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MaintenanceManual for
AIL Cast Steel Gate,
Globe and Gheck Valves
On receipt check that the r.alr es
a n d a c c e s s o r i eas r e i n t a c t .E n s u r e
that the valve is in fullv closcd

End protectors on either side of

the valve should be kept intactand
remor,ed only, at the time of

\,'alve should bc stored in a

covcrcd arca. Ifthe covcrcd area
is not ar ailablc u'ater proof
covering material should be
spread over the r.alves and the
valves should be kept on a
rvoodenpallet at least6" ( I50nrm)
above the ground level.

Do not appl1.tar. paint. urcaseor anv othcr uraterialinsidc

the vah'e as this ri'ill impair the perfomranceof the valve.

2.0 C O N S T R U C T ION
A I L G a t e . G l o b e a n d C h e c k r a l r e s a r e o f s t u r d v d e s i g na n d
give tight sealing against r.aried pressureand temperatureof
the line tluid.

All gate and globe valves are of OLrtsideScreu' and Yoke

(OS&Y) t-vpe.

All check 'u'alvesare of ssing tvpe.

Gate Valves
AIL gate valves can be categorised into tu.o bv the type of
Body-Bonnet joint and Gate design. This ntanual cor.ers the
A) Valve rvith l. Boltcd Body-Bonnet.loint
2. Pressure Seal BonnetJoint
B) Valvesrvith l. Flex Wed*eetype Gate
2. ParallelSlide Gate

Check Valves
AIL Checkvalr.esarecategorised
into trvoby thetype of Body-
Coverjoint. This manualco\:ersthe follorving types
Valves rvith l. BoltedCover Joint
2. PressureSeal Cover Joinl
3.1 Preparationfor Installation
Move the valves as close as possible to
the installation site before removins
packaging and end protectors. After
removing the end protector, check the
inside of the valr.e and remove anv rust
inhibitor or dirt. If the valves have been
in storage for a lon_speriod clean the
stem threads after removing the
protectivepaperand apply lresh grease.
3.2 Pre-commissioningTests
All valves are factory testedin accordance'*,ith the relevant
testingstandardas mentionedin the productcatalogue.
Wherevervalvesarerequiredto be re-testedbeforeinstallation
ensurethatproperTestrig is availableat the site.Valvesshould
be testedas per the relevanttestingstandard.
If \\,ateris used for-testingit is recommendedthat after testing
i s o v c r t h c r a l r e i n t e n r a l sb e d r i e d n ' i t h d n ' r r i t r o g e n o r a i r .
It rr.ould bc adr isable to add comosion inhibitor in the u'ater.

3.3 Installation configuration

For best pcrlomrance it is recolnnrendedthat Gate and Globe
valves are installed \ crtical u ith stem operating end at the top.
horizontal or at anv angle in betu,ec'r.r.

S u ' i n s c h e c k r a l r e s c a n b e i n s t a l l e de i t h e r i n h o r i z o n t a l o r
verlical pipelines.Hou'ever in vcrtical pipelinesthe flou, should
be only in upu'ard direction. Su'ing check valves should not
be installedat the outlet of a reciprocatingpump as the pulsating
flou' is likell' to damagc thc intcrnals.
A I L G a t e v a l v e s h a r e b i - d i r e c t i o n a ls e a l i n - qc a p a b i l i t i e sa n d
therefore can be installed in an1' direction. Hou,ever if the
v a l v e s a r e u ' i t h p r e s s u r e r e l i e v i n g f - e a t u r e( a h o l e i n t h e
upstream side of the gate) they. can be installed onlv in the
direction of arrou'.
Though AIL Globe valr.es har e bi-directional sealirrg
capabilities.tlie direction of flou'is influencedby the operating
c o n d i t i o n s .H o u ' e v e rl o r v a l v e s i n s t a l l e di n d r a i n l i n e s o f h i g h
tenrperaturc flLrids (cspcciallv steam) llorv over the disc is
strongly' recommendecl.
A I L C h e c k v a l v e s a r c u n i - d i r e c t i o n a la n d a r e i n s t a l l e ds u c h
that the arrou nrark is in line uith the t-lou.direction. If this
is not ensured check ralvc s'ill stop the flou, altogether.

