INSTALLATION AND MAINTENANCE MANUAL

FOR FORGED GATE, GLOBE & CHECK VALVES

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 INSTALLATION AND MAINTENANCE MANUAL
FOR GATE VALVE

Contents

. Usage and property specification····································3

. Adopted standards······················································ 3

. Construction feature and theory······································4

. Materials for main components ······································4

. Storage, installation, usage and inspection······················· 5

. Potential failure and disposal method·······························7

. Attention·····································································8

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. Usage and property specification
1．1 Usage

a、The product is used as the open and close device on pipelines for gas or liquid.

b、Applicable scope: industries like chemical, oil, metallurgy, paper-making, pharmacy

and etc.

1．2 Property specification

Nominal size（NPS） 1/2~2 in

Pressure rating（Class） 800,1500,2500 Lb

Shell test 21,37.5,63

Pressure

Air test 0.6

MPa
Seat test 14.9,27.5,46.2,

Back seat test 14.9,27.5,46.2,

Suitable temperature -29~425 ºC

Non-corrosive gas or liquid like water,

Suitable medium
steam and oil

. Adopted standards
2．1 Design and manufacture as per API 602,

2．2 Test and inspection as per API 602,

2．3 Socket welded ends as per ASME B16.11,

2．4 Screw ends as per ASME B16.25

2．5 Flange ends as per ASME B16.5

2．6 Face to face dimension as per manufacturer’s standard,

2．7 Pressure-temperature rating as per ASME B16.34.

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. Construction feature and theory
3．1 The valve construction and main dimensions follow to the drawing .

3．2 The valve is used for opening or closing purpose by rotating hand wheel which

makes the stem up and down and this in return makes the disc move in the direction

vertical to the straight line of fluid.

3．3 The valve is closed by rotating the hand wheel clockwise.( There is marking on hand

wheel.)

3．4 The seat of the valve is renewable and easy to repair.

3．5 The valve has backseat design which helps the seal of packing.

3．6 The valve has a conic seal construction which realizes larger specific seal pressure

and smaller operation torque.

3．7 The seal face is welded with wearable material which improve realize better seal

property and longer service life.

. Materials for main components

Welded
Body
Name Stem material on Packing Gasket Bolt Nut
Bonnet
seal face

ASTM Graphite ASTM ASTM

ASTM Flexible
Material A182 13Cr spiral wound A193 A194
A105 graphite
F6a with SS B7 2H

ASTM ASTM Graphite ASTM ASTM

Flexible
Material A182 A182 STL.6 spiral wound A193 A194
graphite
F22 F316 with SS B16 4

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. Storage, installation, usage and inspection
5．1 Storage

a． The valve should be stored indoors orderly under dry and ventilate condition, and

the stem cannot be loaded by any force.

b． The valve should be in “closed” position during storage.

c．During storage, the stem threads and machined surface should be coated by

antirust which is easy to clean.

d． The valves to be stored for a long period should be checked regularly and

protected in time.

5．2 Installation

a． The valve can be installed in any position where easy to repair and operate.

b． Before installation, the installer or user must check the compatibility of the marks

and identification plate with the requirements of service condition

c．The operator shall clean the body cavity and sealing face, check sealing face,

bolting, packing, and stem before installation.

d． Bolts should be tightened evenly.

e． After installation, the valve should be fully opened for blasting and system

pressure test.

5．3 Usage

a． The working condition of the valve should be in accordance with that on

nameplate and operation instruction.

b． The valve is not suitable for medium with particles, large viscosity or easy to coke.

c．Normally, the valve should not be used to modulate flow.

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 d． The stem height is regarded as the opening indicator for the valve. That is to say,

the position where the stem cannot be moved anymore is the fully open position for

the valve. But actually, we regard the position where the stem cannot be moved

anymore and move back 1/2 or 1 turn as the fully opening position to avoid the lock

hole phenomenon caused by temperature fluctuation.

e． Grease should be added to thread and stem nut regularly when the valve is in

operation.

f． The disc is moved by rotation of the hand wheel. Other assistant lever or power

should not be used.

