damage bolts correctly. In addition. use conduit tubes or suitable
after connecting the electrical wiring and before starting connectors for the electrical supply entrance to prevent
operation. intrusion of water or rain.
2) Declutch the lever to shift to manual operation. and turn
the handwheel to check whether it moves smoothly or not. 2. Lubrication IltcAuTiONI
3) Open up to halfway of the valve lift manually. and switch Periodically grease the threads of the stem to facilitate easy
on the electric power ·to check the opening and closing opening and closing of the valve. Our UTE large size valves
directions of the stem. If it turns in reverse. replace one and gate valves have grease nipples. (Valves with revolving and
power source wire with another one. rising type stem do not have nipples for grease. so apply grease
directly to stem threads.) In addition. sometimes dust from
4) Check for operation of the opening and closing limit
outside. oil from packing rings. etc. stick to this part of the
switches by watching the dial indicator on the operator.
stem. which will result in heavy or difficult handwheel opera-
Standard seating controls for UTE valves are as follows:
tion. so take care of the stem at the same time.
( Gate Valve: Controlled by the position limit switch for
Also apply the proper amount of oil or grease to the revolving
both opening and closing. It has a torque
parts of gears and remote control operator.
switch for protection that opens with excessive
Read the Instruction Manual for the motor. LimiTorque.
torque.
Rotork or others. Then apply a lubricant according to lnstruc-
Globe Valve: Controlled by torque switch for closing and
tions. Lubrication inspection for the motor operated valve is
by position limit switch for opening. It has a
recommended at regular intervals of approximately six months.
torque switch for protection.
UTE's recommended lubricant and frequency of application
5) Check if there is unusual noise or not. are shown in Table 13.

Table 13. UTE Recommendable Lubrication

......_----- --- __ . _. .__ ._._-_., --',
~I-- St.mTh",ads
_•..__
Yoke Sleeve
• •
All threaded pa'"
'except Ilem & StuffingBox Gears, Bearings
inUtrN' ~!.'!..I-11------+--:.-------
Daphne Carnex Oaphne Cornex Oaphne Cornex
10EMITSU Gr.... EPNo.0 Gr.... EPNo_0 Gr••se EPNo.0
Daphne XCZ No.1 Dophn.XCZ No.1
MOBIL(JAPAN) MobilTemp1 Mobilr.mp 1 MobilTemp1
____ • j.-::M~0~b.~ilp~I.~x.::4~7
__ l-
J.,..:M~0~bi~lp~I.:!x.::4!..7
__ l- -!...:::M:::ob:::;iI:J::p;.:I.::_x
.:.47:""_1
HURONINDUSTRIES N.oIube
(USA) in case of
__ Nuclear Valve .._
---------~-------+-----~r_------_1
""NEVERSEEZ--- Never Seez
Never Seez
COMPOUND CORP.
MOLYKOTE MoIykot."G"
CORP.(USA) or equal

( GULF
G. Crown
Gr.... (EP)No.0
G. Crown
Gr.as.(EP)No.O
G. Crown
Greas.(EP)No.0
or equal or equal or equal
Alnni. No. 0 Alvania No. 0 Alvania No..0
SHELL or equal 01' .qull or equal
~-------~M~O;bi~IU~X---~;M~o~bi~IU~x---~-------~-------1-~M~ob~il;~UX~------
MOBIL(USA) Grease No. 0 Grelse No. 0 Grease No.O
M~ M~ m~
Ustan 0 Ustaft 0 Listan 0
ESSO or equal or equal or equal

=~~~~~read
Directly Directly Directly Directly Dir.c'''tl'-y:-to---1
APPLICATION to Threads to Threads to Thre.cls to Surface Threads or Surface

When Threads When Threads On valve When appears

FREQUENCY _a r dry -pear dry o..emblyonly_L dry
L- , _L ~N~~~ic.~ti~on~ i__~ _L _"

2) Excessive rise of pressure in gate valves.

