KE-0001-09

8/9/2019 KE-0001-09

1/62

OaoMM

ForKITZCarbonSteel,LowAlloySteel,StainlessSteel

andNickelBasedAlloy

Gate,GlobeandCheckValves

(Flanged,ButtWelding,ThreadedandSocketWeldingEnds)

ThankyouforhavingchosenKITZproducts.

Forsafeandtrouble-freefunctionandperformanceof theproduc t,

ensuretoreadandunderstandall itemsofthismanualbeforeva lve

mountingandoperation.

Keepthismanualinaconvenientplaceforyourvalveoperators feasy

access.

8/9/2019 KE-0001-09

2/62

ThismanualappliestotheKITZgate,globeandcheckvalvesmad eofcarbonsteel,lowalloysteel,

stainlesssteelandnickelbasedalloy.

Thismanualispreparedformanualvalveoperation.

For electricor pneumaticvalveoperation, refer totheoperatio nmanual preparedbythe

manufacturersofrelevantvalveactuators.

CAUTIONANDWARNING

Toensuresafeandtrouble-freefunctionandperformance,please readallthecontentsofthis

manualbeforehandling,transportation,mounting,operationand maintenanceofvalves.Keepthis

manualinaconvenientplaceforyourvalveoperatorsfeasyacce ss.

Thesignalwords g WARNING h and g CAUTION h aredefinedasfollows:

Indicatesapotentiallyhazardous situationwhich,ifnotavoide d,willresultin

deathorseriousinjury.

Indicatesapotentiallyhazardous situationwhich,ifnotavoide d,couldresult

inminorormoderateinjury.

Indicatesaprohibitedactionthatmustnotbecarriedout.

Indicatesamandatoryactionthatmustbecarriedout.

NOTESTOUSERS

Thismanualcoversthenormalusageoftheproduct. Technicald ataandinstructionsforoperation,

maintenanceandinspectionoftheproductarepreparedinconsid erationofsafety.However,they

aregoodonlytocover typical applications andprovidedas age neral guidelinetousers. If

technicalassistancebeyondthescopeofthismanualisrequired ,contactKITZCorporation.

Theillustrationsgiveninthis manualdonotintroducealldeta ils. Ifmoredetaileddataisneeded,

refertotherelevantvalveassemblydrawings.

*Anyinformationprovidedinthisoperationmanualissubjectt orevisionatanytimewithoutnotice.

Thiseditioncancelsallpreviousissues.

8/9/2019 KE-0001-09

3/62

CONTENTS

Sheet

T ConstructionandDesignFeatures

GateValveswithOutsideScrewandYoke 2

GlobeValveswithOutsideScrewandYoke 3

SwingCheckValves 4

LiftCheckValves 5

U ValveOperatingDevice

Handwheel 7

HammerBlowHandle 8

BevelGearOperator 9

V TransportationandStorage 10

W ValveMounting

FlangedType 14

ButtWeldingType 18

ThreadedType 21

SocketWeldingType 25

X ValveOperation 28

Y PeriodicInspection 35

Z DisassemblyandAssembly

GateValveswithOutsideScrewandYoke 42

GlobeValveswithOutsideScrewandYoke 47

SwingCheckValves 52

LiftCheckValves 56

8/9/2019 KE-0001-09

4/62

8/9/2019 KE-0001-09

5/62


1. GateValveswithOutsideScrewandYoke

1.1 Thetypicalvalvedesign isasillustratedbelow.

1.2 Thethreadedportionofthestemisexposedbeyondthebonne t,knownasoutsidescrew.

Rotationof thehandwheel mountedonthestemtopraisesor lowe rsstemanddisc

together.

1.3 Clearanceforstemrisingisrequiredforvalveoperation.

1.4 Outside screwdesigns have anadvantage of better resistance against erosionand

corrosionthaninsidescrewdesignsbecausetheirstemthreadsa renot incontactwith

servicefluid.

1.5 Gatevalvesaredesignedforuseinthefullyopenorfully closedpositiononly.

Servicesinintermediatepositioncandamagevalvediscandsea ts.

1.6 Fluidcanflowthroughvalveportinbothdirections.

Thisillustrationintroducesatypicalconstruction.

8/9/2019 KE-0001-09

6/62


2. GlobeValveswithOutsideScrewandYoke

2.1 Thetypicalvalvedesignisasillustratedbelow.

2.2 Thethreadedportionofthestemisexposedbeyondthebonne t,knownasoutsidescrew.

Rotationofthehandwheelmountedonthestemtopcausesthehan dwheeltoriseorfall

togetherwiththestemanddisc.

2.3 Clearanceforhandwheelandstemrisingisrequiredforvalv eoperation.

2.4 Outsidescrewdesignshavean advantageofbetter resistance against theerosionand

corrosionthaninsidescrewdesignsbecausetheirstemthreadsa renot incontactwith

servicefluid.

2.5 Globevalvesaredesignedforuseinthefullyopen,fullyc losedandintermediatepositions

forregulatingservices.

2.6 Globevalveshaveahighfluidresistanceduetotheirdesig n.

2.7 Whenthevalveisintheclosedpositionwithflowunderthe seat,thefluidpushesagainst

thediscandgreatertorqueisrequiredforoperation.

2.8 Flowundertheseatisthepreferreddirectionofflow.


FlowDirection

8/9/2019 KE-0001-09

7/62


3. SwingCheckValves


3.2 Thehingepinretainsthearmanddisc. Thediscmovesupwa rdswithfluidflow.

Withflowinonedirectionthedischingesupwardtopermitflo wthroughthevalve. With

reverseflowthediscisheldclosed.

3.3 Swingcheckvalvespermitflowinonedirectionandprevent thebackflow.

3.4 Fluidcanflowthroughvalveportinonedirection.

3.5 Swingcheckvalvescanbeusedbothonhorizontalandvertic alpiping.

Onverticalpiping,theycanbeusedwithupwardflowandshoul dbeinstalledaccordingto

thearrowonthebody.

Onhorizontalpiping,theyshouldbeinstalledinuprightposit iontopipelines.

3.6 Thediscmaytendtofloatinthebodyandflapagainstthe bodyseatduetoalowvolume

offluidflow,whichisknownasgchatteringh.

