STORAGE & INSTALLATION

1. STORAGE & HANDLING

 Until the installation, store all valves indoors and cover them
with watertight sheets to prevent dust, rainwater, and moisture.
During storage, do not remove the flange facing cover or bevel
end protector.
 Care should be taken not to drop the valves on the ground, and
not to bump valves against anything. Especially, be careful not
to damage the flange surface.
 Valves shall have their seats in closed position when they are
kept in store.
 If out door storage is unavoidable, valve should be supported off
the ground and protected by a watertight cover.
 Valves for special service such as for oxygen should be
prevented to come in contact with oil or grease.
 When storage of valves is expected to be for a long time,
proper cleaning and lubrication, should be done at regular
intervals.
 Preservative or grease should be applied on the threads of the
outside screw valves to prevent corrosion.
 Valves should be stacked proper and tagged be easy
identification.

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2. INSTALLATION

 Remove any foreign materials inside the connecting piping, such

as dirt, sand, scale, metal chips, and grit particles, which
damage the valve seat.
 Install valves in the connecting piping, so that the arrowhead
marked on the valve body coincides with the flow direction in the
piping, in the event that there is an arrowhead marked on the
body of valve.
 When lifting the valve, never apply lifting device on the hand
wheel and actuator.
 It is necessary at the design stage to consider where and how
the valve will be located in the pipeline. Valve should be
provided with adequate support where necessary.
 The valve should not carry the weight of the line; otherwise it
will create distortion, which result in insufficient operation,
jamming and the necessity of early maintenance. If the valve is
of flanged construction, it will be difficult to tighten the flanges
properly.
 Valve should be accessible for adjustment, maintenance and
repair.
 Consideration should be given to the possibility of
removing single valve for overhauling, without having to
shut down the whole system.
 Easy removal and replacement of important valves should be
ensured by provision of slip joints etc. and isolating valves at
appropriate locations.

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 OPERATION OF GLOBE, CHECK VALVE

1. For manually operated valves, turn the hand wheel counterclockwise to

open and clockwise to close. Turn the hand wheel slowly, especially in
the initial opening.
Never use too much force in either opening or closing. If the hand
wheel is tight and you want to use any tools, such as lever, spanner, or
pipe wrench, do not use too long one, which gives too much moment
and stress to the stem and yoke. Do not close the valve too tightly.
For automatically operated valves, use push buttons or operation
switches for opening, closing and stopping.
2. Carefully check if no leakage occurs from the gasket or gland packing.
In case of some leakage, tighten the nut further.
3. Put the lubricant into the grease nipple and the stem threaded part.
4. When valves are provided with built in bypasses, by-pass valve should
be opened gradually before opening the main valve. This will enable
the pipeline to warm up and the pressures on either side of main valve
will equalize.
5. It is recommended that all-important valves be thoroughly inspected
after trial operation. This should be done to ensure that there is no
damage cause to the valve components during trial run.
6. If a valve leaks slightly when shut-off, open it a little to flush particles
that may be hindering the seats. Trying to force it shut with a crow bar
is likely to ruin the seats.
7. The valves must be closed tightly otherwise premature failure of the
valve seat discs can occur due to wire drawing.

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TROUBLE SHOOTING FOR GLOBE, GATE VALVES
A) Seat Mating surfaces
1) Wedge/Disc Ring and Body Ring.
2) Spindle Back seat and Back Seat of Bush.
Inspect the Body Ring and Wedge/Disc Ring for corrosion/ pitting marks
before installation in the pipeline, if marks are there clean it properly with the
help of kerosene oil. Lap the body ring with the help of C.I. Guided Bore
lapping plate by applying suitable lapping compound.
Apply suitable Lapping Compound on Wedge/Disc Ring & Lap it on C.I.
Wedge shaped Lapping Plate.
Apply suitable Lapping Compound on Stem Back Seat & Lap it with respect to
Back Seat Bush.

B) Gland Packing

1) Prolonged storage may spoil the gland packing, so before operating the
valve for the first time packing should be checked and if the need be, stuffing
box should be filled with a fresh set of packing.
2) It is important that the stuffing box be inspected before and during
operation. The Gland must be tightened before and during operation,
because the packing generally tends to settle down in the early stages of use.
3) To change Gland Packing while valve is under pressure: The valve should
be fully open with the stem backseat completely attached with backseat by
opening the valve fully, so that there is no danger of the fluid leakage
through the stuffing box, while the operator is doing the refilling operation of
the stuffing box. Literatures should be checked whenever the valves are back-
seated type, before changing the Gland packing.

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 MAINTENANCE FOR GLOBE VALVE

1. Loosen the Body/Bonnet Studs & Nuts.

2. Remove the Total Upper assembly from the Body.
3. Remove the Gasket from the Body gasket groove.

Inspect the Body Ring and Disc for corrosion/ pitting marks before installation
in the pipeline, if marks are there clean it properly with the help of kerosene
oil. Lap the body ring with the help of C.I. Guided Bore lapping plate by
applying suitable lapping compound

REASSEMBLE THE VALVE AS UNDER

1. Replace the old Gasket with the new one & put the total Upper
assembly inside the Body.
2. Tighten the Body/Bonnet joint Studs & Nuts properly, so that there
should be no leakage from the joint.

Test the valve Seat at Fully Closed Position with water at test pressure and
there should be no visible Leakage from the Seat.
Test the Back seat leakage by completely attaching the Stem Back seat to
Bonnet with water at test pressure.

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 MAINTENANCE FOR GATE VALVE

1. Loosen the Body/Bonnet Studs & Nuts.

2. Remove the Total Upper assembly from the Body.
3. Remove the Gasket from the Body gasket groove.

Inspect the Body Ring and Disc for corrosion/ pitting marks before installation
in the pipeline, if marks are there clean it properly with the help of kerosene
oil. Lap the body ring with the help of C.I. Guided Bore lapping plate by
applying suitable lapping compound

REASSEMBLE THE VALVE AS UNDER

1) Replace the old Gasket with the new one & put the total Upper
assembly inside the Body.
2) Tighten the Body/Bonnet joint Studs & Nuts properly, so that there
should be no leakage from the joint.

Test the valve Seat at Fully Closed Position with water at test pressure and
there should be no visible Leakage from the Seat.
Test the Back seat leakage by completely attaching the Stem Back seat to
Bonnet with water at test pressure.