5．4 Inspection

1． The following points shall be inspected regularly during usage. The parts in

question must be repaired in time.

a． If the fasteners are loose.

b． If the packing is damaged or fray seriously.(In this case, it has to be stopped to

check)

c．If the actuator can be operated smoothly without any blocking.( In this case, it has

to be stopped to check)

d． If the sealing face is damaged or fray seriously.( In this case, it has to be stopped

to check)

e． If there is leakage at the joint of seat and body. ( In this case, it has to be stopped

to check)

f． If the acme thread is fray severely.( In this case, it has to be stopped to check)

g． If the body is corroded or fray severely so as to make the body too thin obviously

and even cause leakage or crackle, and thus has to be deserted.( In this case, it

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 has to be stopped to check)

2,The valve shall be tested according to relevant standard after installation and

examination. The installer or user shall record carefully for every examination for future

review.

. Potential failure and disposal method

failure cause elimination

1、 The packing gland is not 1、 Tightening nut evenly

tight enough

2、 The packing ring is not 2、 Adding more packing rings

Leakage from enough (cutting the packing cord

packing into 45ºand stagger the

adjacent two rings to 120º)

3、 Breakage and deficiency 3、 Replacing the packing

of packing

Leakage 1. irregular tighteness of 1. tighening the bolting

between vavle
bolting evenly
body and

bonnet 2. damage of flange surface

3. breakage or deficiency of 2. retrimming

gasket 3. replacing the gasket

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 1、 contaminant attached to 1、 remove the contaminant

the sealing face 2、 retrimming，polishing the

2、 damage of sealing face sealing face. If the welding

Leakage from
layer of the sealing face is
the sealing
not enough,then rewelding
surface
it or replacing the seat

3、 weared off due to longtime 3、 rewelding the sealing face

usage or replacing it.

Clumsy turning 1、 packing is overtightened 1、 properly loose the nut of

of the 2、 packing gland device is packing gland

handwheel or inclining 2、 adjusting the packing

the disc is 3、 damage or contaminant on gland

immovable stem thread 3、 dismantling the stem and

4、 severe damage or crackle retrimming the thread or

on stem nut thread removing the contaminant

5、 bending of stem 4、 replacing stem nut

5、 Correcting stem

. Attention
7．1 User should be responsible to valve material selection and possible material

transformation. User should also do necessary inspection regularly.

7．2 The valve is designed according to normal working condition. Special requirement

should be specified in contract.

7．3 The valve is designed for light corrosion. The valve is not suitable for sever or

special corrosive condition.

7．4 The working temperature of the valve should not exceed the value stated in

Section 1.2. User will be responsible for the consequence caused by working

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 temperature exceeding the stated value, even instantaneously exceeding.

7．5 The maximum working pressure should not exceed the value stated in Section 1.3

under relative working temperature. User will be responsible for the consequence

caused by working pressure exceeding the stated value or inaccurate pressure

under that temperature.

7．6 The suitable media are stated in Section 1.2. User should be responsible for the

consequence caused by exceeding this scope.

7．7 The passage for media inside the valve is a little twisted, so it will consume more
energy and easy to be corrupted and eroded.

7．8 The closing torque for the valve maybe large, for the media flow underneath the disc

and the obstruction of media should be overcome when the disc is being closed.

7．9 Surface temperature of the valve may be high enough to hurt human body, so the

user should post a warning indication at the relative part.

7．10 Packing should not be added or replaced when the valve is under pressure, even

the valve has backseat design.

7．11 Valve should not be welding repaired or painted during operation.

7．12 Valve should not be moved when it is under pressure.

7．13 User should select material according to Section 4 when repairing the valve.

7．14 The valve is designed without life expectancy calculation and test, nor fatigue

check, so user must check, inspect and do necessary replacement during usage.