3.7 Fluidvortex, turbulenceandpulsationareexpectedat pump outlet anddownstreamof

reducerandelbow,whichmaydamagethevalvesandresultinsho rteninglifecyclesofthe

valves.

Itisrecommendedtoplacevalvesatthedistanceof6timesnom inalsizeorfurtherfromthesedevices.

Thisillustrationintroducesatypicalconstruction

FlowDirection

8/9/2019 KE-0001-09

8/62


4. LiftCheckValves


4.2 Thediscmovesupwardanddownwardalongtheguideprovided withinsideofthecover.

Withflowinonedirection,thediscmovesupwardtopermitflow throughthevalve. With

reverseflow,thediscisheldclosed.

4.3 Liftcheckvalvespermitflowinacertaindirectionandpre ventthebackflow.

4.4 Fluidcanflowthroughvalveportinonedirection.

4.5 Liftcheckvalvescanbeusedonlyonthehorizontalpiping withuprightinstallationposition

tothepiping.

4.6 Thediscmaytendtofloatinthebodyandflaponthebody seatduetoalowvolumeof

fluidflow,whichisknownasgchatteringh(See3.6).

4.7 Fluidvortex, turbulenceandpulsationareexpectedat pump outlet anddownstreamof

reducerandelbow,whichmaydamagethevalvesandresultinsho rteninglifecyclesofthe

valves.

Itisrecommendedtoplacevalvesatthedistanceof6timesnom inalsizeorfurther from

thesedevices.


FlowDirection

8/9/2019 KE-0001-09

9/62

CHAPTER U

ValveOperatingDevice

8/9/2019 KE-0001-09

10/62


1. Handwheel

1.1 Thehandwheel isdirectlymountedtothevalvestemonglobe valvesandtotheyoke

sleeveongatevalves.

1.2 Accordingtothearroworletteronthehandwheel,turningt hehandwheelclockwisecloses

thevalve,andturningthehandwheelcounterclockwiseopensthe valve.

1.3 Handwheeloperatingtorquedependsonthetypeofvalves,thedi rectionforopeningorclosing,pressureinpiping,and thetighteningconditionofthe glandpacking.

Handwheel

8/9/2019 KE-0001-09

11/62


2. HammerBlowHandle

2.1 Thehandwheel isdirectlymountedtothevalvestemonglobe valvesandtotheyoke

sleeveongatevalves.



2.3 Handwheeloperatingtorquedependsonthetypeofvalves,thedi rectionforopeningor

closing,pressureinpiping,and thetighteningconditionofthe glandpacking.

2.4 Theimpactgeneratedbytheblowofhandwheelandbossconve rtstheappliedtorqueinto

alargertorque.

Thisiseffectivewhenalargertorqueisimmediatelyneededfo rthevalveoperation. 2.4.1 Therotationofthehandwheelistransmittedthroughboss tostem.

2.4.2 Aclearance(backlash)withtheconnectingareaofhandwhe elandbossisfurnished.

2.4.3 Theclearance(backlash) helpshammer bloweffect toincre asethevalveoperator

output.

8/9/2019 KE-0001-09

12/62


3. BevelGearOperator

3.1 Forvalveoperation,thebevelgearoperatorismountedont hevalve.



3.3 Handwheeloperatingtorquedependsonthetypeofvalves,thedi rectionforopeningor

closing,pressureinpiping,and thetighteningconditionofthe glandpacking.

3.4 Bevelgearoperatorsareabletotransmitagreatertorquet ovalvestems,byconverting

thetorquefromdriveshaftbymeansofareductiongearingunit .

3.5 Asimilarmechanismtothehammerblowhandleisbuiltinto thegearoperator.

Thisiseffectivewhenalargertorqueoutputisimmediatelynee dedforvalveoperation.

DriveShaft

Stem

BevelGear

8/9/2019 KE-0001-09

13/62

CHAPTER V

TransportationandStorage

8/9/2019 KE-0001-09

14/62

V TransportationandStorage

1. Transportation

1.1 Cautionsforsafety

(1) Keepoffthevalveliftingareatopreventpersonalinjuryc ausedbyunsecuredvalves.

(1) Takecarenottodamagepaintingsurfaceofvalvesduringtr ansportation,whichmaysubsequentlycausecorrosionandrust.

Anydamagedsurfaceshouldbeadequatelytouchedupbeforeinst allation.(2) Takecarewhenhandlingcartonpackedproducts.

Highhumiditymaydamagethecartons.

1.2 Transportation

1.2.1 Keeppackagesastheyaredelivereduntilinstallation. If theprotectivecoversarefoundmissingduringtransportatio n, provideappropriate

typeofprotectivecovers.

1.2.2 Handle valves carefullysothat theymaynot fall or drop onthe ground. Any

extraordinarymechanicalimpactshouldbeavoided.

8/9/2019 KE-0001-09

15/62

V TransportationandStorage

2. Storage


(1) Donotstorevalvesinacorrosiveenvironment,whichmayca usecorrosionon

threadedportionsofvalves.(2) Donotremoveprotectivecoversuntilinstallation.(3) Do not place any other objects on valves, and do not step on them.

Overloadingmaydamagevalves.(4) Donot pileupvalvesforst orage. Unstablepilingmaydamag ethevalvesor

causepersonalinjury.

2.2 Storage

2.2.1 Storevalvesinadust-free,lowhumidityandwellventila tedplace.

Indoorstorageisrecommended.

2.2.2 Storageofvalvesdirectlyonthegroundorconcretefloor isnotrecommended.

Packedvalvesshouldbeplacedonracksforstorage.

2.2.3 Ifvalvesshouldbestoredoutdoors,takeappropriatemeas urestopreventvalvesfrom

directexposuretodust,rainandsunlight.

8/9/2019 KE-0001-09

16/62

CHAPTER W

ValveMounting

8/9/2019 KE-0001-09

17/62

W ValveMounting

1. FlangedType


(1) Check the valve specifications with the catalogs and/or the attachednameplate.

Servicesbeyondthevalvespecificationsmaycausefluidleakag eandvalvemalfunctions.

(2) Donotinstallvalvesforpipeendservice.Itmaycauseext ernalleakage.

Insuchacase,useablankflangetopreventexternalleakage.

(1) Keepasecurefootingforvalveinstallationandoperation.(2) Appropriateleveloflighting shouldbeprovidedtothevalv emountingarea.(3) Pipingshouldbeproperlysupported.

