Installation, Operation

& Maintenance Manual

VAAS

Table of Contents
This manual contains
A) Bi-Directional Valve Installation, Operation & Maintenance Manual
B) Exploded view of Basic valve with parts identification

Bi-Directional Valve Model: 740

IOM-std/2008

Model and Features

Model 740 Bi-directional, elastomer seated gate valve with body designed to
mount between pipeline flanges drilled suitably
For all pressure and temperature capabilities of the valve, please refer to relevant
VAAS catalogues.
Short time storage

Wrap the valve with polyethylene cover. Place caps for pneumatic actuator
ports/accessories ports. Store these valves in the same packing indoors and
without direct exposure to environment.
Caution

If the valve is to be stored for a long period of time before installation it should
be stored in a vertical position (preferable) and in a cool, clean area to
prevent damaging effects on the packing.
Unpacking
After ensuring that the box is not damaged externally, open the box carefully and
takeout the valve. Check for any damage to valve and its components during transit.
Notify the damages, if any, inform to the relevant insurance agency. Consult VAAS
with exact details for an offer for damaged parts.
Markings
Valve size and brief material specification of body (markings such as SS or DI)
are marked on the valve body. Stainless steel nameplate ( FIG:1) fixed on to the
yoke of valve contains most of the relevant information on the valve including VAAS
work order number and unique serial number of the valve. These details should
be quoted for all requirements of service and spares.

Installation, Operation
& Maintenance Manual

Seat material

Do not exceed rating

pressure
FIG : 1

VAAS

Do not exceed
max. temp

Misapplication of product may result in injuries or property damage. A selection of

valve components of the proper material consistent with the particular performance
requirement is important for proper application.

Installation & mounting Orientation

Valves can be mounted with flow on both directions.

Install the valve between flanges using fasteners & Gaskets.
Use a gasket material suitable for pressure, temperature and media.
Bolt holes in the chest area are always blind tapped and care should take not
to bottom the bolts while tightening. Refer to GA Drawing /Technical Bulletin
for qty and size of Blind tapped holes on valve chest area. Studs and nuts are
recommended for chest area holes to avoid damage of body.

Caution
If the valve is installed in horizontal position and a powered actuator is
included with the valve, support of the actuator may be required.

Commissioning Guidelines

Gland packing is tightened to hold the specified pressure and tested for no
leakage before dispatch. However, this may require some adjustment at site
due to loosening in transit etc.

Check for Gland leakage after the valve is subjected to pressure and if any
leak is observed; tighten the gland uniformly in cris-cross pattern till leakage
stops.

Over tightening may cause excessive pressure against the gate making the
valve difficult to operate and cause rapid packing wear.

Installation, Operation
& Maintenance Manual

VAAS

Caution
Seal reinforcement wire anchored with one of the gland bolt. Do not remove
this wire except for seal replacement.
Seal

Seal reinforcement wire

FIG : 2
Cylinder operated valves

Connect instrument quality air preferably through Air Filter Regulator of
adequate size. Preferable air supply pressure is 5-8 bar (80-120 psi). Refer to
Bulletin/Drawing for port and cylinder size details.
Ensure supply air is free from moisture, dirt and other foreign particles. Drain
the Filter regulator before operating the actuator so that pipe rust and dirt if
any in the airline will be removed before actuation.

If valves are supplied with electrical accessories like Limit switch and solenoid
valve, ensure wiring is done as per local electrical safety codes and
regulations. Ensure correct electrical supply as indicated on electrical
accessories for proper functioning and safety of the equipment.

Open the valve by energizing the Solenoid valve/giving air supply to cylinder
and operate the valve 2-3 times.
Manual valves

Open/ Close the valve manually and observe valve operation.
Caution
* Wrong electrical supply to accessories will damage the equipment.
* Do not over tighten the gland nuts as this may cause excessive friction
And premature damage to packing

Maintenance
Lubrication
Manual valve stem (item 15) should be lubricated at regular interval for smooth
operation of valve. Lubrication nipple is provided on the collar (item 14). Cylinder
operated valves do not require routine lubrication. However cylinder actuator if disassembled for repair, then cylinder wall and seals are to be lubricated with lithium
based grease.