\alves shouldbe liftedLrsinssuitablemechanical equipment.
Chains-Slingsaudotherlitiin_eequipnrent shouldbe regularlv
inspected.Do not atten.rptto lift the r.alveby applyingload
on hand u,heel.Gearunit. Actuatoror Bv-passpiping.Chains
or Slinss shall be fired aroundthe valve bodv.

3.5 M a k i n g E n d co n n e cti o n s
AIL Gate. Globe and Check ralves are offered rvith Flanged
and Butt n'eld ends. The ends are machined in accordanceto
the standardspecified in the product caraloguesunless
otherrvisespecified by tlre custon-ler.

3.5.1 Flanged connections

Gasketsand flange bolting rvhich are not suppliedu ith the
valve should n'leetthe requirementsof end flangestandardof
the valve. Flangesshould be pulled togetherevenl1., by
tighteningoppositepairs of bolts.

3. 5. 2 W e l d e d c o n n e cti o n s
All u,eldingshouldbe performedby thequalifiedrveldersusing
approvedprocedures.It is recomnrended that goodengineering
practicesareadoptedto ensurethat the heatfrom r.veldingdoes
not affect the internals.Though there are no soft seatsto be
affectedin AIL Gate,Globe and Check valves.care should
be taken to avoid rveld splatter so as to prevent damageto
metal to metal seating.
GateandGlobevalvesareto be in fully closedposition,uvhile
weldingon to thepipelineto prevent'*,eld
splatterfrom falling
directly on to the seatingsurfaceand sparkingbetu'eengate
and body.
Local post u'eld heattreatment(PWHT) of the heataffected
zonecanbe safebut u,edo not recommendthatthe entirevalve
be subjectedto PWHT. Excessivedirect heat may affect the
stem packingand other operatingequipnrents.

3.6 Installationof valve operators

As a standardAIL Gate and Globe rralvesare suppliedrvith
or gear unit for manual operation.
Check valvesdo not requiredany operatorsfor they open and
close automaticallydependingon the flou.condition.
WheneverGate and Globe valvesare orderedwith Actuators
it is fitted at factory itself. All valves with actuatorsare set
and testedat the factory before despatch.
It is stron-elv reconlntended that the actuator setting be not
disturbed,'alteredat site.

3.7 Start up
All vahes should be checkedfbr operationbeforestart-up.
For an actuatedvalve keepingthe gate/discin n-ridposition
by handrvheel,start the actuatorand check if the working
directionis correct.If not. check the wiring corrections.
The pipelineshouldbe cleanedby flushingthoroughlyrvith
\\'ateror air. The valvesshouldbe eitherfully closedor fully
openduringcleaningoperation.If they arepartiallyopenthe
gate/discseatingmay be damagedby the debris flushedout.
Somepipelinesarerequiredto be flushedout at very high speed
(suchassteamblou'in turbineinlet)andin suchcasesparticles
in the pipelinemi-shtdarnageeventhe body seating.Usemetal
protectorsaround the body seatingto prevent damage.

3.8 CommissioningTests
Valves are to be testedas per the relevant testing standard.
If thereis an operationalrequirementto testthevah'esat higher
pressures.temperaturesor durationsthesetest parameters
should be specified and checkedout with AIL prior to
subjectingthe valvesto such tests.

4.1 Gate Valves
Gate valvesare multi tutl valves
rvith rising stem i.e.. they require
number of turns of rotation of
handw'heelfor full closing or full
o p e n i n go f t h e v a l v e . A l l g a t e
valvesshouldbe usedonly in fully
openor fully closeposition.IF used
in slight or half openposition,the Top view of the Valve
gate may vibrateichatterand also
cause u,ire dran'ing at the seatins itrca. gatc r alve
should not be uscd lbr le-gulation.

A l l r a l r e s c l o s cb v r o t a t i n gt h e h a n d u ' h c c lc l o c k u ' i s ca n d o p e n
b y , r o t a t i n g a n t i - c l o c k ui s c .

For handrvheelopcratedvalr es thc-projectionof the stentirbove

t h e h a n d u ' h e e li n d i c a t e su h e t h e r t h c -r a l v e i s i n o p e n o r c l o s e
position. In Gear operated valr.es as the ster.r-r top ,uvillnot be
visible. a separatc indicator can be pror icled if required.

