INDUSTRIAL

VALVES &
EQUIPMENTS

INSTALLATION OPERATION
AND MAINTENANCE
MANUAL

Industrial Valves & Equipments

A/2, Prakash Kunj, B.P. Road,
Goddev Naka, Bhayendar
(East), Thane, Maharashtra,
India, Pin Code.: 401105.
Phone:+91-22-28044565
Fax: +91-22-28045840
e.mail : [email protected]

Page 1
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INTRODUCTION
“IVE” FLUSH BOTTOM VALVES have been designed and manufactured to give you long,
excellent and trouble free service.
This manual provides you with all the relevant information to install, operate and maintain
the valve for long trouble free life. Please note that all the drawings provided in this
manual are typical views.

1.0 PRIOR TO INSTALLATION

1.1. On receipt of material check for any damage during transportation.

1.2. Wrapping and protection applied should be left in place until the valve is
installed.

1.3. If the valves are left exposed, they should be protected against entry of foreign
material in the valve parts.

1.4. Flush the Tank clean before mounting the valve at the Bottom Outlet of the
Tank. Impurities such as sand and parts of welding electrodes could damage
the seats & surfaces of the Valves.

1.5. If the valves are stored for a long time, they should be cleaned, lubricated and
tested prior to installation. It is advisable to store the valve in full open position.

1.6. In Lever operated valve, the position of Handle is an indication of whether the
valve is open or closed. When the Handle is aligned with axis of the pipe the
valve is open. When it is Perpendicular to the pipe, the valve is closed.
While in the Hand Wheel Operated Valves, you can identify the open & close
positions by checking it in Clock wise & Anticlock wise directions.
Clockwise :- Close & Anticlock wise :- Open

2.0 INSTALLATION

2.1 Flush Bottom Valves are generally installed b e l o w t h e T a n k however

avoid stem position on sides. It is recommended to mount the valve having
stem in v e r t i c l e position.

2.2 Valve should not carry the weight of the Tank & piping. Proper support of the
pipeline will minimize strain on the valve caused by shock in the pipe
system. Do not fasten supporting structure to the valve flanges.

2.3 Do not attempt to correct pipe misalignment by means of flange bolts.

2.4 Do not allow the valves to carry the weight of pipeline to avoid distortion and
jamming.

2.5 If necessary, tighten the gland packing uniformly during the trial operation of
the valve.
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2.6 A qualified welder must perform all welding operations and the welding
procedure shall be in accordance with r e l e v a n t s t a n d a r d s .

2.7 When mounting the screwed end, butt weld end, socket weld end and flanged
end type valves the following respective procedures must be followed, for
better performance.

2.8 SCREWED END VALVE INSTALLATION

2.8a Clean both the mating parts before assembly.

2.8b Sealant if necessary should be applied only to the pipe or male threads.

2.8c Use correct size wrenches with flat jaws on hexagon or octagon ends.

2.8d Do not use undersized threads on section of pipe where the valves are to
be installed.

2.9 BUTT WELD END VALVE INSTALLATION

2.9a Keep the valve in ‘Full Open’ position.

2.9b Space the joint apart, co-axially with a 2 to 3 mm gap.

2.9c Use an internal welding backing ring where practical.

2.9d After finishing the welding operation clean the pipeline and valve parts by
flushing or pigging to remove the impurities formed during welding.

2.9e Do not allow rapid application of excess welding material.

2.9f Do not allow the temperature of valve body seat area to exceed 120° C
(248° F) to prevent seat and seal damage.

2.9g When butt weld end valves are purchased with no extended nipple,
before welding, remove the central body assembly along with ball and
seats, place a spacer of same dimensions and then weld the ends.

2.10 SOCKET WELD END VALVE INSTALLATION

2.10a Keep the valve in ‘Full Open’ position.

2.10b First insert the pipe to full depth of socket then pull out about 1.5mm and
weld.

2.10c Provide adequate support to the pipe on each side or to the valve prior
to welding.
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2.10d Weld each end of the valve with a continuous bead. The welding rod
should not exceed 3.2 mm diameter.

2.10e Remove the spacer and reassemble the valve body assembly when the
system cools down to ambient temperature.

2.10f Do not allow the temperature of valve body seat area to exceed 120° C
(248° F) to prevent seat and seal damage.

2.10g When socket end valves are purchased with no extended nipple, before
welding, remove the central body assembly along with ball and seats,
place a spacer of same dimensions and then weld the ends.