3. Elimination of Drain Il:h DANGER I If the drain is left over or closed. and if its temperature is
accidentally raised in the gate valve body. there is danger
If the drain remains in the piping line. the following troubles of an abnormal rise of the inside pressure from the fluid
may occur. To avoid those. be sure to eliminate the drain expansion. of leaks from the gasket. of the valve becoming
completely when warming up before starting operation. hard to open and of damage to the valve. So be especially
careful about high temperature when using pressure seal
1) Leaks from the seat and gasket caused by the body deform- type valves.
ation from temperature gradient and effect of heat.
3) Water hammer.
There is a possibility to incur water hammer which will
consequently damage the disc.
SECTION IV MAINTENANCE

1. Packing Adjustment to Stem Leaks lit CAUTION I

It is known that leakage of fluid around the stem is most

frequently observed. If your valve develops such a leak, eli-
minate it by tightening the gland bolt nuts evenly. The com-
pressive force on packings being increased, leaks will stop if this
adjustment is made soon after the leakage starts and the packing
material is relatively new, that is, has not lost its resilience in
service.

2. Other Points to Stem Leaks 1£ CAUTION I

Stem leaks may have been caused by the following points.

So before deciding to replace old packings, investigate them. Fig. 35-a Removal of Packing
If the gland ring has been fully taken up and is touching the
bonnet, add additional packing rings. If the stem is deeply
( . Itched or otherwise damaged from careless handling and has
worn, tapered or been bent, the stem should be replaced.
If the split packings have not been staggered appropriately
around the stem (each consecutive ring should be staggered
90° to 1800 apart). the packing rings should be inserted ap-
propriately. If the gland ring is binding against the stuffing box
wall or stem and does not compress the packing appropriately,
the gland ring has to be aligned and tightened down equally
on all sides.

3. Replacement of Packing

Fig. 35-b Packing Tool Kit

3-2 Replacement of Packing Rings

Having gland flange and gland ring lifted and held in position
by a wire holding the bushings to handwheel after gland bolts
have been removed (swing bolts hang down), proceed packing
removal. The packing should be taken out individually by
using special flexible removal tools, See Fig. 35-a, Fig. 35-b
2'5-
and Fig. 35-c.
r ..:~~.. --- ... =:><........

Fig. 35-1: Packing Tools

3-3 Cleaning the Stuffing Box ILhCAUTION I Stuff each ring into place one at a time. Do not try to stuff
in two or three rings at once.
Clean and inspect the interior surface of the stuffing box
Fit the lantern ring into position without stuffing up the
after removing the old packing and lantern ring.
impregnation hole.
If the old packing has left a stain, remove it completely with
Fit the packing rings in such a way that the cut ends are stag-
care and make certain that there is no dirt or foreign matter
gered at 90 - 180 degrees as shown in Fig. 38~&CAUTION/-
remaining in the box. Clean the impact part of bush and stem,
inspect for flaws or abnormal appearance, and make any 1 4
correction that may be necessary. Use fine mesh emery-paper
if the impact part is to be polished.

3-4 Lubrication of the Valve Parts

Before inserting the packing into the stuffing box, lubricate

the inner surface of stuffing box, stem, bush, etc. with suitable
2
lubricant. Also apply a little "Never-Seez" to each ring of
packing to be fitted into place. SeeTable 13 on page 28.
Fig. 38 Packing-Fitting Staggered
"l~5Insertion of New Packing
( When all packing rings have been fitted into place, clamp with
Carefully spread the rings open and fit them around the stem. gland bolts.
Open the ring by twisting the cut ends as shown in Fig. 36.
Adjust bolts alternately and little by little so as to ensure equal