1.1.1 Allowsufficientroomforoperation,installationandsubs equentmaintenanceofvalves.

1.1.2 Forsmoothoperation, inspectionandmaintenance, takeapp ropriateactionsforvalves

whicharerequiredtobeinsta lledinlimitedaccesslocations.

1.1.3 Trynottoinstallvalvesinlocationswherevalvefunctio nalitymaybehamperedbysuch

externalforces,suchasvibrationandother.

1.1.4 Itisrecommendedtoinstallvalvesonhorizontalpipingi nanuprightposition.

1.1.5 Swingcheckvalvescanbeusedbothonhorizontalandvert icalpiping.

Wheninstalledonverticalpiping,theycanbeusedonlywithu pwardflow.

1.1.6 Liftcheckvalvescanbeusedonlyonhorizontalpiping.

8/9/2019 KE-0001-09

18/62

W ValveMounting



(1) Takecarenottocatchfingersinflangesduringmountingwo rk.(2) Takecarenottodamage flangeandseatsurfaces.(3) Pipesshouldbeproperlysupported,ifneeded.(4) Checkvalves areprovidedwithstuffinginsidefor protectio nof theseat

damageduringtransportation. Besuretoremovethesestuffing completelybeforevalvemounting.

(5) Incaseofglobeorcheckvalves, thearrowonthevalvebod yindicatesthe

directionoffluidflow. Valvesshouldbemountedaccordingto thisarrow.

Forgatevalveswithventholes,ventholesshouldbepositione dtothehigherpressuresideinfullyclosedposition.(6) Retightenglandboltsbeforeoperation. Packingtightening stressmayhave

beenloweredduetothestressrelaxationduringtransportation andstorage,whichmaycauseleakageproblemfromglandarea.

(7) Besuretoinsertnewgasketsbetweenthevalveandthepipe flangeforvalve

mounting.(8) Retightenboltsatworkingtemperaturestorestoresurfaces tressat sealing

areasofvalvesusedathightemperatures({200andover).

8/9/2019 KE-0001-09

19/62

W ValveMounting

1.2.1 Checkthefollowingitemsbeforevalvemounting:

(1) Service conditions shouldbe within the range of the valve c lass and material

specifications.

(2) Valveflangesshouldcorre spondwithpipingflanges.

(3) Noscratchordefectshould befoundontheflangegasketsu rfaces.

(4) Theappropriatelengthshouldbesecuredbetweenthepipefl angeswiththevalve

face-to-facedimensionsandgasketthicknesstakenintoconsider ation.

(5) Pipesshouldbealignedaccurately.

(6) Pipeflangesshouldfacepara llel toeachother. Bolt holes of flangesshouldbe

arrangedsymmetricallysuchthattheyarelinedupagainstthec enterlineofflanges.

1.2.2 Beforevalvemounting, removeanyforeignobjectssuchas sand, dust andwelding

spattersfromtheconnectingpipeinterior.

1.2.3 Handle valves carefully so that they do not fall or drop o n the ground. Any


1.2.4 Removeprotectivecoversjustbeforevalvemounting.

1.2.5 Aftervalvemounting,allthreadedportionsshouldbechec ked.

Retightenthem,ifneeded.

1.2.6 Thevalveandpipeinteriorshouldbeflushedtoremovefo reignobjects.

Donotoperatevalvesduringflushing.

8/9/2019 KE-0001-09

20/62

W ValveMounting

1.3 Installationprocedures

1.3.1 Makesurethatpipesarealignedaccurately.

1.3.2 Thelengthbetweenthepipeflangesshouldcorrespondwith thevalveface-to-face

dimensionsincludinggasketthickness.

1.3.3 Insertthevalvebetweenthepipeflanges. Threadboltst hroughbottomboltholesand

tightenboltslightly.

1.3.4 Insertgasketsbetweenthevalveandthepipeflange. It isrecommendedtoapplya

gasketpastetogasketfaces.

1.3.5 Makesurethecorrectalignmentofgaskets,whichareheld bybottomboltsbetweenthe

valveandthepipeflange.

1.3.6 Threadboltsthroughtheotherboltholesandtightenthem lightly.

1.3.7 Tightenboltsevenly,graduallyandalternatelyonthedia gonallineshownasfollows.

Theendsofalltightenedboltsshouldprotrudeequallybeyond thenuts.

1.3.8 Raisethelinetemperatureandincreasepressuregraduall yontestoperation.Retightenthethreadedportions,ifneeded.

8/9/2019 KE-0001-09

21/62

W ValveMounting

2. ButtWeldingType





(1) Keepasecurefootingforvalveinstallationandoperation.(2) Appropriateleveloflighting shouldbeprovidedtothevalv emountingarea.(3) Pipingshouldbeproperlysupported.




2.1.3 Trynot toinstall valvesinlocationswherevalvefunctio nalitymaybehamperedby





8/9/2019 KE-0001-09

22/62

W ValveMounting



(1) Takecarenottodamagebu ttweldingendsandseatsurfaces.

(2) Pipesshouldbeproperlysupported,ifneeded.

(3) Checkvalvesareprovidedwithstuffinginsideforprotectio noftheseatdamageduringtransportation. Besuretoremovethesestuffingcomplet elybeforevalvemounting.

(4) Incaseofglobeorcheckvalves, thearrowonthevalvebod yindicatesthedirectionoffluidflow. Valvesshouldbemountedaccordingto thisarrow.Forgatevalveswithventholes,ventholesshouldbepositioned tothehigher

pressuresideinfullyclosedposition.

(5) Retightenglandboltsbeforeoperation.Packingtightenings tressmayhavebeenloweredduetothestressrelaxationduringtransportationands torage, whichmaycauseleakagefromglandarea.

(6) Retightenboltsat workingtemperaturestorestoresurfaces tressat sealingareasforvalvesusedathightemperatures({200andover).

2.2.1 Theserviceconditionsshouldbewithintherangeof thev alveclassandmaterial

specifications.

2.2.2 Beforevalvemounting,removesand,dustandweldingspatt ersfromtheconnectingpipe

interior.

2.2.3 Handle valves carefullysothat theymaynot fall or drop onthe ground. Any



2.2.5 After valvemounting, all threadedportionshouldbecheck ed. Retightenthem, if

needed.