4.1.1 Wedge Gate Valves

The rah.'eis closed bl,driring thc uedge dou,n into the
corresponding tapcr in the bodv. The $'ed-eeand bodv seat
rin_eare matched and lapped fbr perfect sealing. \\"hen thc r,alve
is fulll'open the stem back seatsinto the bonnet bush. llou.er-er
in tlre case of actuator valr.es the stem is not allou.ed to fullv
backseat to avoid dantagc.

A I L u e d - e es a t e r a l v c ' s f L r l l l ' c l o s e b v t o r q u e l i m i t a n d f u l l v
open (backseat) bl travel limit.

4 . 1 . 2 Pa r a l l e lS l i d e Ga te V a l ve s
Unlike \fu'edgesate valves. Parallcl slide gate valves do not
require rved_s:ing actiolt fbr seatin_rr. Tuo independent discs.
held toeetherbv a disc canier and a spring.moves dol'n parallel
and closethe valr e. As soon as the bodv port is sealed.a stopper
in the stent prevr-ntsfirrtht'r travcl. \\'hcn the ralre is opened.
the disc moves up and the stent backseats.Hou,ever in the
caseof actuatorvalvt-sthc stc-r"n is not allou.edto fullv backseat
to avoid danta_qe.

AIL Parallel slide sate \alves fullv close and open by travel

4.2 Globe Valves

All Globe r.alr.esare ntulti turn r.alvess.ith rotating stent and
rising handrvheel.Globe valves can be used for nomtal florv
regulation. Hor'"ever if it is used in slightly opened position
rvhenthe differcntialpressureis very high. the seatingnray
erode.It is advisablenot to usea globevalve for florv control
belo* l0o,ool- lull opcnirrr-1.
All r,alvescloseby rotatingthehandhu,eel
by rotatinganli-clocku'ise.
As the stemtrar.elis verv small in Globe valve comparedto
a samesizegatevalve.it is difficult to makeout rvhetherthe
valve is in open or close position from the stem position.
Generally,Globe r,alvesare handu'heeloperated.In casethe
Globe valve is requiredto be gearoperatedthe valve will be
modified to non-rotatingslem.

4.3 Check Valves

AIL Checkvalvesare srvingtype which automaticallyopens
by the velocity pressureof the flow and closes by the
gravitational force rvhen the florv reversesor stops.

Fig.4 Fig.5

5.0 I N . L I NEMA IN T E N A N C E
G a t e a n d G l o b e v a l v e sr e q u i r eo n l y a m i n i m u m i n - l i n e
maintenancefor satisfactoryperformance.
5.1 Check the gland eye bolts for tightnessat regular intervals.
If loose tighten them evenll,'.
5.2 Greasethe stemthreadsin Gateand Globe Valvesas required.
5.3 Applf' a drop of oil into tlrc stenr packing arca to rcduce thc
friction betueen stell altd pacl<ing.

Greasethe \bke slec're in sate r alve throush tltc srcascnipple


6_0 R O U T I N EMA IN T E N A N C E
6.1 Gland leak
C h e c k t h e t i g h t n e s so f t h e g l a n d e v e b o l t s a n d t i g h t e n n ' e n l 1 '
i f r e q u i r e d .I f t h e l e a k p e r s i s t s t. h e p a c k i n e r n u s tb e r e n e u c d .
For this the valve must be either in full1,'open position (back
seated) or the pipeline n.rustbe shut off so that there is no
p r e s s u r ei n s i d e t h e v a l r e b e f o r e t h e g l a n d c r e b o l t s a r e

Cautiotr: For certain applications like high prL-ssuresteatn,

toric chemicals. etc.. it is uot safer to rento\.ethe gland evcn
u'ith valve fulll' back seated. lt is adr isable to shut ofT the
pipeline belbre attentpting to rcne\\' the packing.

Most of tlre packing rinss are alreadv cut so that thev can be
inserted around the stem. In case of solid rnoulded packing
l i k e G r a p h i t er i n g s . u s e a s h a r p k n i l e a n d c u t t h e l i n s a t 3 0 "
angle.Then sliuhtll.trvist the ring and insert it around the stcr.t.r.
Do not ollen up the rin,s as it could break.

