1.

INSTTALLATIO
ON,OPER
RATIONA
AND
M
MAINTEN
NANCEM
MANUAL
GA
ATEVALV
VE

DOC
CNO

CAM
MTS0030

REV
V.NO

00

DATTE

150
022012

PAG
GENO 1O
OF11

GEENERAL
Itiisrecommen
ndedthatthiisentiredocumentshallbereadprio
ortoproceed
dingwiththeeinstallation
nor
repair.Onlyco
orrectinstallaation,mainteenanceandoperationwillensuresm
moothvalveo
operationan
nd
maaximumlife.

Caamtechshallnotacceptaanyliabilityifftheinstructtionssetfortthinthismanualarenottcompliedw
with.

DITION
DEESIGNCOND
a) Valvesaredesignedan
ndmanufacturedtobein
nstalledinap
pplicationsw
wherenomo
orethan1go
of
dinanydirecction.This1ggforcecanb
beaneffecto
oftraffic,win
ndor
forceinexxcessofgraviityisapplied
Earthquake.
b) Valveareintendedforrcleanfluidwithoutanyspecificcorrrosive,chem
micalattacko
orabrasion
pleasegettheerecommen
ndationforsuchapplicationifabrasio
onpresents.
presentsp

1.1 REESPONSIBILITTYFORVALV
VESELECTIO
ONANDAPPLLICATION
Duetothe
evarietyofd
dutiesonwhichtheprod
ductcanbeeemployed,itistheendussersresponssibility
toensurethecompatiibilityofthemediawithtthevalverattingandmatterialsofcon
nstructionofthe
oreachspeciificapplicatio
on(i.e.corro
osion,erosionandwearw
whichmayaaffecttheintegrity
productfo
ofthepressurecontainingparts.C
Camtechmaayoffersugge
estionsintheselectionb
buttheselecction
ntdesignerssshouldtakeintoaccounttthe
processissolelythereesponsibilityofplantdessigners.Plan
heprocessmediawillhavveonthevalvewallthickknessandco
orrespondingg
specificefffectsthatth
servicelife
eandensureethatthesellectedmaterrialiscorresp
pondingwith
htheprocessmedia.
Waarning:Theu
userisadviseedthatmisap
pplicationofftheproducttmayresultininjuriesorr
propertyd
damage.

2.0 HEEALTHANDSSAFETY
2.1 W
Wheninstallin
ngandmaintainingvalve
es
a.))Conductarriskassessmeentandelim
minateorreducehazards..
b.))Workinacccordancewitthsafesystemsofwork.
c.))Observeallsitehealthaandsafetyru
ules,andincconformityw
withthelegalllocalcompaanyspecific
insstructionson
noccupation
nalhealthandsafetyandpreventionofaccidentss
d.))Valveshallonlybeoperratedbypersonnelqualifiedbytraining/experien
nce.
e.))Certainpro
ocessesutilizeeflammablee,Causticorunstableme
edia.Caresho
ouldbetakeeninthese
cirrcumstancestoensureth
hattheoperaatorisawareeofthespeccifichealthandsafetyrisksassociated
d
withthatmedia.
f.)Whenoperaatingmanualvalves,glovvesshouldbeworntominimizetherriskofinjurytothe
mperature/lowtemperaturevalvebo
ody.
haands/skindueetohightem
g.))Whenoperratinganyvaalvestandcleearofanym
movingpartsssuchasthesstemand/orroperatorm
moving
paarts.
h.))Iftheproceessorenviro
onmentsthatttheproducctsareusediinarelikelyttocausetem
mperatures(h
high
orlow)thatmaycauseinju
urytoperson
nneliftouched,thenadeequateinsulaation/protecctionmustbee
fittted.

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KEDBY:KMP
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FORMATTNO:0401
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ATE:01022012

APPROVEDBY:G
GMR

INSTTALLATIO
ON,OPER
RATIONA
AND
M
MAINTEN
NANCEM
MANUAL
GA
ATEVALV
VE

DOC
CNO

CAM
MTS0030

REV
V.NO

00

DATTE

150
022012

PAG
GENO 2O
OF11

Warnin
ng:Nonobservanceofsafetyinstructtionsandwarningmayprovokerisksofpersonneel
injjuryanddam
magetothevvalvesordam
magetotheequipmentaandpollution
nordamagetothe
en
nvironment

3.0
3.1

Warningg:Donotexcceedthemaaximumoperratingcondittionsspecifieedinthenam
meplate.No
on
ob
bservanceofthiswarninggmaycausepersonnelinjuryanddaamagetopro
opertylikein
njuriesresulting
fro
omfluidleakkage(cold,h
hottoxic,und
derpressure)andimpairrmentofvalvvefunction.