2.11 FLANGED END VALVE INSTALLATION

2.11a Be sure that flange gaskets and fasteners are suitable for the operating
conditions.

2.11b Insert the valve (fully open position) along with suitable gasket between
the mating flanges, align the flange boltholes & hold it in place.

2.11c Hold the nuts first on backside of the valve flange and then insert the
bolts.

2.11d Tighten all the bolts to finger tight.

2.11e Use two spanners to tighten the joint, in the sequence as shown in
Figure 1.
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BOLTING SEQUENCE CHART

Figure -1
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3.0 OPERATION AND MAINTENANCE

3.1 Flush the pipeline carefully once more when the valves are mounted to remove all
the possible impurities. Before flushing keep the valve open fully in case of Ball
Valves & partly in case of “y” type Valves.

3.2 Valves should be opened and closed slowly to avoid hammering effect on the
valve and pipeline.

3.3 Valve should be “fully opened” or "fully closed” to prevent damage to the seat
and ball caused by wire drawing.

3.4 Flush Bottom valves is intended for on-off service only, it should not be used
for throttling services.

3.5 If stem leak develops, tighten the gland nut until leakage has been stopped. If
the stem leak cannot be stopped then replacement of stem packing is
necessary.

3.6 If a through leak occurs, ensure that the valve is fully closed. Don’t use extra
leverage or extra force on the stem to prevent leakage. If leakage persists,
replacement or Lapping of seats is necessary.

3.7 After a long service life, when through valve leakage is observed, the seats
should be replaced by new ones.

3.8 The ball valve needs no regular maintenance or lubrication.

3.9 Replacement of stem packing:

When replacing the packing, be sure that the valve is not under pressure.
Remove all accessories including actuator to give access to the packing. After
loosening and removing the gland nut, the packing can be removed by means of
a hooked wire.

3.10 Do not try to correct the through valve leakage by giving packing pieces behind
the seat to make it tight. Instead replace the packing.

3.11 If a body seal leak develops, do not over tighten the body end cover studs and
nuts. This may damage the valve. Instead body seal should be removed and
replaced by new one.

3.12 Flush Bottom Valves (“Y” Type”) are Generally made to Order Valves & the size of
all the Parts Differ from Customer to Customer. Hence the parts to be changed or
replaced needs to be send to us for making a duplicate ones or the whole valve.
We recommend the valve to be send to us for overhauling if needed.
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4.0 DISASSEMBLY

For your safety and protection, it is important that the following precautions
be taken prior to removing the valve from service or before any disassembly of
the valve.

4.1 DISASSEMBLY FROM PIPE LINE

4.1a Keep hands out, since remotely actuated valves could close at any time.
Disconnect all auxiliary piping of jackets and pneumatic or electric
connections.

4.1b Wear any protective clothing or equipment normally required when

working with media involved.

4.1c De-pressurize all the lines and drain the system fluid. Cycle the valve
several times to relieve any pressure still inside the valve.

4.1d Keep the valve in full open position. Remove the valve and place it on a
level surface in vertical position.

WARNING!

VALVES SHALL NOT BE DISMANTLED IN CLOSED POSITION

4.2 DISASSEMBLY OF THE FLUSH BOTTOM BALL VALVE

(REFER FIGURE-2)

4.2a Flush the valve to remove the residuals in the valve.

4.2b Support the valve on a platform.

4.2c Remove all accessories if fitted and also adapter, lever or gear operator.

4.2d Remove check nut / gland nut, spring, locking plate and gland.

4.2e Unscrew the body end connection studs and separate the body and end
pieces/tail piece.

4.2f Place the disassembled parts on clean wooden or cardboard surface.

Do not keep ball and seats on cement or metal surfaces to avoid
damage.

4.2g Take out the seat rings and body seal. Body seal to be replaced during
re-assembly.

4.2h Keep the valve in CLOSED position and remove the ball.

4.2i Push the stem into the body cavity and then takeout through the end
port. Remove the stem washer and stem seal.
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4.2j Clean all parts carefully. If necessary use suitable solvent.

4.2k Check all the sealing surfaces and parts for damage or uneven wear.
Minor scratches or flashes on the ball surface can be removed using a
fine abrasive cloth.

4.2l Check the condition of the stem.

4.2M Check for the wear or any damage at all the sealing area of stem, ball,
seat, bearings and stuffing box bore. Correct / replace the damaged
parts if necessary.