e
pressure all around. If bolts are clamped tight all at one time,
clamping is likely to be one-sided, which will give rise to
unequal surface pressure. Cycle the valve at least 5 times from
full closed to full open position, whenever possible under line
pressure, and retighten gland nuts. lit; CAUTION I
t
Wrong Way
Fig. 36 Fitting Method of New Packing 3-6 Completion of Process and Operation ILh CAUTION I
If the rings are pulled straight open, there is a danger that When replacement work is completed, leave packings as they
the back of the ring may be split. Once the, ring has been are for a..whole day before operation to ensure that the clamp-
fitted around the stem, push it down into the stuffing box, ing force will be equally distributed.
with your fingers, making sure that the cut ends fit together For a while after resumption of operation, slight leakage may
uniformly. When pushing into the stuffing box, make sure that occur, due to the fact that packing is not yet adjusted to its
ring stays at right angle to the stem. actual service. So clamp again, but do it slowly with adjust-
It is important that each packing ring clamps firmly into place ment.
( , such a way that contact pressure is equal at all points. To
ensure this, it is convenient to push the packing into place by
using a wooden tube split in two, utilizing the gland as shown 4. Disassembly and Reassembly
in Fig. 37.
4-' General
4-'-' Study Procedures of Disassembly and Reassembly
Weexplained our design in Section I for UTE valvesand showed
illustration of each style. However, in the next paragraph 4-2,
we set down the Procedures of Disassembly and Reassembly
for our valves. It's' a bit bothersome, but read this Section
IV until you fully understand disassembly and reassembly.
and then make your maintenance plan.

Wooden Split Tube

Fig. 37 Gland for Packing Fitting

4·1·2 Steps before Disassembly of Valve 4·1·3 Precautions before Disassembly; 1& CAUTION I
1) Estimate possible troubles and their causes. 1) Make space around the valve and- prepare containers for
disassembled parts, especially for small parts.
2) Check the marker plate and record the marking, size, type;
etc. of the valve. 2) With motor operated valves, turn off the power, and check
3) Check the model number and drawing of the valve, and
the position 'of the limit switches, etc. and mark them.
study the structure and material on the pertinent drawing. 3) When dismantling a valve with leak-off connection, take
4) Check for the existence of spare parts for th at valve. off the water supply pipe (or leak-off pipe).

5) Read carefully the disassembly and reassembly procedure 4) Check the valve in open and closed positions and the clear-
for that valve. ance, etc. in all directions.
6) Plan your disassembly, repair, change of parts, reassembly 5) Turn the handwheel one revolution open from the closed
and adjustment. Prepare the necessary tools, machines and position, so it is slightly open.
material. 6) Check the temperature and pressure inside the piping.
Make and put up a sign saying "Under Repair", and tell
those associated with the work about the repair. Check for
safe operation and repair.
7) Loosen the gland bolts slightly, but don't take out the
packing u nless necessary.
8) Put strong penetrating oil on the stud bolts and nuts
holding the bonnet and cover, but don't torce them. If the
valves have been used for a very long time at high tempera-
tures, the nuts may be seized. If you warm this part, they
will turn easier. Don't use a cutting' torch or cold chisel to
remove them unless absolutely necessary.
9) If the outer diameter of the bolted bonnet flange doesn't
touch, measure and record that clearance. This will help
when you have to readjust during reassembly.

4·1-4 Body·Bonnet Bolt Torques ILt;; CAUTlct41

Fig.39·a Valve disassembling Fig.39·b Valve disassembling Body-bonnet bolts must be tightened with proper torque
wrench at the final torque value rated below in Table 14.

Table 14. Body-Bonnet Bolt Torques

Bolt Dia. Torque H,"(kgf·.)