Donotoperatethevalveduringflushing.

8/9/2019 KE-0001-09

23/62

W ValveMounting

2.3 Cautionsforweldingwork

Topreventvalvedamagefromoverheating,weldingworkshouldb emadecarefullyaccording

tothefollowingcautions:

2.3.1 Valveshouldbeweldedwiththediscslightlyopened.

2.3.2 Allweldingworkformountingvalvesonthepipelineshoul dbemadebyqualifiedwelders

inaccordancewiththequalifiedweldingprocedures.

2.3.3 Selectappropriateweldingrodsforvalvesandpipingmate rials.

Ifcoveredweldingrodsareused,checkthattheyarestoredan ddriedappropriately.

2.3.4 Itisrecommendedtouseback-shieldinggasforthefirst layerofwelding.

2.3.5 Visual inspectionornon-destructiveexaminationsarerequ iredtocheckweldcracks,

overlapsandundercutorotherdefects.

2.3.6 Dependingonthevalveandpipematerials, heat treatment after weldingmaybe

required.

2.3.7 Valvesshouldbeprotectedfromoverheatingbymeansof co veringthemwithwet

cloths.

8/9/2019 KE-0001-09

24/62

W ValveMounting

3. ThreadedType




(2) Donotinstallvalvesforpipeendservice. Itmaycauseex ternalleakage.

(1) Keepasecurefootingforvalveinstallationandoperation.

(2) Appropriateleveloflighting shouldbeprovidedtothevalv emountingarea.

(3) Pipingshouldbeproperlysupported,ifneeded.


3.1.2 Forsmoothoperation,inspectionandmaintenance,takeapp ropriateactionsforvalves










8/9/2019 KE-0001-09

25/62

W ValveMounting

(1) Takecarenottodamagethreadedareasandseatsurfaces.

(2) Donotdisassemblevalvesduringmountingwork.

(3) Checkvalvesareprovidedwithstuffingforprotectionof th eseat damageduringtransportation. Besuretoremovethestuffingcompletel ybeforevalvemounting.

(4) Incaseofglobeorcheckvalves, anarrowonthevalvebody indicatesthedirectionoffluidflow. Valvesshouldbemountedaccordingto thisarrow.

(5) Usesealingmaterialsapplicabletothetemperatureandthe fluidatthreaded

areas.

(6) Usespannersoranyotherappr opriatetools. It isprohibite dtouseapipewrench.

(7) Fitspannersonthevalveendstobeconnectedwithpipes.D onotfitthemontheotherends.

(8) Donotovertightenvalves.Itmaydamagevalveinternals.

(9) Retightentheglandboltsbefo reoperation. Packingtighten ingstressmaybeloweredduetothestressrelaxationduringtransportationands torage,whichmaycauseleakageproblemfromtheglandarea.

(10) Retightenboltsatworkingtemperaturestorestoresurface stressatsealingareasforvalvesusedathightemperatures({200andover).

8/9/2019 KE-0001-09

26/62

W ValveMounting

3.2.1 Checkthefollowingitemsbeforevalvemounting:

(1) Service conditions should be within the range of the valve c lass and material

specifications.

(2) Valvethreadsshouldcorre spondwithpipingthreads.

(3) Nodamageshouldbefound onvalveandpipingthreads.

(4) Threadsdimensionsshouldcorrespondwiththeapplicablesta ndards.

3.2.2 Removeforeignobjectssuchassand, dustandweldingspat tersfromtheconnecting

pipeinterior.







Donotoperatevalvesduringflushing.

8/9/2019 KE-0001-09

27/62

W ValveMounting

3.3 Installationprocedures(threaded)

3.3.1 Makesurethatvalvesandpipesarethreadedproperly .

3.3.2 Remove foreignobjects suchas cuttingoil andspatters fr ompipe internals and

threadedareaswithdetergentorwastecloth.

3.3.3 Applysealingmaterialsuchassealingtapetothepipeth reads.

3.3.4 Useappropriatetoolstothreadpipesintovalves.

3.3.5 Donot applyanyexcessivetorquetothreadpipeendsinto valves. Torquestobe

appliedshouldbewithinthefollowingranges.

NominalSize 1/8 1/4 3/8 1/2 3/4 1

TorqueNEm

20to29 20to29 20to29 20to29 39to49 49to59

NominalSize 1-1/4 1-1/2 2 2-1/2 3andup

TorqueNEm 59to69 69to78 78to88 108to118 127to137

3.3.6 Raisethelinetemperatureandincreasepressuregradually ontestoperation.Retighten

thethreadedareas,ifneeded.

8/9/2019 KE-0001-09

28/62

W ValveMounting

4. SocketWeldingType





(1) Keepasecurefootingforvalveinstallationandoperation.(2) Appropriateleveloflighting shouldbeprovidedtothevalv emountingarea.(3) Pipingshouldbeproperlysupported,ifneeded.










8/9/2019 KE-0001-09

29/62

W ValveMounting



(1) Takecarenottodamagesock etweldingendsandseatsurface s.

(2) Checkvalves areprovidedwith stuffinginsidefor protectio nof theseatdamageduringtransportation. Besuretoremovethesestuffing completely

beforevalvemounting.

(3) Incaseofglobeorcheckvalves, anarrowonthevalvebody indicatesthedirectionoffluidflow.Valvesshouldbemountedaccordingtot hisarrow.Forgatevalveswithventholes,ventholesshouldbepositioned tothehigher

pressuresideinfullyclosedposition.

(4) Retightenboltsatworkingtemperaturestorestoresurfaces tressat sealingareasforvalvesusedathightemperatures(+200 andover).

(5) Retightenglandboltsbeforeoperation. Packingtightening stressmayhavebeenloweredduetothestressrelaxationduringtransportation andstorage,whichmaycauseleakagefromglandarea.

4.2.1 Theserviceconditionsshouldbewithintherangeof thev alveclassandmaterial

specifications.

4.2.2 Beforevalvemounting,removeforeignobjectssuchassand ,dustandweldingspatters

fromtheconnectingpipeinterior.






4.2.6 Thevalveandpipeinteriorshouldbeflushedtoremovefo reignobjects. Donotoperatevalvesduringflushing.

8/9/2019 KE-0001-09

30/62

W ValveMounting

4.3 Cautionsforweldingwork

Topreventvalvesfromoverheating, weldingworkshouldbemade carefullyaccordingto

thefollowingcautions.