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 No PAR TS
1 BO D Y
2 SEAT R IN G
3 W ED G E
4 STEM
5 G ASKET
6 BO N NET
7 BO LT
8 PAC KING
9 PIN
10 G LAN D
11 EYE BO LT
12 G LAN D FLANG E
13 NUT
14 G ASKET
15 YO KE N U T
16 H AN D W H EEL

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 INSTALLATION AND MAINTENANCE MANUAL
FOR GLOBE VALVE

Content

. Installation of Globe··············································12

. Maintenance of Globe valve ···································12

. Potential failure and disposal method ·······················13

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 INSTALLATION AND MAINTENANCE MANUAL
FOR GLOBE VALVE

Ⅰ Installation of globe valve

1.1 Preparation before installation:

(1) The installor must ensure that piping is ready. Pipings shall in a same axis and both
sealing faces of flanges shall be parallel to each other. Meanwhile pipings shall be
capable to support the weights of valve. Otherwise, the piping must be assembled with
sutible support.
(2) Piping must be wiped and cleaned thoroughly, free of oil spot, welding slag and any
other impurities inside the piping.
(3) The installer or user must check the compatibility of the marks and indentification plate
with the requirements of service condition and ensure the valve is in good condition.
(4) Dismantling the protecting pieces off the flanges of valve body.
(5) The operator shall clean the internal cavity and sealing face, check sealing face, bolting,
packing, and stem.
1.2 Installation:
(1) When installing the valve into the piping, the installer must pay attention to the direction
of the fluid and ensure the accordance between the normal fluid’s flow and the arrow
engraved on the valve body.
(2) It must be assembled with sealing gaskets between the flanges of valve body and
piping, according to the design requirements of pipeline layout.
(3) The valve shall be connected with moter pipeline when it’s actuated by a moter.

1.3 Examination after installation

(1) After installation, the valve and the piping shall be cleaned with the obturator of valve
being totally open and the valve shall undergo systematic pressure test.
(2) The installer or user shall test the sealing performance of the connection between the
flanges of piping and check valve according to the design requirements of pipeline
layout.
Ⅱ Maintenance of globe valve

2.1 General requirements

The following points shall be checked regularly during usage. The parts in question must be
repaired in time.
(1) If the fasteners are loose.

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 (2) If the sealing face is damaged or weared seriously.(In this case, it has to be stopped to
check)
(3) If the actuator can be operated smoothly without any blocking.( In this case, it has to be
stopped to check)
(4) If the sealing face is damaged or weared seriously.( In this case, it has to be stopped to
check)
(5) If the acme thread is weared severely.( In this case, it has to be stopped to check)
(6) If the body is corroded or weared severely so as to make the body too thin obviously
and even cause leakage or crackle, and thus has to be deserted.( In this case, it has to
be stopped to check)
(7) The valve shall be tested according to relevant standard after installation and
examination. The installer or user shall record carefully for every examination for future
review.

2.2 Potential failure and disposal method

failure cause elimination

1.The packing gland(11) is 1.Tightening nut (12)

not tight enough evenly

2.The packing ring (7) is

not enough 2.Adding more packing

Leakage
3.Breakage and deficiency rings (cutting the packing
from packing
of packing cord into 45ºand stagger

the adjacent two rings to

120º)

3.Replacing the packing

Leakage 1.irregular tighteness of 1.tighening the bolting (7)

between
bolting (7) evenly
vavle body
and bonnet 2.damage of flange 2.retrimming

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 surface 3.replacing the gasket (4)

3.breakage or deficiency

of gasket

1.contaminant attached to 1.remove the contaminant

the sealing face 2.retrimming，polishing the
Leakage 2.damage of sealing face sealing face. If the welding
from the layer of the sealing face is
sealing not enough,then rewelding
surface 3.weared off due to it or replacing the seat
longtime usage 3.rewelding the sealing
face or replacing it.
Clumsy 1.packing is overtightened 1.properly loose the
turning of the 2.packing gland device is nut(12) of packing gland
handwheel inclining 2.adjusting the packing
or the disc is 3.damage or contaminant gland (11)
immovable on stem thread 3.dismantling the stem
4.severe damage or and retrimming the thread
crackle on stem nut thread or removing the
5.bending of stem contaminant
4.replacing stem nut (13)
5.corrcting stem (3)

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 No PARTS
1 BODY
2 DISC
3 STEM
4 GASKET
5 BONNET
6 BOLT
7 PACKING
8 PIN
9 GLAND
10 EYE BOLT
11 GLAND FLANGE
12 NUT
13 YOKE NUT
14 HAND WHEEL
15 NUT