MI ( 63.7 (6.5)
M 16 9R.1 (10)
M1 8 131.3 (14)
M20 196.1 (20)
M2 2 214.6 (28)
( M2 4 343.2 (35)
M21 509.9 (52)
M30 x 3 706.1 (12)
M3 3 x 3 931.6 (95)
M3 6 x 3 1177 (120)
M3 9 x 3 1520 (155)
M4 2 x 3 1961 (200)
M( 8 x 3 2942 (300)
M5 6 x 3 4903 (SOO)
, Fig. 39·c Valve disassembling
M6 4 x 3 7453 (160)

The above Fig. 39·a, Fig. 39·b and Fig. 39·c show the disas- The bolts (or nuts) should be gradually tightened a little at
sembly scenes of UTE pressure seal gate valve (Style 9) which a time and alternately in the turn as numbered in Fig. 40, to
is mounted in upside down posture. Before starting any main- prevent one-sided tightening and to keep the pressure on the
tenance/repair service, be sure to provide your servicemen with gasket surf ace evenly.
all necessary tools and hardwares.
5. Mark the position or record set length of adjusting nut (2)
on the stem, so it will not be changed. Take out split pin ®
and the adjusting nut. This step will apply to Style 2 and 3
and also in case of Style I, to Type No. U114004 - Ul 14006
and UI15004. Then secure the valve stem so it doesn't
turn. Turn the handwheel in the closing direction, disengage
yoke sleeve and stem. Then remove it.
6. Remove the gland bolt nut, gland flange @ and gland ring
@. Take off packing ® and lantern ring @ from the stuff-
ing box.
7. For disassembly of the handwheel from the bonnet and
yoke, loosen set screw 09. (Style 1 and J of small size do
not have set screw ®, but one point of screw is stopped
with calking.) Turn the handwheel nut counterclockwise
and remove from the yoke sleeve. For Style I, the yoke
sleeve must also be removed from the bonnet, but be
careful not to lose key ® and washers ® and @.
Fig.40 Bolt Tightening Sequence 8. For Style 2 and J, when you take out hexagonal bolt @,
then yoke flange® yoke sleeve @. thrust ball bearing ®,
4.1.5 Packing Gland Bolt Torques etc. can be removed from the yoke. In addition, for Style 4
and 5, cut off the tack weld, and turn yoke nut@counter·
When replacement of old packing ring is completed, gland
bolts must be tightened applying the maximum torque limit clockwise for removal.
as rated in the following Table 15. 9. For the gear mechanism of Style 6, remove gear cover ®
first. Removal of other parts is the same as for other styles.
Table 15. Packing Gland Bolt Torques However, when you remove pinion fix,ing nut, you can
remove bevel gear ® and pinion ®.
Bolt Dia Torque H -. (kg f -.)

(1.1) (b) Reassembly

M 10 10.8
M 1 Z 19.6 (2) 1. Clean and inspect the interior surface of the valve body
M'l 6 49.0 (5) and parts. (Be especially careful of emery powder after
M 1 8 68.6 (7) lapping.)
MZO 98.1 (10)
131.3 (14) 2. Apply a lubricant such as "Molykote" or "Never-Seez"
MZZ
111.6 (11.5), to prevent bonnet bolt @, gland bolt @, etc. from seizing.
M Z 4
M Z 7 255.0 (26) J. Fit the yoke sleeve, handwheel. etc. to the bonnet in
M30 353.0 (36) reverse order to Step 7 and 8 of disassembly procedure.
M 3 3 460.9 (41)
Then insert packing stop ring ®, lantern ring @, gland ring
M 3 6 588.4 (60) @. gland flange <13>, etc. in their proper positions, and
insert the stem. Next, check the marks and screw adjusting
( 4-2 Procedures of Disassembly and Reassembly
nut (l) to the top of the stem, and fix with the split pin ~.
4. Apply "Never·Seez" or equivalent tq- the gasket. {How·
4-2.' Gate Valve - (11 Bolted Bonnet Type, Style 1, 2, 3,
4,5 and 6 ever, don't apply it it the gasket is a metal plate or spiral
(See Fig. 7, 8, 9, 10, II, 12 and Table 2 in Section (·7, on wound gasket.1 Then insert it in the body.
Hang the disc on the end of the above-mentioned assembled
page 6, 7.8.1
T·head stem, and fit it to the body while checking the
(a) Disassembly position of the guide rail and mark.
1. Turn handwheel(~, and open the valve about 1/4 of the total
5. Attach and tighten the bonnet bolt. Tighten the bolts
lift, and ,slightly loosen nut of the gland bolt @.
(or nuts) a little at a time and alternately to prevent one-
2. Mark the position on the outside of the flange pointed to sided tightening and to keep the pressure on the gasket
body(j,)and bonnet@. surface uniform. As forbolt tightening sequence, see Fig. 40.
3. Take off bonnet bolt @ and taper pin @ in case of StylI! 2. Apply the maximum torque limit as shown in'Table 14.
Before doing this for Style 2, however, put in taper pin
4. Leave the bonnet<n yoke(D. stem®and disc®as assembled"
® and fix its position.
and remove them from the valve body. Then immediately
mark the positions of the body guide rail and disc guide II!). 6. Press in the packing ring and tighten the gland bolt nuts.
However, as mentioned before, there is a disc guide in For details, refer to Section 1V·3. And for gland bolt
bodies of Style 4 and Style 5'. Mark its position, so it will tightening. apply the maximum torque limit as shown in
not be changed. Table 15.
~t:\.., I ~
UI \I V