4.3.1 Valvesshouldbeweldedwiththediscslightlyopened.

4.3.2 Allweldingworkformountingvalvesonthepipelineshoul dbemadebyqualifiedwelders

inaccordancewiththequalifiedweldingprocedures.

4.3.3 Selectappropriateweldingrodsforvalvesandpipingmate rials.

Ifcoveredweldingrodsareused,checkthattheyarestoredan ddriedappropriately.

4.3.4 It isrecommendedthat thepipebewithdrawnapproximately 1.6mmawayfromthe

bottomofthesocket,whenthepipeisseatedagainstthebottom ofthesocket.

4.3.5 Visual inspectionornon-destructiveexaminationsarerequ iredtocheckweldcracks,

overlapsandundercutorotherdefects.

4.3.6 Dependingonthevalveandpipematerials, heat treatment after weldingmaybe

required.

4.3.7 Valvesshouldbeprotectedfromoverheatingbymeansof co veringthemwithwet

cloths.

Valve

Approx0.06 h

(1.6mm)

beforewelding

Pipe

8/9/2019 KE-0001-09

31/62

CHAPTER X

ValveOperation

8/9/2019 KE-0001-09

32/62

X ValveOperation

1. Cautionsforsafety

(1) Donotapplytoomuchtorquetothevalveoperatingdevices.

(2) Donotloosenboltsandnutsofglandandbonnetofpressuri zedvalves.

(3) Donotoperategatevalvesintheintermediatepositionfor alongperiod.Itmaydamagethediscandseats.

(4) Openvalvesgraduallytopreventdamageofpipes,whenthev alvehandleshightemperaturefluidsuchassteam.

(5) Closevalvesgraduallytopreventwaterhammer,ifthevalve handlesliquidfluid.

(6) Takeappropriatemeasurestopreventvalvesandpipesfromf reezing.

2. Operation(GateandGlobeValves)

2.1 Turnthehandwheelclockwiseaccordingtothesymbolsormar ksindicatingthedirectionto

closevalves. Turnitcounterclockwisetoopenthem.

2.2 Operatingtorquedependsonthetypeofvalve,openingdegree,a ndserviceconditions.

2.3 Besuretoturnthehandwheelofgatevalvesbacktotherev ersedirectionbyabout90 ,

whenvalvesreachfullyclosedposition. Thisisimportantinh ightemperatureservicesto

preventthermalstressandenablevalvereopeningeasierandsmo other.

8/9/2019 KE-0001-09

33/62

X ValveOperation

3. Whenthespecialtoolillustra tedbelowisusedfortheeasy valveoperation,donotapplytoo

muchtorquetovalves.

Refertothefollowingtableforrecommendedmaximumsizesoft ools.

(Unit:mm)

GlobeValve GateValveJIS10K

ASMEClass150JIS20K

ASMEClass300JIS10K

ASMEClass150JIS20K

ASMEClass300

ValveNominal

Size(mm)

Length(L) Length(L) Length(L) Length(L)

40

50

65

80

100

125

150

200

250

300

70

100

200

225

380

660

680

750

185

200

285

460

650

1150

80

80

150

150

250

360

515

590

670

800

130

200

300

320

440

600

620

670

820

1040

Note) Thetableshownabovequotedfrom Guidelineof Valve

Handling , f ourthedition, issuedbyHighPressureGas

SafetyInstituteofJapan.

Ao1m )

8/9/2019 KE-0001-09

34/62

X ValveOperation

4. DailyInspection

Inorder tooperateyour valves safetyandsatisfactorily, the dailyinspectionis very

important. Herearetheinspectionitems.

Periodicretighteningofpackingisnecessaryasamaintenance procedure.

Iemtob

inpe

Vvty

etob

npe

Inpo

mh

Rmma

mue

GatevalvesGlovevalves

Glandarea

VisualcheckSoapwater

Retightenglandbolts.Replaceglandpacking.

FlangedareasVisualcheck

Soapwater

Retightenflangebolts.

Replacegaskets.

ThreadedportionsVisualcheckSoapwater

Retighteneachthreadedportion.Replacecomponentsasrequired.

Externalleakage

All

BodysurfaceVisualcheckSoapwater

Replacethevalvewhenexcessivecorrosionordamageisobserved.

Valvebody Auditorycheck Consultapipingengineer.

Loosenedbolts Auditorycheck Retightenbolts.Abnormal

noises

All

Vibrationofpipes Auditory check Consultapipingengineer

Loosenedboltsandnuts

All BoltsandnutsVisualcheckTactualcheck

Retightenboltsandnuts.

Seatleakage

All - -

Removeanyforeignobjects.Disassembleandinspectthevalvecomponents.(Laptheseatsurfaces)Replacethevalve.

GatevalvesGlobevalves

Operatingposition VisualcheckMakesurethatthevalveisinanappropriatepredeterminedposition.

Valveoperation

All UnsmoothoperationTestoperationAuditorycheck

Lubricatethemovingarea.Disassembleandinspectthevalvecomponents.

8/9/2019 KE-0001-09

35/62

X ValveOperation

Thisillustrationshowsinjection andapplicationofgreasetot heyokesleevesection.

5. RemedialMeasures

(1) Wearprotectiveitemssuchasgoggles,glovesandworkingbo otsasrequiredatworksite.

(2) Takesafetymeasuresagainsttoxic,flammableorcorrosivef luids.

(3) Reducelinepressuretothe atmosphericlevel beforeretight eningglandandflangeboltsandnuts.

(4) Operatorsshouldtakeprotectivemeasurestopreventdirect exposuretothefluid,whenthefluidspoutsoutfromflangedareas.

(5) Reducelinepressuretotheatmosphericlevelwhenthepacki ngandgasketsarereplacedorboltsandnutsareloosened.

Loosentheglandboltsgradually,whenthevalvehandlesvolati lefluid.

(6) When the packing needs to be replaced with valves installed on piping,backseatingofthestemandbodyiseffectiveinthevalvesfull yopenposition.Butsometimesforeignobjectsmaybestuckbetweenthebackseat surfaceandcauseleakage. Besuretocheckthatnoleakageisobservedbefo repacking

replacementToavoidreplacement ofallpackingrings,addorre placeoneortwopackingringsasatemporaryremedy,andreplaceallpacking ringsduringthenextplannedmaintenance.