PR
RESERVATION,SHIPMEN
NTANDHANDLING
Allvalvesarep
properlypacckedinorderrtoprotecttthepartsthaataresubjectttodeteriorrationduringg
nandstorageeonsite.Th
hevalvesareepackedwith
hthewedgeintheclosed
dposition.V
Valve
traansportation
en
ndsbothflan
ngedandbutttweldendssareprotecteedwithsuitaableplastico
orwoodencaaps.Thepaccking
arreappropriattetoensuresafetranspo
ortation,pro
otectthevalvvesagainstexternalforceessuchas
im
mpacts,andvvibration.Du
uringhandlin
nguseappro
opriatetoolslikebrackets,hook,fastener,ropes,etc.
reespectingtheeloadcapacityasapprop
priate.

1. Donotliftthevalvethroughhand wheel,eyeb
bolt,gearbo
oxoractuator.
2. Cautionmustbetaken
nduringtheh
handlingtoaavoidthatth
hisequipmen
ntpassesoveertheworkeersor
othersplacew
whereapossiblefallcou
uldcausedam
mage.Inanyycase,thelo
ocalsafety
overanyo
regulationsmustbefo
ollowed.

4.0

STTORAGE
a.)) Storethevvalveincloseeddryroomssonsolidgro
oundinadirrtfreeatmossphere.Allo
owthevalvessto
remaininttheiroriginalprotectivepackings.
b.)) Donotplacetheconsignmentpackkagesdirectllyonthegro
ound.
c.)) Donotexp
poseconsign
nmentpackaggestothew
weatherordirectlytothesun.

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ATE:01022012

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INSTTALLATIO
ON,OPER
RATIONA
AND
M
MAINTEN
NANCEM
MANUAL
GA
ATEVALV
VE

DOC
CNO

CAM
MTS0030

REV
V.NO

00

DATTE

150
022012

PAG
GENO 3O
OF11

5.0

6.0

d.)) Checkthepaintcoatingfordamageandcorrossionatregulaarintervals.
e.)) Checkthepackagingevverytwomo
onths.
f.) Repairtheprotectiveccoatingifneccessary.

MA
ARKING
Vaalvesareprovidedwith1
1nameplate

INSTALLATION
N

WRONG IN
NSTALLATION

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ATE:01022012

CORR
RECT INSTALL
LATION

APPROVEDBY:G
GMR

6.1

INSTALLATION,OPERATIONAND
MAINTENANCEMANUAL
GATEVALVE

DOCNO

CAMTS0030

REV.NO

00

DATE

15022012

PAGENO 4OF11

PREPARATIONBEFOREINSTALLATION
1. Asarule,theengineeringcontractor,ConstructionCompanyoroperator/userisresponsibleforthe
positioningandinstallationofthevalves.Planningandinstallationerrorsmayimpairthereliable
functionofthevalvesandposeasubstantialsafetyhazard.
2. Confirmthatthematerialsofconstructionofthevalve,andthemaximumpressure/temperature
specifiedinthenameplatesareappropriatefortheserviceintendedandareasspecified.
3. Thoroughlycleanadjacentpipingsystemtoremoveanyforeignmaterial,weld,piecesof
wood/plastic.
4. Verifythatthespaceavailableforinstallationisadequatetoallowthevalvetobeinstalledandto
beoperated.
5. Cleanthoroughlytheaccessibleinteriorspacesofbodyends,surfacesandfunctionalpartsand
mountingparts(stem,flangeforactuator,mountingetc.)
6. Gatevalvescanbeinstallednormallyinhorizontalpipelineswithverticalstemandwithflowfrom
eitherdirection.Valvescanalsobeinstalledinverticalpipeline.
7. Valveshallnotbeusedattheendofthepipeline.