'.8 Perform a blueing test on the disc and seat, and check
1. Repair of Valve Body or Bonnet that there is no distortion. If anything is wrong, fix it by
lapping.
At our factory, we inspect UTE valves during production with
magnetic particle testing, liquid penetrant testing, radiographic
testing, ultrasonic testing which we accept and hydraulic ,.g When the work is finished satisfactorily, reassemble the
pressure testing, so we deliver products with no body leaks. valve. At this time, put in a new gasket or seal ring.
However, during the course of service over a long period of
time, leakage will on rare occasions develop due to connection
of internal pin holes, erosion, etc. In such cases, decide whether
the leak can be repaired according to the ASME Boiler and
Pressure Vessel Code Section III, Code for Pressure Piping
ANSI B31.1 or other applicable standards. And if it can be 2. Repair of Seat of Gate Valve and Swing Check
repaired, have it done by a qualified welder. Valve

1.' Repair Procedure of Valve Body 2·' General

First make a visua{ inspection all around the area, if possible An indication that a valve leak exists after the valve has been
noting where jlaws may occur. Next wash the area with a properly closed, might be given by observing a definite pressure
suitable solvent, and dry it with clean rags. Polish it, if loss in the high pressure line side of the valve, or in the case of
necessary, with a fiqe grade of emery cloth to remove any hot water or steam lines, by noting that the downstream pipe
undesirable scale or foreign matter that may have deposited on remains still hot beyond the usual length of time and con-
the area suspected of having flaws. Make a dye penetrant test ductivity. Such a leak may be the result of a distorted seat
if cracks are suspected. Where it is necessary to repair the caused by improper initial welding of the valve into the line
body, inlay by welding, taking note of the following. and/or stress relieving temperatures that were induced during
. installation. Leaks will also develop because of the operator's
,.,., Prior to any cutting or welding work on the valve, it is failure to close the valve tight that causes a flow through a
necessary that adequate seat joint protection be provided in small opening at very high velocity, resulting in possible damage
order that cutting chips, weld spatter or other foreign matter to seats or discs by particles of scale or rust.
may not get into the pipe line, if the valve is permanently AIthough the stellite·hardfaced seat, wedge or disc are cerro-
mounted. A thick bed of asbestos sheet placed over the seat sion/erosion.resistant, yet grooves, pit marks and other surface
and cemented in place will provide adequate protection. irregularities may be formed on the seating faces, when the
wedge or disc is closed against foreign matter. Valves which
leak should be repaired as soon as possible to prevent greater
1·2 Chip out the defective area in the body, being careful to damage caused by high velocity of flow.
remove the affected portion to its boundary inside the casting
and to throughly clean it away.
2.2 Disassemble the valve as described in Section IV -4 and
remove the wedge. Mark both sides of the wedge and seats to
'·3With a small portable hand grinder, grind the chipped area match after repair, and inspect the wedge for scratches or
smoothly. damage. If seating faces are scratched, they can sometimes be
polished with a fine emery cloth mounted on a perfectly flat
surface to avoid an uneven finish.
1-4 Welding may then be performed by proper procedures.