(7) Donotapplylubricantstothepipesandvalveswhichhandle oxygen.

HANDWHEEYOKESLEEVE

INJECTGREASE

GREASENIPPLE

SLEEVENUT

APPLYGREASE.

8/9/2019 KE-0001-09

36/62

XValveOperation

5.1 Leakagefromtheglandarea

Retightenthe glandbolts or nuts if the leakage is foundfrom the glandarea. If

retighteningtheglandboltsornutscannotsolvetheleakagepr oblem, theglandpackingshouldbereplacedwithanewset.

5.2 Leakagefromtheflangearea

Tightenflangeboltsevenly, graduallyandalternatelyonthe

diagonallineshownasfollows.

8/9/2019 KE-0001-09

37/62

X ValveOperation

6. Troubleshooting

Toe Pbec Romndmm

Threadedsections onthestembecomestiff because thevalvewasnotusedforalongperiod.

Applylubricant totheyokesleeveand the stemscrewengagement

part.Injectiongreasethroughthegreasenippleifapplicable(seepage32/59).

Operationimpossible

Foreign objects choke up theseats.

Flushout theforeignobjectswithfluidflow.

Foreign objects adhere to the

stem.

Remove the foreign objects andcheckthevalve.Then,evenlyapplygreasetothethreadedportions.

Foreign objects choke up thevalvecavity.

Flushout theforeignobjectswithfluidflow.Disassembleandinspect thevalvecomponents.

Unsmoothoperation

Gland bolts and nuts areovertightened.

Loosenglandbolts andnuts andretightenthemadequately.

Stemdamage Toomuchtorqueisapplied. Replacethedamagedcomp onents.

Gland bolts and nuts areloosened.

Retightenglandboltsandnuts.

Gland bolts and nuts aretightenedunevenly.

Tightenboltsandnutsevenly.

Glandpackingisdamaged. Replacetheglandpacking.

Leakagefromglandarea

Stemisdamaged. Replacethestem.

Seatsaredamaged.i cavitation j

Consultthepipingengineer.Leakagefromseatareawhenthevalveisinthefullyclosedposition Seatsaredeformed. Consultthepipingengineer

Generationofabnormalnoisesandvibration

Boltsandnutsareloosened. Retightenboltsandnuts.

8/9/2019 KE-0001-09

38/62

CHAPTER Y

PeriodicInspection

8/9/2019 KE-0001-09

39/62

Y PeriodicInspection

1. PeriodicInspection

1.1 Itisrecommendedtocarryoutaperiodicinspectionabouto nceayearagainstvalveson

pipes.

1.2 Ensurethesmoothoperationandsufficientvalvefunction.

1.3 SeeChapterXgValveOperationhforinspectionitemsandins pectionmethods.

1.4 Carryouttheperiodicinspectionforvalveswhicharenoto peratedforalongperiodornot

subjectedtodailyinspection.

1.5 It is extremelyimportant tocheckanyvalves whensuchvalv es areusedunder the

followingservicesorconditions:

a) Whereerosionandcorrosionofvalveinteriorareexpected.

b) Wherechokingoffluidisexpected.

c) Whereperformancefailureofvalvescouldresult inamajors hutdownofanentire

plant.

1.6 Itisrecommendedtoreplacetheglandpackingonperiodici nspection.

8/9/2019 KE-0001-09

40/62


2. MaintenanceandInspection

Inpipingfacilitieswherevalvesareinstalledandaretobes etopenforperiodicmaintenance

and inspection, it is recommended to carry out leakage and opera tional tests. No

internal/seat leakageandexternal leakageshouldbedetected, a ndvalvesshouldoperate

smoothlywithoutgallingandsticki ng. Ifdetectinganyofabov eproblems,disassembleand

checkthevalvecomponents. After reassembly, theabove-mention edtests shouldbe

carriedoutandresultsshouldbesatisfactory.


(1) Dischargefluidfromthepipesandreducethelinepressure toatmosphericlevel. Trappedpressureofflui disverydangerousandmaycaus eaccidentsresultinginpersonalinjury.

Incaseofinstallationforpipeendservice,fluidmightbeenc losedbetweenthevalveandtheblankflange.Openthevalveanddischargethe fluidfromthepipebeforeremovingtheblankflange.

(2) For gate valves, dismantle valves frompiping with the valve in theintermediateposition. Dischargefluidandpressuretrappedwit hinthefullyclosedvalvebody.

(3) Completelydischargetoxic,flammableorcorrosivefluidfro mpipeandvalveinterior.

(4) Operatorsmust takeprotectivemeasuresagainst fluidspouti ng. Nofireshouldbeallowedinworkingarea.


(1) Wearprotectiveitemssuchasgoggles,glovesandworkingbo ots.

(2) Keepasecurefootingforvalvedismantlingandinstallation .

(3) Pipingandvalvesshouldbeproperlysupported,ifneeded.

(4) Beforedismantlingvalvesfromthepipeline,markthevalve bodyandcoupledpipeflangeswiththeiroriginalposition. Reinstallthevalve onpipesaligningthesematchmarksafterassembly.

(5) Besuretoinsert newgaske tsbetweenthevalveandtheflan geforvalvemounting.

8/9/2019 KE-0001-09

41/62


2.2 Disassembly

DisassemblethevalveaccordingtotheinstructionsinChapter Z ofthismanual.

2.3 Eachdisassembledpartshouldbeinspectedaccordingtothe followingtable.

Remedial methods

weldrepair* weldrepair* weldrepair andmachining lapping weldrepair andmachining replacement ofthedisc

replacement grinding grinding

Judgment

nocorrosion noharmfuldamage

nocrack nocorrosion minimumwall thickness smoothoperation nocorrosion noharmfuldamage

goodlapping smoothoperation nocorrosion nodeformation nocorrosion smoothoperation smoothoperation

Inspection methods

visualexamination measurementof wallthickness visualexamination measurementof wallthickness NDE visualexamination visualexamination visualexamination visualexamination visualexamination tactual examination tactual examination

Itemstobe inspected

corrosionharmfuldamage crack corrosion scratch crack corrosion erosion corrosion scratch crack erosion corrosion erosion corrosiondeformation corrosion smoothoperation smoothoperation

Areastobe inspected

flanges wetted areas discguide seat surfaces discguide stem-disc connection locknut slidingareaof disc&cover/arm movingareaof hingepin&arm

Valve types all gate all gate globe check

Partstobe inspected

body and

bonnetseat anddisc

*Replacethevalve,ifweldrepairisimpossible.