Installation, Operation
& Maintenance Manual

VAAS

Packing replacement
Caution
Relieve line pressure before loosening gland nuts to avoid injury and/or
equipment damage

Relieve line pressure

Close the valve fully

Ensure the line is empty, if necessary flush the line

For Cylinder operated valves: Switch off the electrical supply to Sol. Valve and limit switches.
Remove cylinder tubing and drain off the air inside the cylinder.
Disconnect piston rod from gate by removing clevis bolts & nuts.
Apply air slightly to the top port of actuator so that Piston rod is
retracted from the gate.
Remove the actuator assy from the valve by removing fasteners
connecting yokes to valve body.
For Manual Valves: Close the valve fully if not closed.
Disconnect stem from gate by removing lug bolts & nuts.
Rotate the Hand wheel anti-clockwise by holding the stem from
rotation, so that stem is retracted from gate fully.
If valves are supplied with bellows, ensure stem is not rotating, as
rotation will damage the bellows.
It is recommended to service the valve at clean workplace
(Like instrument workshop etc.,).
Packing strip and quantity
Valve size Packing
(in)
Size
2
3
4
5
6
8
10
12
14
16
18
20
24
30
36

Number rows
(per side)

8mm

10mm
3

12.7mm
16mm
4
19mm

Packing
Length
(in)
3
4
5
6
8
10
12
14
16
18
20
22
26
33
39

Installation, Operation
& Maintenance Manual

VAAS

Remove the gland nuts and the gland (item 2)

Remove the old packing (item 4) from the packing chamber, one layer at a
time, using a long thin tool (say, a screwdriver) to pry it out

Remove the chest liner/ PTFE Strip (item 6) from the packing area.

Insert the new chest liner/ PTFE Strip (item 6)

Ensure the gate ( item 3) is fully closed and centered in the body before
packing

Install new packing (item 4) one at a time and to fit along each side of the
gate. The ends must be square cut. Wrap the ends with TFE tape to prevent
fraying and packing should be perfect fit in the seal & gate area both sides.
Note that a chest liner/ PTFE Strip is placed on the bottom of the packing
area and packing is placed on the chest liner/ PTFE Strip . The orientation of
the chest liner should minimize the gap between the body chest and the gate.

Install the packing gland and gland nuts (item 2)

Ensure that the gap between the gland (item 2) gate (item 3) is uniform all
around.

Tighten the gland nuts finger tight plus turn.

Mount the actuator with the valve.

Apply air slightly for cylinder operated valves to lower piston rod and fasten
the gate.

Lower the stem by rotating hand wheel clockwise by holding the stem from
rotation and fasten stem to gate with nuts & bolts( item 17 )
If leakage is observed from the packing area after installing the valve in
pipeline and valve is pressurized or charged with media, tighten the
gland nuts evenly side to side just enough to stop leakage. Do not overtighten the gland nuts

Seal Replacement
Caution
Relieve line pressure before attempting to remove the valve from line to avoid
personnel injury and/or equipment damage. If valve is with pneumatic
actuator, solenoid valve, Limit switches and other accessories, disconnect
electrical and pneumatic supply.

Relieve line pressure and close the valve. If necessary flush the line.

Remove the valve from line by loosening Flange mounting bolts, studs and
nuts. It would be better if the valve is serviced at clean area like inst. work
shop etc.,

Installation, Operation
& Maintenance Manual

VAAS

Clamp the valve in the vertical position to a fixture, workbench that is

anchored to the floor. Do not block valve port when clamping the valve.
Note: an overhead hoist is helpful especially on larger size valves.

Remove the actuator from the valve and gate.

Remove Gland (item 2) and Gland packing ( item 4 ) from the valve.

Remove the gate (item 3) carefully from the valve body. Clean the gate and
smooth out any rough surfaces.

Remove the chest liner/ PTFE strip ( item 6)

Remove the damaged Seal ( item 5 ) by pulling the seal out the top of the
valve body.

