Operation and Maintenance Manual

Gate Valves
References:

16-219
WSB/PMCES/ZD15INTE/L-0001
K695 Nam Kong 2

Size:

GOMM-219-2016

DN 2000 PN 10

PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

CONTENT:
1. General information / Purpose
2. Technical description
3. Storage / Handling
4. Installation
5. Exploitation
6. Maintenance
7. Possible irregularities, causes and corrective actions
8. Terms of safety in servicing
9. Certificates and documentation
10. General and specific safety information

K695 Nam Kong 2

Page 2 of 11

PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

1. General information / Purpose

Gate valves (GV) are made of construction steel, double flanged, non-rising stem.
Fabricated (welded construction), applied as a pipe valves on pipelines for transport
in treatment plants for non-aggressive, and aggressive fluids, depending on the
material from which the parts of the valve are made, allowed temperatures are up
to 200 C (473 F).
According to the method of management, the bolts supplied with: manual,
electromechanical or hydraulic driven.
The housing and gate as standard are made of carbon steel (S235 or S355), but other
grades are possible, as well as stainless steel.
The stem is made from non-corrodible, single piece design, with special materials
available on request.

K695 Nam Kong 2

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PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

2. Technical description
Gate valves consist from the following parts and components:
The valve housing is with the straight passage, and the flow of fluid is possible when
the shut-off body (gate) is in the position "open".
The sealing surface of the valve housing and the shut off body (gate) are made of
stainless steel with a corresponding difference in surfaces hardness.
In the cover of valve housing are spindle seals.
The assembly of shut off body (gate) provides an appropriate class sealing
according to EN 1984.
Shut off body (gate) consists from two discs, which are also hard welded, and
bearing puller brass nut that is achieved through axial movement of shut off body.
Spindle assembly of latches and bolts, are bolted, which allows converting rotary
movement of the drive, to the axial movement of shut off body. Drive of valve allows
you to manage it.
It is possible to use the following types of drives:
1. Manual mode, which can be direct (hand wheel) or via the pinion.
2. Electromechanical drive, which can also be direct or through the gearbox.
Electromechanical drives come with hand-wheel, providing option for manual
operation (override).
3. Hydraulic drive, where instead of the threaded spindle, on the assembly of
shutoff discs mounted body clip, through which the axially movement is
possible. On the hydraulic drive are mounted limit switches, which regulate
the stroke and assembly of the shutoff discs.

K695 Nam Kong 2

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PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

3. Storage / Handling
During storage period the valve has to be protected against impurities, direct
sunlight, rain, frost and other weather elements.
On site the valve must be stored so as to be protected against mechanical damage
and/or corrosion. The preferable storage condition is in dry closed room with
ambient temperature and low humidity. Flanges or weld ends can be sealed using
plugs, lids, plastic caps or oil paper.
Internal surfaces can be treated with preservatives or moisture absorbers.
The protective packaging we provide must be left intact during storage and
removed prior to installation or operation respectively.
If valve is stored for longer than twelve months, it is necessary to replace sealing
elements and gaskets in the valve.
If valve is going to be stored sitting on its flange connection, make sure that valve is
stored on a wooden pallet to protect flange surface against mechanical damages.
Never lift valve using actuator mechanism as an anchor. This may cause
serious damage to actuation mechanism and the valve, and it is
extremely dangerous for persons around the valve.
To lift the valve, hook up it by the lifting eye and at least additional 3 sports on valve
housing, flange holes or provided lifting bolts. In all cases never drag the valve along
the floor. During handling and moving avoid any damages of the valve and take
care of personal safety.
When loading or unloading ensure that the valves are not thrown or subjected to
sudden knocks. Large valves should be handled with hemp or synthetic ropes slung
to the yoke arms or the bonnet flange. Valves with actuators should be slung using a
three-point suspension at the main connection nozzle and the yoke arms or yoke
head. Special eyebolts must be used when supplied with heavy valves.

K695 Nam Kong 2

Page 5 of 11

PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

4. Installation
Remove the protective covers from the pipe connections where valve is going to be
installed, and when the shut-off body (discs) is in closed position, carefully clean
inside surface of the valve.
Check the uniformity of opening and closing the shutoff valve body (gate).
Check the parallelism of counter flanges and their axial alignment at the place of
valve installation.
Before installation check if there is enough space for valve, operation device and to
have free access all around the valve.
Place the o-rings on counter flange connections and make tightening screws and
nuts. Use correct sealing material for flanges according to applicable medium and
temperature.
Clean the valve sealing surfaces
Bring valve to installation site in most suitable way, align it to the axis of the pipeline
and check out matching screw holes between valve flanges and counter flanges.
Tighten connecting bolts evenly and crosswise.
Never lift valve using actuator mechanism as an anchor. This may cause
serious damage to actuation mechanism and the valve, and it is extremely
dangerous for persons around the valve.
Dont lift the valve using the lever or the other operation device. To lift the valve,
hook up it by the lifting eye and at least additional 3 sports on valve housing or
flange holes. In all cases never drag the valve along the floor. During handling and
moving avoid any damages of the valve and take care of personal safety.
When loading or unloading ensure that the valves are not thrown or subjected to
sudden knocks. Large valves should be handled with hemp or synthetic ropes slung
to the yoke arms or the bonnet flange. Valves with actuators should be slung using a
three-point suspension at the main connection nozzle and the yoke arms or yoke
head (note centre of gravity). Special eyebolts must be used when supplied with
heavy valves.
Valve should not be installed in area which is permanently accessible by
personnel OR area without clearly displayed warnings for dangerous moving
objects!!!