6.2 B o d y - Bo n n e tj o i n t l e a k
Checkthe tightness of the boltingandti_uhten the boltsat the
vicinitv-of the leak. lf leak still persists.reneu the bonnet
gasket.The pipelrnenrustbe shut off bctbre disntantlinsthe

Pressure Seal Bonnet Joint:

ln this ty'pe of joint. there is no nced fbr anr.,'t.naintenanceas
t h e l i n e p r e s s u r ei t s e l f a i d s t h e s e a l i n e .T h e p o s s i b i l i t yo f l c a k
in this type of bonnet is verv remote. If any leak is found.
the gasket must be renewed (see section 7.0).
6.3 G e a r u n i ts
Gear operatedvalr cs are flttcd n'ith enclose\\ atL'rtisht be\.el
_ g e a ru n i t s . T h e g e a r s a r e d e s i q n e d t o f u n c t i o n u , i t l r o u t
maintenancefor lnan1'vears.All gear units are lubricatedri.itlr
a heavv bearing qrcase *.hen assentbledand nrav be refilled
as required.

6. 4 Actuators
For operational
detailsand ntaintenance instructionconsult
the Actuatornranul-acturc-r's
Ensurethatproperelectricalconnections aregivenasindicated
in the u-irirrgdia_erant
for the speciticactuator.

7."1 D i s m a n tl i n g
All valr-esare desisnedto permit inspectionu.itltout rernoving
the body' lrom tlre pipcline. The scction of the pipe must be
shut off before disntantling the valve for inspection.
1.2 Gate and Globc r alvescan be inspectedby rentovingthe bonnet
assemblv.Check r.alvescan be inspectedby.'removingthe cor.er
In the case of Check valr es there is no stent and hence only
the cor.er is to be rer-no\ed. The disc is hinsed inside thc body.
F o r e a s e o f i l l u s t r a t i o no n l v t h e u o r d b o n n e t i s u s e d i n t h e
disnrantlin-rr and reassen.rbly procedure.This nrav be chan-sed
to read as cover n ith respcct to check valves.

7.4 Bolted bonnet / cover valves

1.1.1 Keep the ralve in ntid position and rentovethe handu.heeli
gear unit,'actuatorfronr the top of the r.alve.

7.1.2 Loosen the bod-v-bonnetboltin-qand rernovethe studsand nuts.

7.4.3 Lift the bonnet assemblv includin_ethe stem and satei'discout

of the body. Care should be taken not to drop the gare/disc
rvhile lifting out. N4arkthe matching surfacesof rhe gate and
the bod.v seat rings of gate valves so that thev are not
i ntercIranged durin-rr rL-assemb

I .1.1 Remol'e the bor.rnctgasket.

7.5 Pressure seal bonnet/covervalves

7.-5.1 Keep the valve in mid position.
7.5.2 Stoppershould be first reruovedfrom the stem. For handhu-eeloperatedr.alvesthe stoppercan be takenout
by removin-uthe cylindricalpin and the split pin. For gearoperatedr,alves.first removethe positionindicator
and then the stopperu'ill be clearly visible. For actuatorvalves.first the actuatoris to be dismantledfrom
its thrustbaseandthenthe stopperu'ill be visiblefor removal.
After remor.ingthe stopperassembletlte actuatoragainon to
the adopter.
Important: Stoppcr is machittedto suit each ortd even vah'e
and slrculd not be interchanged.Illile disnnnrling pleasekeep
the stoppet' sa-fel.v.As a nteasure of catrtiort it ttottld be
adfisable to nteosurethe dinrcnsionand nnke u note o-ftlrc
dintensiottof crosslrcle to bottorrtof the stopperinmtediatelv
after disnruntlirtg.This will lrclp in nruking o spare stopper
in an unlbreseenerent o/'stopper being lost in the shop.
7. 5 . 3 Loosenthe voke retaininenuts and pre-loadingnuts of the
7.5.1 Rotatethe handrvheelin clockuise directioll so as to close
the r-alr-e.
The stem-discu.ill traveldou'nand aftertouchingthebottom,
the 1'okeassemblvwill lift up along u'ith actuator'gear
7.5.5 Removalof bonnetretainer. For threadedretainerunscre\\.theretainerin anti-clockwise
directionusinga specialtool throughthe driving slots.[n case
of difficulty cautioushamnreringat the slots rvill be effective
10 For Segmentedretainer
a) remor.eany two bonnetpre-loadingstuds
b) pushthe bonnetdorvnso thatthe segmentar
over the top of the bonnet.
c) drive a pin rhoroughtlre hole providedon the body and
rentovethe segmentalring out.
d) by rotatingthe othersegmenralrings to the sameposition
(oppositethe hole), they can be removed.