Clean and inspect the body (item 1) inside area for any damage, particularly
sharp edges that may cut the seal. Smooth out if necessary.

Saturate the body seal groove area with good watersoluble lubricant that will
not affect the seal or process.

Inspect the new seal (item 5 ) and trim both ends of the seal.

Insert the seal reinforcement wire into seal hole and keep extra length 50 mm
each end of the seal for 2-12 valve and above 12 valve onwards 100 mm
each end of the seal.

Insert one end of the seal from top side and reaching the port area and pull it
(the seal) via groove of the port area and pull it (the seal) from the top of the
body, to be sure seal is not overstretched. ( As per FIG : 3 )

Insert the chest liner/ PTFE strip ( item 6 ) in the packing area.

Install the gate (item 6) and close the gate with little extra force up to valve
port. After reaching the gate to port then mount the actuator or hand wheel.

Two side of the seal end should hold during install the gate and ensure seal
should not move/downwards along with gate.

After fully closing the valve, again open the gate up by 50mm and operate the
gate to seat the seal into the bottom groove and operate min 5 times. The
reasons for this is to get the gate to push the seal fully into the groove and to
avoid overstretch.

Then remove the actuator or hanwheel.

Repack the valve by using the packing replacement procedures as stated
above.

With the seal being forced fully into the seal groove, cut each end of the seal
off to required extended length. (Up to 8 20mm, 10-16-25mm and 18
onwards 100mm from top of the body) and Seal reinforcement wire end
should be anchored as shown in the FIG : 2.

Adjust the packing for tight shutoff when the valve is installed and pressurized
to operating pressure.

Installation, Operation
& Maintenance Manual

VAAS

Actuators
Pneumatic Cylinder
VAAS pneumatic cylinder actuator is a low maintenance design and does not require
any routine maintenance. This has a FRP tube which is lubricated for life with a
special coating on the inside wall. However if the actuator is dis-assembled, then
lubricate the cylinder wall and piston seal, cylinder seals according to the
instructions given. Filtered dry instrument quality air (non-lubricated) shall be used
for its operation at the specified air supply pressure.

Maintenance
Refer to VAAS IOM 94560/12/2004for details, as the actuators parts are
common for both Standard Knife Gate Valve and Bi-Directional Gate Valve.
Recommended spare parts
Following are the parts recommended as spares, which may be stocked. Please
note the requirement and quantity of spares would vary with severity of applications
Following are general recommended spares for valves. Provide Valves serial
number and work order number from the nameplate for proper parts.

Gland packing ( item 4 ) Code: Type C FUW xxxx, Fig 740

Spare Seal( item 5) , Code : RSxx FUW xxxx, Fig 740 (RSxx Seal material;
xxxx- Valve size code ; e.g 0300-3 (80 NB), 1200-12 (300 NB)

Chest liner/PTFE Strip ( item 6 )

Cylinder repair kit (consists of O-rings for Cylinder head, cap Piston & Piston
Rod and Piston seal code: CRK FUW xxxxx (actuator model)


In case of any clarification on the product / manual please contact
VAAS INDUSTRIES PVT LIMITED
73, Industrial Estate, Perungudi
CHENNAI 600 096,
INDIA
E-mail: field_service@vaasval.com
Web: www.vaasval.com

Installation, Operation
& Maintenance Manual
4

VAAS

4
6

2 to 12 CHEST LINER-ITEM NO:6

14 to 36 PTFE STRIP-ITEM NO:6

GATE

SEAL

BODY

FIG : 3
( Seal replacement )

Installation, Operation
& Maintenance Manual

Components Identification: 1) Body

8) Fasteners
2) Gland
9) Washer
3) Gate
10) Hand wheel
4) Gland Packing
11) Yoke sleeve
5) Seal
12) Thrust Washer
6) Chest liner/PTFE Strip 13) Yoke
7) Gland bolts
14) Collar

VAAS

15) Stem
16) Lock nut
17) Lug bolt
18) Fasteners
19) Yoke bolts
20) Yoke bolts
21) Grub screw