2.3 If polishing is not quite sufficient, the wedge must be

1·5 After welding, grind the welded surface to equal height lapped. Only slight pitting, grooving or indentations not
with a hand grinder, and smooth the surrounding area as well. deeper than 0.010" can be removed by lapping. If defects
cannot be corrected by lapping, a new wedge must be put in
place.
1.6 Remove all dirt, chips, slag, spatter and grinding dust from
the body, and then throughly clean it.
2·4 For the lapping, a flat plate preferably made of cast iron
should be used, and the abrasive lapping compound mixed
'·7 Examine the welds by liquid penetrant testing. If there with olive oil evenly distributed over the plate. Only light and
are no flaws, wipe them clean. even pressure should be applied, when the wedge is moved
circularly on the plate, lifting the wedge as often as possible to
prevent accumulation of removed particles in one pit, and to
allow proper distribution of the lapping compound. The
lapping plate should be turned slightly every few strokes to
keep a flat surface. The wedge should be lapped until both 3. Repair of Seat of Globe Valve
seating faces have a smooth finish. Lapping may be slow due
to the eroslon-resistant surface. But too much lapping must
be avoided, as it may destroy the original seating angle. Stellited body seat- facing . and disc-Iacinq of UTE valves arc
not easily scored, but they require repair when pit marks
appear on the seating surfaces. The seat may become distorted
2·5 After lapping, the compound must be cleaned off with a due to abnormal heating conditions during the welding in the
suitable cleaning solvent such as acetone or alcohol. Do not line, or a groove may be formed by closing the valve against
use solvents containing chloride or fluoride. A blueing test of foreign particles. All these damages will cause leakage and must
wedge and seat should follow then to determine full circum- be repaired.
ferential contact. In the case of gate valves, the downstream
seating face at least must have a perfect contact.
3·' It is recommended first to make a verification of the faulty
condition by a blueing test and/or careful visual inspection.
2·6 Seat lapping Jigs Where reconditioning is necessary, the following points should
Figure 43 shows one example of lapping jigs for gate valve be observed. Disassemble the valve, and remove the disc from
body seat and swirig check valve body seat. the bonnet assembly as described in Section (VA. Inspect all
seating faces for scratches and damage. Where indentation of
pit marks on the valve seat is deep, that is, 0.01" or greater,
a cast iron lap with suitable lapping compound should be used
first, finishing later with the disc itself. The inclined angle of
the valve seat is 20° or 300. The cast iron lap, reflecting the
proper seat angle, must be closely guided in the body bore
during the lapping. A small quantity of lapping compound
mixed with olive oil evenly distributed must be applied to the
two mating surfaces.
It is important to apply slight pressure of the lap against the
Lapping Handle seat, and to rotate it reciprocally. Best results are obtained by
using an air or electric hand tool with adjustable speed and
Seat Ring reciprocal movement. The lap should be lifted frequently
and turned to a new starting position, to keep a flat surface. In
Lapping Plate
order to assure that the pressure strokes are light, it is necessary,
on valves 6" or larger, to suspend the spindle with lap assembly
by a coil spring in such a manner as to allow the lap to press
only lightly against the seat.

Bolt 3·2 Conical Seat lapping Jigs

Figure 44 shows one example of lapping jigs for globe valve

with conical seat.

Fig. 43 Seat lapping Jigs

Fig. 44 Conical Seat lapping Jigs

3·3 Flat Seat Lapping Jigs 4-2 If the leak won't stop with this method, then locate a
spare seal ring and make preparations for disassembly.
Figure 45 shows one example of lapping jigs for globe valve
with flat seat.
4-3 As you disassemble, visually inspect the flaws in each
part. Measure and record their size and type. Determine the
cause of the flaws, and study the possibility of repair.