Fig.7 Fig.8
7.-'r.(r Lift the bonnet using gland studs.

7 . 5 . 6 . 1 There is no need to remove the gasket set tronr the bonnet

and it can be used man)' times if there is no daurageduring

Fig.9 F i g .1 0

i.5.6.2 to reltlove the gland packirrg and can

It is also not necessar-v-
be re-used as it is if there is no damage.

7.5.7 Lift the entire stem-disc assenrblvout of the bodl'. Check the
disc seatin-eand do not dismantle the assenrbl;-unless any
damage is noticed. I1'damagedthen remove the locking rrire,
lock nut and bolt of the disc carrier.

7. 6 I n s p e c ti o n
7.6.1 Check thc seatingort the bodv seat ring and satei'discfor rvear
or danrage.

,1.6.2 Check the stem and back seat lbr danraqe.

7.6.3 Lap the seating of gate'disc if required. If the body seating

is damaged it mav be lapped rvith a special tool '*'ithout
removing the bodl' lront the pipeline. Hou'ever for this the
valve should be installed at a convenient location. Otherwise
the body' should be removed fron-rthe pipeline for lapping the
seating face.

7.7 Reassemblyof Bolted bonnet/covervalves
7 . 1. l [-ou'er the bonnet asser.nblvincludin-athe gate'disc sntoothl!'
into the bod1.kecpins the gatei'discin open position. Rententber
to match the nrarkingsdone earlieron gate and bodt.seal riugs.
A blue bearing test u'ill confirnr if there is a unifornt contact
betu'een gater'discand body seat rings.
1.1.2 Replace the gland packing. if
necessaryand tighten the eye bolts
onto the eland.
1.1.3 Place the gasket on the bod1.
7.7.4 Fit the bonnet studsand tighten the
nuts evenlv u orkins at diagonally
oppositepairs. Do not over tighten
as rhe gasket ntav get danra-9ed.
I .1.5 Assemble the handhu.eel.oear
F i g .1 1
7. 7 . 6 Operate the ralve front fullv
closed to full;. open position rnanually and ensure free

7. 8 R e a s s e mb l y o f P re ssu re seal bonnet/cover

7.8.1 Assemblethe disc. disc carrier,stemand limit piecesrvith a
bolt.Tightenthe lock nut till the drill hole in the bolt aligns
s'ith the hole in the lock nut. Insefia stainlesssteelu irc and
fold it.
7.8.2 Keepingthediscspressed closelv,slidethedisc-stent
smoothlvinto thebodv u'ithoutdamagingtheseatingsurfaces.
7.8.3 Lou.erthe bonnetalongrviththe gasketsmoothlythroughthe
stem into the bod1.'.
7.8.4 If the ,easketis to be renerved.
a) first low,erthe bonnetalone into the bodv
b) put the bottom ring over the bonnet

c) place the graphitering or.er the bottom ring
d) put the top ring and spaceror er it
e) pushthegasketsetinto thecavityavailablebetu.een
OD and body bore.
7.8.5 If it is a threadedretainerapply anti-seizecompoundlike
Molybdenum Di-sulphategreaseliberally on the threaded
portion of the body and the retainer.Tightenthe retainerin
clockrvisedirectionfully into the body till it touchesthe step
in the bod,vbore.