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 INSTALLATION AND MAINTENANCE MANUAL
FOR CHECK VALVE

Content

. Installation of Check Vlave·····································17

. Maintenance of Check Valve ··································17

. Potential failure and disposal method ·······················18

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 INSTALLATION AND MAINTENANCE MANUAL

FOR CHECK VALVE

1 Installation of check valve

1.1 Preparation before installation:

(6) The installer must ensure that piping is ready. Pipings shall in a same axis and both
sealing faces of flanges shall be parallel to each other. Meanwhile pipings shall be
capable to support the weights of valve. Otherwise, the piping must be assembled with
suitable support.
(7) Piping must be wiped and cleaned thoroughly, free of oil spot, welding slag and any
other impurities inside the piping.
(8) The installer or user must check the compatibility of the marks and indentification plate
with the requirements of service condition and ensure the valve is in good condition.
(9) Dismantling the protecting pieces off the flanges of valve body.
(10) The operator shall check the internal cavity, remove the fixing device of the disc,
operate the disc to verify the sealings and clean it.
1.2 Installation:
(4) When installing the valve into the piping, the installer must pay attention to the direction
of the fluid and ensure the accordance between the normal fluid’s flow and the arrow
engraved on the valve body. Otherwise, it will stop the normal flow direction of the fluid.
(5) It must be assembled with sealing gaskets between the flanges of valve body and
piping, according to the design requirements of pipeline layout.
(6) The bolting of flanges shall be tightened symmetrically, evenly and one by one.

1.3 Examination after installation

(3) The installer shall check if it can work normally.
(4) The installer or user shall test the sealing performance of the connection between the
flanges of piping and check valve according to the design requirements of pipeline
layout.

2 Protection of check valve

2.1 General requirements

The following points shall be checked regularly during usage. The parts in question must be
repaired in time.
(8) If the fasteners are loose.
(9) If the sealing face is damaged or weared seriously.(In this case, it has to be stopped to
check)

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 (10) If there is any leakage between the valve seats and body.( In this case, it has to be
stopped to check)
(11) If the disc is clogged or blocked.( In this case, it has to be stopped to check)
(12) If the body is corroded or weared severely so as to make the body too thin obviously
and even cause leakage or crackle, and thus has to be deserted.( In this case, it has to
be stopped to check)
(13) The valve shall be tested according to relevant standard after installation and
examination. The installer or user shall record carefully for every examination for future
review.
2.2 Potential failure and disposal method

failure cause elimination

Leakage 1. irregular tighteness of 1. tighening the bolting

between bolting (9) (9) evenly
vavle body 2. damage of flange 2. retrimming
and cap surface 3. replacing the gasket
3. breakage or (7)
deficiency of gasket
Leakage 1.contaminant attached 1.remove the
from the to the sealing face contaminant
sealing 2.damage of sealing face 2.retrimming or replacing
surface
Leakage
between Tightening the valve seat
Loose valve seat
valve seat (2)
and body

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 No PARTS
1 BODY
2 DISC
3 GASKET
4 BONNET
5 BOLT
6 NAME PLATE
7 RIVET

Page 19 of 20
 SALES OFFICES
Chennai Kolkatta
147, KARAPAKKAM VILLAGE, 55 CHOWRIUGHEE ROAD,
CHENNAI – 600 097, 4th FLOOR CHOWRIUGHEE
Tel: 044 2450 4401, COURT, KOLKATA – 700 071,
FAX: +91 44 2450 2236 Tel: +91 33 2282 2448
Fax: +91 33 2282 2190

Pune New Delhi

406-408 IV FLOOR CENTURY ARCADE
NARANGI BAUG ROAD,
OPP BOATCLUB ROAD,Z
PUNE – 411 001,
Tel: +91 20 2616 1855
FAX: +91 20 3058 5859
M-2 THIRD FLOOR SOUTH EXTENSION PART II,
NEW DELHI – 110 049,
Tel: +91 11 4259 7999
FAX: +91 11 4259 7910

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