INSTALLATION, OPERATION

And

MAINTENANCE

(GRS)

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CONTENT

UNI- B 9001

1. INTRODUCTION
A. GENERAL NOTE B. STRUCTURE I TYPE C. OPERATION D.GENERALFEATURES CONSTRUCTION VIEW

2. INSTALLATION
A. PREINSPECTION B. INSTALLATION

3. MAINTENANCE / INSPECTION
A. MAINTENANCE B. INSPECTION I MINOR TREATMENT

4. REPLACEMENT
A. SEPARATION OF VALVE FROM THE PIPE B. DISASSEMBLY OF THE SEAT C. REPLACEMENT

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A. General Note

INTRODUCTION

UNI- B - 9001

Unicorn GRS (General Rubber Lined Valve) has an Elastomer Resilient seat material and concentric shaft design. This type is designed primarily for usage of general purpose in low temperature and low pressure of water & sewage treatment line. The most benefit of using GRS is a simple operation, easy repair work and economical price.

B. Structure / Type
GRS type butterfly valves are classified as Wafer Type, Lug Type by their shape. Its principal part consists of body, disc, seat and shaft, and materials of each part are selected according to the duty and working condition.

C. Operation
The valve operator could be classified into a lever handle, manual gear, pneumatic actuator and electric motor operated actuator. By rotating or closing the disc located at the inside of valve, the fluid flows through the pipe can be shut-off or regulated. (Generally, on-off direction is indicated on the operator)

D. General Features
Bi-directional function Bubble tight shut-off Application: Chemical Processing, Oil Field, Power Plant, Ship building.

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CONSTRUCTION VIEW

UNI- B 9001

'3

Hex.

Bolt

,,
'2 '0 9 8

Spring Washer
Gasket
~nd

Flange

Stem O-Ring Stem Bush

X-Ring Retainer Stem X-Ring Upper Stem
Lower Stem

7
6

5
4

3
2

Seat

Disc

'-2 Lugged Body , -1 Wafer Body

I No1

Description

'4"-40"(350A-'000A)
Hex. Bolt Spring Washer

,,
10 9 8
7

Gasket
End
F"longe

Stem Bush

Stem O-Ring
Disc

5
4

Pin

Stem

Seat

2 Disc 1-2 Lugged Body 1-1 Wafer Body

No.1

Description

Note:
3

Recommended spare parts: Seat, Stem G-Ring & X-Ring

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INSTALLATION

UNI- B 9001

A. Pre-Inspection Before installation of valve to the 'Pipe Line', it is recommended to inspect a valve closely as below. 1. Inspecting Valve & Accessory Ensure any damage that might be occurred during the transportation. Remove the protection cover of valve just before installation and clean a dust or mote with an air blaster or smooth dust cloth / mop. Check the tightness of all kinds of bolts and nuts. 2. Inspecting Pipeline Remove foreign materials such as a rust, welding chip, etc, which remain in the pipe or flange. Make sure the clearness of pipe flange and gasket surface.

lID Caution:
When the fluid is flowing through the line, any foreign material is subject to scratch the disc, seat and inner body, so that the scratch may cause leakage and shortening of the valve lifetime.

B. Installation Make sure valve disc should be fully closed. GRS Type Valve is bi-directional, though be sure of the fluid direction with the location of operator. GRS Valve does not need a flange gasket when it be installed to the pipe When you connect the valve to the pipe with a bolt or stud, screw it diagonally.

lID Caution:
Over torque on the bolt might cause damage ofgasket.

MAINTENANCE / INSPECTION

UNI- B - 9001

A. Maintenance
The following routine inspections are recommended for safety and longer lasting lifetime of valve; Visual inspection of the body, disc and packing part of valve at the initial service or at the re-operation after long-term recess. Check up the valve when abnormal sound is perceived during the operation. Ensure tightness of each bolt regularly.

B. Inspection / Minor Treatment

1. Packing (Gasket I D-ring, X-ring)

Most leakage from packing parts of valve could be prevented effectively by tightening of End flange's nuts and bolts (See Page 3. Construction View). If the leaks don't stop in spite of re-tightening bolts, packing replacement shall be required.

2. Seat
If it sounds the leakage from inside of the valve after full closing of disc, or if the fluid flows over the drain valve, which is equipped at the bottom of pipe, then check the seat condition and necessity of the replacement.
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Remark: See Page 6, the section of disassembly ofseat, for the replacement ofseat.

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REPLACEMENT
(ASSEMBLY / DISASSEMBLy)

UNI- B - 9001

1. Separation of Valve from the Pipe To repair leaking valve, the valve must be removed from pipeline and then parts must be separated as below;
Shut down the line, and make sure no pressure inside. Drain all mediums from the pipe. Completely close the disc of the valve. Remove the operator from the valve prior to removal the valve from the pipe. Mark the location of each part of valve and pipe in order to be installed at same places where they were.
~

Caution: If the fluid is toxic, proper protection should be required before the removal of valve.

2.

Disassembly of the Seat ( See the Construction View on Page 3 ) Open the disc of valve (5~10 degree) using a kind of rubber or urethane hammer. De-fasten the bolt of the end flange and take off the end flange. Remove a stem joint and bushing, and then pullout the stem. If the valve size is 350mm (14 ") or larger, remove the disc pin first before pulling out the stem. Take out the Rubber-Ring seat and replace the new Seat

Remark:

After disassembly, please check the surface of disc. found, the disc and shaft must be replaced together. sure to get advice from Unicom:S person in charge.

If any damage of disc

is

In this case, please be

REPLACEMENT
(ASSEMBLY / DISASSEMBLY)

UNI- B - 9001

3_

Replacement
Packing (Gasket / O-ring, X-ring) Replacement:

CD

For replacement of packing, please take the steps as below.

A. Replacing Stem X-ring

i . Remove the Operator with any accessories (Lever, Gear and Bracket). i i. Take out the Stem Bushing. iii. Remove the Stem X-ring by using a packing extractor such as the corkscrew, awl and gimlet and then replace new one.

B. Replacing Stem a-ring and Gasket

i . Remove End flange by de-fastening end flange bolts and washers. i i. Take out the end flange and gasket, and then remove the Stem a-ring by using a packing extractor such as the corkscrew, awl and gimlet. iii. Replace new O-ring and Gasket.

C2l

Seat Replacement

i . Take the step of disassembly of Seat as page 6. i i. To remove the seat, take the same procedure of packing disassembly first as above. iii. Once disassemble the packing and stem of the valve for replacement of the seat, please use new packing kits when assemble the parts after replacing the seat.
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Note: Please use the parts of 'Spare Part Kit' supplied by 'Unicorn'