8/9/2019 KE-0001-09

42/62


Remedial methods

replacement repair replacement replacement replacement repairandlubrication replacement replacement

Judgment

nocorrosion noscratch nodeformation nocorrosion noerosion nocorrosion noerosion noscratch replacement (onceayear)

smoothoperation noerosion nocrack nodeformation

Inspection methods

visualexamination measurement visualexamination visualexamination visualexamination tactual examination visualexamination visualexamination

Itemstobe

inspected

corrosion erosion scratchdeformation corrosion erosion corrosion erosion scratch deterioration smoothoperation erosion crackdeformation

Areastobe inspected

stem threadedareas insidesurfaceof

stuffingbox glandpackinggasket

slidingareas threadedareas shoulder

Valve types gate globe gate globe gate globe gate globe

Partstobe inspected

stem

stuffingbox glandpacking

gasket

yokesleeve yokebush

2.4 Assembly

AssemblethevalveaccordingtotheinstructionsinChapter Z ofthismanual.

8/9/2019 KE-0001-09

43/62


2.5 TestsandInspections

Thefollowingaremainitemsrequiredfortestsandinspections ofvalves.

2.5.1 Operationtest

(1)Thevalveshouldbeoperatedsmoothlybyhandwheelwithout gallingorsticking.

(2)Thestemshouldbefirmlyconnectedwiththedisc.

(3)Forgatevalves,whentheyarefullyclosed,thecenterof thediscshouldbelocated

upwardsfromthecenterofthebodyseat. Andwhentheyareful lyopened, the

lowerendofthediscshouldnotprotrudeintotheportofthev alve.

(4)Forglobevalves,thediscshouldbeseatedandalignedon thebodyseatsperfectly,

whenthevalveisfullyclosed. Nomisalignmentoroffsetofdi scandseatcenter

shallbeacceptable.

(5)For checkvalves, thediscshouldmovesmoothly. Andwhen valves arefully

opened,thediscshouldbestoppedagainstthestopperprovided inthevalvebody.

2.5.2 Shelltestandseatleakagetest

(1)Cautionsforshellte standseatleakagetest

(1) Wearprotectiveitemssuchasgoggles,glovesandworkingbo ots.(2) Takesufficientprecautionsbe foreperformingshelltestand seatleakage

testforoperator ssafety.

(2) Shelltestandseatleakagetest

Allvalvesaresubjectedtoahydrostaticorpneumaticshellt estandseatleakage

testattherequiredtestpressureafterassembly.

RefertotheJISB2003,JPI-7S-39orAPI598fortestmethods .

8/9/2019 KE-0001-09

44/62

CHAPTER Z

DisassemblyandAssembly

8/9/2019 KE-0001-09

45/62


1. GateValveswithOutsideScrewandYoke

1.1 Disassembly

1.1.1 Cautionsforsafety

(1) Operatorsmust takeprotectivemeasurestoprevent direct ex posuretothe

fluid,whenthefluidspoutsoutfromvalves.

(1) Wearprotectiveitemssuchasgoggles,glovesandworkingbo ots.(2) Takecarenottocatchfingersinflangesduringdisassembly .(3) Whendisassemblingvalvesofla rgesizes,useanappropriate machinetoliftup

valves.

1.1.2 Beforedisassembly

(1) Disassemblethevalveinadust-freeplace.

(2) Takecarenottodamagetheseatsurfaces,stemthreadsand flangesurfaces.

(3) Makematchmarksonthebodyandbonnetflangesforrealignme ntduringassembly.

Alsothediscandbodyshouldbe marked, sothat thedisccanb emountedinthe

originalposition.

8/9/2019 KE-0001-09

46/62

ZDisassemblyandAssembly

1.1.3 Disassembly

Note:seesheet46/59forreferencefigure.

(1) Openthevalvetotheintermediateposition.

(2) Loosenthewheelnuts.

(3) Loosentheglandnuts.

(4) Removethebonnetboltsandnuts.

(5) Removethebonnet upwardsfromthebodyslowly. Thesteman ddisccomeup

togetherwiththebonnet. Careshouldbetakennottodropthe discintothebody.

Checkandmarkthediscoriginalposition.

(6) Removethediscfromthestem.

(7) Removethegasketfromthebonnetflange.

(8) Turnthehandwheelclockwisetodisengagethestemfromthe yokesleeve.

(9) Removethestemfromthebonnet.

(10)Removetheglandnuts,gland,glandpackingandotherauxil iaryparts.

(11)Removethewheelnut,handwheelandyokesleeveandothera uxiliaryparts.

8/9/2019 KE-0001-09

47/62

ZDisassemblyandAssembly

1.2 Assembly

1.2.1 Cautionforsafety

(1) Wearprotectiveitemssuchasgoggles,glovesandworkingbo ots.(2) Nofireshouldbe allowedinworkingarea.(3) Takecarenottocatchfingersinflangesduringassembly.

(4) Replacethepackingandgasket withnewonestoensuresatis factorysealingperformance.

(5) Whenassemblingvalvesoflargesize,useappropriatemachin etoliftupvalves.

(6) Donotapplylubricantstothepipesandvalveswhichhandl eoxygen.

1.2.2 Beforeassembly

(1) Theconsumablesshouldbepreparedbeforeassembly.

(2) Cleanpartstoremovedustandotherforeignobjects.

(3) Assemblethevalveinadust-freeplace.


(5) Assemblethevalvealigningthematchmarksprovidedbefored isassembly.

(6) Allboltsandnutsshouldbetightenedsecurely.

8/9/2019 KE-0001-09

48/62


1.2.3 Assembly


(1) Mounttheyokesleeve,handwh eelandotherauxiliarypartso nthebonnet,andtighten

thewheelnut.

(2) Assembletheglandpacking, glandandother auxiliaryparts withbonnet. Tighten

glandboltsandnutstemporarily.

(3) Assemblethestemwithbonnet,andengagethestemthreadsw ithyokesleeve. Turn

thehandwheelcounterclockwisetotheintermediateposition.