4-4 If the flaws are 0.01" or smaller, polishing and lapping will
do. After finishing, reassemble concentrically.

4-5 For large flaws, remove the seal ring completely, and
measure the body bore and bonnet diameter with a micrometer
or vernier calipers. Contact us for supply of proper seal ring
and instructions.

Fig. 45. Flat Seat Lapping Jigs

5. Repair of Stem and Yoke Bushing (or Yoke Sleeve)
3-4 Repair of Globe Valve Disc These are the most important parts for opening and closing
the valve. Major flaws sometimes occur from dusty atmosphere,
If a lathe machine is available, globe valve disc can be polished
poor lubrication, rough handling and severe erosion. Lubricate
or lapped easily.
properlv.clean and inspect periodically. Tightening the packing
gland bolts and back seat excessively will also cause flaws.

4. Repair of Sealing Area of Body (Pressure Seal Type)

If you use pressure seal type valves, special attention should be
paid to the following points:
5-1 If the valve doesn't open and close smoothly or if you find
1) Always use a NEW seal ring, when you reassemble the valve. scratches or flaws, look carefully for the cause. If you find
that repair is necessary, make a disassembly plan and prepare
2) There must be concentric positioning among body, seal for repair.
ring and bonnet.
3) When assembling, precise and even tightening of bonnet
stud bolts must be performed. 5-2 Small flaws can be easily repaired by polishing, lapping,
If anyone of the above points is overlooked, serious leaks cleaning, re-oiling, etc ..
will result.

5-3 When you observe large flaws and cannot wait for smooth
operation, get in touch with us and order new parts.
4-1 If the leaks are little, first use a torque wrench to check
whether the nuts are tightened evenly or not. Then carefully
tighten the bonnet stud bolts in the order of their looseness.
S!!e if the leak lessens. If the leak comes to lessen in this way,
tighten all the cover bolts to the prescribed torque (See Table
14 on page 31.) in order to achieve good zero-leak.
.......:.''::~:{;?':ji:~:~,:·~,·:~:F.~~:':·' ....

,.,' .,. ..
:: ,
,,' ;..~;.<~::}.;.~:~
-r- !.> . ~",

The following items are recommended spare parts which are to

be replaced by new ones at each disassembling occasion. When
ordering these parts, please specify UTE Type No. of your
valve.
It is also highly desirable that a full description of the service
conditions be supplied.

1. Gate and Globe Valve

1-1 Bolted Bonnet Type '·2 Pressure Seal Bonnet Type

• Gasket • Seal Ring
• Set of Packing Rings • Set of Packing Rings
The following style valves of Table 1 on page 4 are subjected to The following style valves of Table 1 are subjected to this
this category. category.

Gate Valve Gate :Valve

Style No. Class Size Style No. Class I Size
150 2·1/2"- 4" 900 2-1/2" - 4"
300 2·1/2"- 4" 7 1500 2·1/2" - 4"
1 1---
2500 2-1/2"- 4"
400 2·1/2"- 6"
600 2·1/2"- 4" 900 5" -16"
2 150 14" - 24" S 1500 5"-16"
- -- ---. 2500 5"- 10"
300 14" - 24" - ._.----
3 400 S"- 24" 1500 6"-16"
9
_. 600 5" - 24" 2500 6" - 16"
4 150 S"-12"
150 5",6"
5
300 5"- 12" Globe Valve
Style No. Class Size
1500 2-1/2", 3"
13 3"
Globe Valve 2500 2-1/2",
Style No. Class Size 1500 4", 5"
14
150 2·1/2"- 16" 2500 4", 5"
10 300 2-112"- 12" 900 S",10"
400 2·1/2"- 10" 15 1500 6", S"
600 2·1/2",3" 2500 6", S"
11
900 2-1/2",3"
600 4" -12"
12
900 4"- 6"
2. Swing Check Valve

2·' Bolted Cover Type

• Gasket
• Gasket (for Spindle)
The following style valves of Table 1 are subjected to this
category.