K695 Nam Kong 2

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PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

ADDITIONAL INFORMATION:
To ensure normal operation of the gate valve, pipeline where valve is to be installed
must have built-in compensators / expansion joints.
The pipeline where valve is to be installed is required to be cleaned from dirt and
debris (electrodes, sheets, pesticides, etc.), before mounting valve.
Installation pipeline must be properly secured, before mounting valve. We strongly
suggest having plinth for installing larger gate valves. As an option, valves can be
provided with feet for anchoring.
Pipeline flanges (counter flanges), must be centric and parallel (without chamfer),
and the location of holes for connecting bolts on counter flanges must be identical
and matching ones on valve flanges.
Tightening the bolts to flange connections should be made with proper torque and
keys that guarantee the preservation of the thread.
Gate valves must be installed on pipeline in places that are accessible for service
and inspection.
Operating position of gate valves can be:
-

on the horizontal pipe - vertically upward or horizontally;

on the vertical pipes: horizontal (flat side, with a horizontal spindle position).

For hydraulic testing of pipeline strength, gate valve must be fully open.
If the valve comes with the electro-mechanical or hydraulic drive, it must be
protected from mechanical damage.
Installation of electro-mechanical or hydraulic drives must be performed by
instructions provided by the manufacturer of the same.

K695 Nam Kong 2

Page 7 of 11

PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

5. Exploitation
Gate valves must be used strictly as intended, according to the information and
instructions in the technical passport.
The application of the valve for flow regulation is not allowed. The gate may be in
fully open or fully closed positions.
Valves, that are equipped with an electromechanical actuator, have micro switches
for the opening stroke, and they are set in way that the drive is shut-off when the
body comes to 10-15 mm from the upper end position, and further (to shock the
body into the lid closing) opening is done by hand through the wheel. Micro switch
for closing stroke is adjusted to provide closure with sealing. This switch should be
adjust taking care of rotation of the inertia and must respond before the micro switch
for limiting torque. Application of additional levers, to increase the value of torque,
on micro switches for limit torque is not allowed.
Working fluid that is transported by pipeline where valves are mounted must
not contain mechanical impurities, in order not to damage the sealing
surfaces.

6. Maintenance
In the exploitation oval valves should be maintained in good and clean condition.
Thread of the spindle, nut and bearings should be periodically, at least once a
month, lubricated with grease.
Maintenance of electro-mechanical drives perform in accordance with their
instructions.
Before starting any maintenance works, it is important to ensure and well note the
following:

drainage of the pipeline;

get complete information on the possible dangers, which can occur
through remainders of the flow medium and take suitable measures
(safety gloves, safety glasses, etc.);
let the valve cool down, if required;
make sure that no third person can put the plant into operation;
remove any pressure, which might build up in a shut-off pipeline.

K695 Nam Kong 2

Page 8 of 11

PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

7. Possible irregularities, causes and

corrective actions
Failure

Possible cause

Leakage on connecting flanges

(connections of valve and
pipeline)

Insufficient tightening of the

bolts of flanges
Damaged seals between
flanges

Leakage of fluid through the

sealing chamber of spindle

Damaged sealing

Starting operating sequence

(open or close), gate does not
move

Broken or damaged wedge

connection drive bolt
Improper operation of
electromechanical drive

Immediately upon starting

opening (when valve in fully
closed position), torque switch
on drive switches it off

An excessive encroachment
caused on the closing blocking
body
Blocking of the shut off body,
formed as a result of
precipitation of impurities with
strong adhesion feature

Action required
Tighten the bolts
Replace sealing between
flange(s)
Replace sealing
Replace it
Eliminate fault as instructed by
the drive manufacturer
Through the opening of the
discharge of sediment, using
the screw steam, move the
shut-off body.
Washing it off through drain
opening by water vapor, steam
or suitable diffuser.

8. Terms of safety in servicing

Gate valves can be operated only by qualified and trained personnel for this
purpose.
To safely control slide valves in larger nominal size, specify the appropriate platform.
On hand wheel (manual and electric-mechanical) drives, must be clearly marked
directions of opening and closing.
If the valves are used in pipelines through which transports fluids harmful to the
environment, suitable protection of flange connections must be provided.
Periodic release an interior valve from potential condensate and sediment is
advised.
Not allowed to be used as control valves.

K695 Nam Kong 2

Page 9 of 11

PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

9. Certificates and documentation

The valve has been manufactured in and shipped from our factory according to the
order and our contract with the customer. The documentation in its content and
extent are provided also according to the order and our contract with the customer.

10. General and specific safety information

Operation of the valve is not dangerous under normal
circumstances. Nevertheless, it is necessary at all times to act with
appropriate care and caution.
In and outside of the valve there are moving parts (lever,
supporter, counterweight, hydraulic, disc, shafts etc.)
-

Never loosen screws in pipelines under pressure.

Have repairs and/or maintenance performed only by skilled personnel.
Do not use force to loosen any screwed joint.
Never loosen hydraulic screws under pressure.
It is absolutely important to inform all personnel of these operation and
maintenance instructions.

^Take care of burning accidents. The valve and the components can be
depending on the operating condition and the purpose heating.
In case of every reparation it must be make ensured that the valve and the hydraulic
are also depressurised.

Warning
In the sense of the operating instructions are persons who are familiar with the
mounting, starting up, and operation of this product and who have the
corresponding qualification for such works, e.g.

Education or training according to the actual safety standards for

maintenance and use of adequate safety equipment.
First aid training
For plants with explosion hazards: Special training or instructions, or the
authorization respectively to carry out works in plants with explosive hazards.

K695 Nam Kong 2

Page 10 of 11

PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

Operating and maintenance manual

Gate Valves
GOMM; 219-2016

October 2016.

PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com

K695 Nam Kong 2

Page 11 of 11