1.8.6 If it is segmentedretainer.
a) removethe pre-loadingstudsand insertthe segmentalrings
one by one in the qroove providedin the body.
b) alignthesegments in thebody groovesuchthatntid portion
of one of the segmentscomeagainstthe hole in the bod.v.
c) fix the pre-loadingstuds.
7.8.1 Yoke assembly
a) place the yoke assemblyover the stem and rotate the
handrvheelso that yoke sleeve/actuator
bush engagesrvith
the stem
b) yoke assemblyu,ill descendon to the body cover face
c) rotatethe bonnet so that pre-loadingstudsand body studs
are aligned to the drilled holes in the yoke.
d) open the valve full_,-to eet the disc back seatedand bonnet
is raised up

e) In that condition tighten all the studs. While tightening the r oke bolting ensurcthar there is a

minimunt gap of l.-{ ntnt betrveenthe 1.,okeraised face bottom
and the retainer top. If this is not achier.edthen rentovc the
yoke and tighten the threaded retainer fr-rrther.There is no need
to check this aspect in the case of segmented retainer.

Fig.13 Tightenthe bonnetnuts so as to pre-loadthe gasketbut do
not over tighten.
7.8.8 Replacethe gland packing.if necessaryand tightenthe eve
bolts on to the gland.
7.8.9 Stopperassemblv
a) screu'in the stopperonto thestemand alignthe drill holes.
b) insertthe cl.lindricalpin and lock it *'ith the split pin.
c) in case of gear operatedvalr.e assemblethe position
d) for actuatorvalves. removethe actuatorfrom the adaptor
and assemblethe stopper.Then mount the actuatorback
onto the adaptor.
7.8.10 Operatethe valve from fully closedto full-vopen position
manuallv and ensurefree operation.
7 . 8 . I1 When the r.alve is pressurizedfor tl-refirst time after reassemblv.
the pre-loading nuts rvill looscn because of con.rpre'ssion of
bonnetgasket.Retight thc-nuts u'hen the valve is under rr orking
pressure but do not over tighten.

7.9 Actuator Setting

Limit ss itchesare requiredto be set to trip orr trarel limit
or torquelimit for full openiclosepositiondependingon the
designof the valr.e.
The follou-ingchar-tprovidesthe settingparameters.
indicatesthat the actuatorshall trip by, torque limit su'itch.
'Position'indicatesthattheactuatorshalltrip b1'tmrel limit sri'itch.

T1'peof vah'e Close Open

\Ved_ee Torque Position
Parallelslide Position Position
Globe Torque Position
1.9.1 Horv to set the Lin-ritsu'itches? To set Closeon Torque:
The limit srvitchis set at the factory to the requiredtorque
for zero leak. Normally u'hen the valve is disn-rantled for
servicingit may'not be requiredto adjustthe torquesettirrg.
While testin-safter sen'icing.if it is found that the valr-eis
not fully'closedat the initial setting,closethe valr.emanuall-v.
If theleakagcstops.increase the torquesettingof theactuator.
i.9.1.2 To set Open on Position:
Open the r.alvemanuall-vtill it getsback seated.Then close
the talre by'rotatingthe handn'heelby' 1,'2rerolution or by'
3 to 4 mm. At this position set the limit sriitch. To set Closeon Position:
Closethe valr,emanuallytill the stoppertouchesthe actuator
bush. Then open the 'i'alve by rotating the handu'heelby'
1"2rer.olutionor by ? to 3 mm. At this positionset the limrt
su'itch.Checkthe operationso that the closingis by.'thelimit
srvitchand not by the stopper.
7.9.2 For detailedprocedureon periodicmaintenance,
and actuator settings refer to Actuator manufacturer's


Trouble Probable
cause Remedl'(see
Leaksacross a . Valvenotclosed a. Re-tighten
thegateidisc fully (4.I )
b. Reset
of theactuator (6.4)
c . \hlveseatins c. Dismantle.
damaged (7.0)
d . By-pass d. Closethevalve
closed iully
e . By-pass e. Checktheseating
seatmaybedamaged of theby-pass
Leaks a. Packing thegland
through loosened (6.0)
b. Packing Replace
$'ornout (6.0)
Leaks t
Bonnedcorer Tighten
through boltingloose (6.2
bonne[icover If thisdoesnot
joint sealthensuspect
b. Gasket
damage Dismantle
Notclosing Debrisinsidethe Cleanthepipeline
fully' valr,e ( 37 )
b . LimiVTorque b. Resetthesrvitches
of the
settings (6.4&
disturbed 7.9)