5.0 ASSEMBLY

Using the parts contained in complete repair kit, reverse the disassembly
procedure. NEVER REUSE PACKING, BODY SEALS, STEM SEAL AND STEM
WASHER.

Incase of damage/wear/corrosion to the parts of the valve, they need to be replaced

during re-assembly.
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FIGURE - 2
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4.3 DISASSEMBLY OF THE FLUSH BOTTOM VALVE “Y” TYPE

(REFER FIGURE-3 & FIGURE -4)

4.3a Flush the valve to remove the residuals in the valve.

4.3b Support the valve on a platform OR on a Vice

4.3c Remove all accessories if fitted (Actuator, Gear, Solenoid Etc)

4.3d Remove check nut / gland nut, spring, locking plate and Hand wheel

4.3e Unscrew the body end & connecting Pillars or Bonnet and separate the
body and end pieces/tail piece.

4.3f Place the disassembled parts on clean wooden or cardboard surface.

Do not keep ball and seats on cement or metal surfaces to avoid
damage.

4.3g Un screw the seat from the Body if it is screwed or loosen if it is fixed
to the body & check for Dents on the sealing area. If Dents are present
Lapping is to be done.

4.3h Un screw the Disc from the spindle & check for Dents on the sealing
area. If Dents are present Lapping is to be done. If the Valve is soft Seated
(PTFE seated) replace the Disc seat

4.3i Clean all parts carefully. If necessary use suitable solvent.

4.2k Check all the sealing surfaces and parts for damage or uneven wear.
Minor scratches or flashes on the ball surface can be removed using a fine
abrasive cloth.

4.2l Check the condition of the stem.

4.2M Check for the wear or any damage at all the sealing area of stem, Disc,
seat, bearings and stuffing box bore. Correct / replace the damaged
parts if necessary.

5.0 ASSEMBLY

Using the parts contained in complete repair kit, reverse the disassembly
procedure. NEVER REUSE PACKING, BODY SEALS, STEM SEAL AND STEM
WASHER.

Incase of damage/wear/corrosion to the parts of the valve, they need to be replaced

during re-assembly.
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FIGURE -3

FIGURE -4

FIGURE -4
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TROUBLESHOOTING
Nature of
Cause Remedy
Defect
1. Damage of Seat due to presence Dismantle, clean & replace by
of foreign particles. new seats
2. Damage of seal Ring at Dismantle, clean & replace by
the seat/retainer. new seal Rings
3. Damage of seat in weld end valves Suggest following right steps as
Seat due to improper precautions. per IOM manual.
1
Leakage 4. Damage of seat at high Check for suitability of seat
temperature. material and design.
5. Improper closing of actuator Ensure correct closing of
operated valves. actuator.
6. Damage of seat due to rust at Dismantle, clean &
body of seat retainer. reassemble/replace.
1. Loosening of check nut or locking Tighten the check nut & locking
bolt. bolts
Gland 2.Damage of stem seal/stem washer Replace the stem seal/stem
2
Leakage washer.
3. Misalignment of actuator, bracket Ensure correct alignment.
& stem.
1. Improper tightening of Body Ensure proper tightening of Body
bolting. bolting.
Body Seal 2. Improper precautions in case of Suggest following right steps as
3
Leakage weld end valves. per our IOM manual.
3. Misalignment of pipe line mating Ensure correct alignment of
flanges. flanges.
1. High temperature of fluid handled. Check for suitability of material
and design.
2. Highly viscous fluid handled. Check for suitability of material
and design.
High 3. Insufficient air supply pressure in Ensure sufficient air pressure.
4 Torque case of pneumatic operated
operation valves
4. Reducing of lever length by user Suggest using levers of correct
due to less space. length.
5. Pipeline flange pressure in case of Face the seat or seat seal to
single piece valves. relieve extra pressure.
1. Presence of foreign particles at Dismantle, Clean & Reassemble.
seat contact area.
2. Peeling of plating of Disc in case Check for service
Jerky
5 of metal seated valves. condition/replace.
operation
3. Insufficient air supply pressure in Ensure sufficient air pressure.
case of pneumatic operated
valves
1. Very high torque operation. Check for causes as covered in
Sl.No.4
Gear
2. Poor material of construction & Check for suitability.
6 Operator
design.
Damage
3.Transit damage Replace the damaged spares &
report accordingly.