(4) Mountthegasketonthebonnetflange.

(5) Assemblethediscwithstem, andplacetheminsidethebody accordingtothedisc

guide. Makesurethediscoriginal positionis alignedaccordin gtothecoupling

matchmarksprovidedbeforedisassembly.

(6) Tightenbonnetboltsandnutsevenly, graduallyandalternat elyonthediagonal line.

Theendofeachtightenedboltshouldprotrudeequallybeyondth enut.

(7) Tightenglandnutsadequately. Toomuchtighteningmaycaus eunsmoothoperation.

(8) Checkeachthreadedportion. Retightenthem,iffoundloose ned.

8/9/2019 KE-0001-09

49/62


1.3 AssemblyIllustration


Refertotheapprovaldrawingbe foredisassemblyandassembly.

No. PartsName1 Body2 Bonnet3 Stem4 Disc7 Gland8 GlandPacking9 Handwheel10 WheelNut16 NamePlate19 Gasket30 BodySeatRing33 BonnetNut34 GlandNut35 BonnetBolt36 GlandBolt38 BonnetBush39 SetScrew41 GlandBoltPin42 YokeSleeve46 GlandFlange

77 SleeveNut122 GreaseNipple

8/9/2019 KE-0001-09

50/62


2. GlobeValveswithOutsideScrewandYoke

2.1 Disassembly





valves.




(3) Matchmarkthebodyandbonnetflangesforeasyassembly.

8/9/2019 KE-0001-09

51/62

8/9/2019 KE-0001-09

52/62


2.2 Assembly


(1) Wearprotectiveitemssuchasgoggles,glovesandworkingbo ots.

(2) Nofireshouldbe allowedinworkingarea.

(3) Takecarenottocatchfingersinflangesduringassembly.

(4) Replacethepackingandgasketwithnewonestoensuresatis factorysealing

performance.(5) Whenassemblingvalvesoflargesize,useappropriatemachin etoliftupvalves.









8/9/2019 KE-0001-09

53/62


2.2.3 Assembly


(1) Assembletheglandpacking, glandandotherauxiliaryparts, andtightenglandboltsand

nutstemporarily.

(2) Assemblethestemwiththebonnet,andengagethestemthrea dswiththeyokebush.

Turnthestemcounterclockwisetotheintermediateposition.

(3) Mountthehandwheelonthestem,andsecureitwiththewhee lnut.

(4) Mountthegasketonthebonnetflange.

(5) Assemblethebonnet withthebodyaligningwiththecoupling matchmarksprovided

beforedisassembly.

(6) Tightenbonnetboltsandnutsevenly, graduallyandalternat elyonthediagonal line.


(7) Tightenglandnutsadequately. Toomuchtighteningmaycaus eunsmoothoperation.


8/9/2019 KE-0001-09

54/62





No. PartsName1 Body2 Bonnet3 Stem4 Disc5 LockNut7 Gland

8 GlandPacking9 Handwheel10 WheelNut16 NamePlate19 Gasket30 BodySeatRing31 StemWasher33 BonnetNut34 GlandNut35 BonnetBolt36 GlandBolt37 YokeBush38 BonnetBush41 GlandBoltPin

46 GlandFlange

8/9/2019 KE-0001-09

55/62


3. SwingCheckValves

3.1 Disassembly





valves.



(2) Takecarenottodamagethe seatsurfacesandflangesurface s.

(3) Matchmarkthebodyandcoverflangesforeasyassembly.

3.1.3 Disassembly


(1) Removethecovernuts.

(2) Removethecover.

(3) Removethegasket.

(4) Removetheplug.

(5) Removethehingepinwhichremainshangingthedisc.

Supportthediscbyhandtoremovethehingepin.

(6) Removethediscfrominsideofbody.

8/9/2019 KE-0001-09

56/62


3.2 Assembly



(4) Replacethegasketwithnewonestoensuresatisfactoryseal ingperformance.(5) Whenassemblingvalvesoflargesize,useappropriatemachin etoliftupvalves.




(2) Cleanpartstoremovethedustandotherforeignobjects.





8/9/2019 KE-0001-09

57/62


3.2.3 Assembly


(1) Insertthedisc-armsub-assemblyintobody.

(2) Assemblethehingepinwiththedisc-armsub-assemblycomple telythroughthebody

hole.

(3) Mountthegasketbetweentheplugandthebody. Assembleth eplugwithbody.

(4) Mountthegasketonthecoverflange.

(5) Assemblethecoverwiththebodyaligningmatchmarksprovide dbeforedisassembly.

(6) Tightencoverboltsandnutsevenly, graduallyandalternate lyonthediagonal line.



8/9/2019 KE-0001-09

58/62



Thisillustrationintroducesatypicalconstruction.Refertotheapprovaldrawingbe foredisassemblyandassembly.

No. PartsName1 Body2 Cover4 Disc13 DiscNut14 SplitPin

16A NamePlate16B Washer17 HingePin

18 Plug19 Gasket30 BodySeatRing33 CoverNut35 CoverBolt44 Gasket69 Arm70 Washer75 EyeBolt

8/9/2019 KE-0001-09

59/62


4. LiftCheckValves

4.1 Disassembly




(1) Wearprotectiveitemssuchasgoggles,glovesandworkingbo ots.(2) Takecarenottocatchfingersinflangesduringdisassembly .




(3) Matchmarkthebodyandcove rflangeforeasyassembly.

4.1.3 Disassembly


(1) Removethecovernuts.

(2) Removethecover.

(3) Removethegasket.

(4) Removethediscfrominsideofbody.

8/9/2019 KE-0001-09

60/62


4.2 Assembly



(4) Replacethegasketwithnewonestoensuresatisfactoryseal ingperformance.









8/9/2019 KE-0001-09

61/62


4.2.3 Assembly


(1) Placethediscinsidethebody.

Makesurethediscseatedonthebodyseatperfectly.

(2) Mountthegasketonthecoverflange.

(3) Assemble the cover with the body aligning the matchmarks pro vided before

disassembly.

(4) Tightencoverboltsandnutsevenly, graduallyandalternate lyonthediagonal line.



8/9/2019 KE-0001-09

62/62





No. PartsName1 Body2 Cover4 Disc

16 NamePlate19 Gasket33 CoverNut35 CoverBolt

Documents

KE-0001-09