Style No. Class' Size

150 2·1/2"- 4"
17
300 2·1/2"- 4"
150 5"- S"
300 5"- S"
lS
400 2·1/2"- 6"
600 2·1/2"- 6"
150 10" - 14"
300 10" - 14"
19 S" -14"
400
600 S" -12"

2·2 Pressure Seal Cover Type

• Seal Ring
• Gasket (for Spindle)
• Set of Packing Rings (for Spindle)
The following style valves of Table 1 are subjected to this
category.

Style No. Class Size

900 '2'1/2" - 10"
20 1500 2·1/2"- 10"
2500 2·1/2"- 10"

3. Special Parts and Tools

Bolt, nuts, washers, special tools, jigs and other equipment for
particular customer needs will be supplied upon request.

A PRUDENT MAN HAS MORE

THAN ONE STRING TO HIS BOW.
UTSUE VAL VE CO., LTD.
Head Office & Plant
2-1-13 Kitamura, Talsho-ku;
Osaka, 551-0032. Japan

TELEPHONE NO. 06(6552)31~1

FAX NO. 06(65~1)3246
7-3 Swing Check Valve

7-3-1 Bolted Cover Type, Style 17, 18 and 19.

This type is illustrated in the following Fig. 23, 24 and 25.

Fig. 23 Style 17 Fig. 24 Style 18

See Table 7.for part names

7.3.2 Pressure Seal Cover Type, Style 20
This type is illustrated in the following Fig. 26.

Fig. 25 Style 19 Fig. 26 Style 20

Table 8. Name of Parts (Style 20)

Table 7. Name of Parts (Style
_. 17, 18 and 19) 1 Body 30 Se'll Pin
1 Body 20 Taper Pin 2 Cover 31-1 Bearing Cover
2 Cover 23 Washer 3 Disc 39 Packing
3 Disc 27 Split Pin 6 Arm 40. Seal Ring
6 Arm 28 Hexagonal Nut 7 Seat Ring 40·1 Gasket
7 Seat Ring 31 Plug 8 Spindle 52 Hexagonal Nut
8 Spindle 31·1 Bearing Cover 9 Bushing 60 Split Pin
9 Bushing 40 Gasket 14 Packing Gland 73 Retainer
15 Cover Bolt 40·1 Gasket 17 Bolt 74 Cover Clamp
17 Bolt and Nut 60 Split Pin 23 Washer 77 'Cover Stud
18 Eye Bolt 77 Start Bolt 27 Split Pin 78 Adapter Ring
28 Hexagonal Nut
8. Motor Operated Valve

On motor operated valves which are operated by LimiTorque,

Rotork or other operators, first examine the data shown on
the motor actuator nameplate. Then find out applicable rated
figures and information in the motor actuator manual which is
published by the manufacturer. The operator unit is mounted
on the top of the bonnet or the yoke extention with bolts or
by welding.

Fig. 27 Motor Operated Gate Valve

See Table 9 for part names

8·1 Gate Valve

The motor operated gate valve is illustrated in Fig. 27, which

also shows how to mount the operator unit on the valve
by welding. Fig. 28 and Fig. 29 show how to connect the
operator unit on the valve by a single flange and a double flange
respectively.

Fig. 28 Single Flange Connection Type Fig. 29 Double Flange Connection Type

Table 9. Name of Parts (Fig. 27, 28 and 29)

1 Body 87 Motor
Hexagonal Cap Screw
2 Bonnet 91
Bolt
Hexagonal Cap Screw
4 Yoke 92
Bolt
-
8 Stem 93 ~exagonal Bolt
67 Control Unit 93·1 Spring Washer
68 Upper Flange 95 Stem Cap
69 Lower Flange