THEFOLLOWINGPROVISIONSSHALLBEMADEINTHEPIPELINE

a) Drainingandventing.Valvesareprovidedwithbossesfordrainingandventing.Drilled,tappedand
pluggedconnectionsfordrainingandventingareprovidedwhenrequestedbythecustomer.
b) Dangerousdischargeofpressurereliefblowoff.
c) Appropriatemeasureinthepipelineduetodecompositionofunstablefluidswhereexist.Operator
shallhavethoroughknowledgeofsuchfluidsandoperatethevalveasperestablisheddocumented
instructions.
d) Pressurereliefvalve,whereunexpectedincreaseinpressure,waterhammerisanticipatedand
allowablepressurelimitcanbeexceeded.
e) Valvesarenotprovidedwithfillingordischarge.Suchprovisionswhererequired,shallbeprovided
inthepipeline.

6.2 VALVEINSTALLATION
1. Installthevalvewithwedgeintheclosedposition.
2. Supportthevalveandadjacentpipelines,suchthatpipelinethrustandtorsionalforcesarenot
transmittedtothevalve.

A.
FLANGEDVALVES
1. Cleantheflangefacestoensurethatitisfreefromdamage.
2. Thegasketsonthematingflangesareproperlycentered.Onlyfastenersandgasketsofapproved
materialsshallbeused.Placethevalvebetweenthetwoflangesofthepipeandputthegasket
betweenthevalveflangesandthepipeflange.Makesurethatitiscorrectlypositioned.Tighten
theflangeboltsprogressivelyandcrosswise.Usetorquewrenchtotightentotherequestedtorque
specifiedbythespecification.Ensurethattheflangesarestraightandalignedtothepipe.

PREPAREDBY:D.K

CHECKEDBY:KMP

FORMATNO:0401F12REV.NO:00DATE:01022012

APPROVEDBY:GMR

INSTTALLATIO
ON,OPER
RATIONA
AND
M
MAINTEN
NANCEM
MANUAL
GA
ATEVALV
VE

DOC
CNO

CAM
MTS0030

REV
V.NO

00

DATTE

150
022012

PAG
GENO 5O
OF11

Bo
oltTightenin
ngSequence

B.

C.

BU
UTTWELDV
VALVES
Po
ositionthevaalveandaliggnwiththepipe.Removeeanygreaseeorprotectivvepaintthattmayhaveb
been
ap
ppliedtotheweldends.Usethesmaallestelectro
odesandtheeminimumamperagepossibleconsisstent
withapproved
dweldingpro
ocedures.Th
hiswillhelptominimizewarpageintheseatareaas.Valvesof
owedtocoolslowly.Theevalvemaybecoveredw
withaheatinsulatingblaanket
caarbonsteelshouldbeallo
to
opromoteslo
owcoolingandlimittheheataffecteedzone.FollowASMEstandardsand
dindustry
staandards.

VA
ALVEVERIFIC
CATIONBEFORESTARTUP
1. Tightenth
hepackingjustenoughto
opreventsteemleakage.Overtighten
ningwilldeccreasepackin
nglife
andincreaaseoperatinggtorque.
2. Checktheoperationo
ofthevalveb
bystrokingittofullopenandfullclosse.

OP
PERATION
1. Valvesareclosedbytu
urningthehaandwheelin
nclockwisedirectionandopenedbytturninginco
ounter
clockwisedirection.
2. Donotuseegatevalvessforthrottlin
ngoperation.Valvesshallbeeitherinfullopeno
orfullclose
position.
3. Subjecttheevalvetotherequiredp
pressureandtemperaturregraduallyaandslowly.
4. Retightenallbolts/nuttsincludingtthestuffingb
boxgland.Cleananddeggreasethesttem.
5. Ensurethaatthereisno
oleakfromthevalveand
dtheoperationissmooth
h.

7.1 USSEOFGATEV
VALVES
Gaatevalvesarreusedforonoffservicee.Gatevalveshallnotbe
eusedforthrrottlingoperration.Valveshall
beeopened/clo
osedslowlyaandgraduallyytotheposiition.

7.0

PREPAREDBY:D.K

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ATE:01022012

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GMR

INSTTALLATIO
ON,OPER
RATIONA
AND
M
MAINTEN
NANCEM
MANUAL
GA
ATEVALV
VE

DOC
CNO

CAM
MTS0030

REV
V.NO

00

DATTE

150
022012

PAG
GENO 6O
OF11

7.2

SH
HUTDOWN
Closethevalvee.Depressu
ureanddrain
n/ventallfluids.Allowthevalvetoco
ooldown.Reemoveany
e.Followtheeprocessguiidelines.
eleectricconnectorbeforemaintenance

XAMINATION
NOFVALVESS
7.3 EX
Peeriodicallyexxaminethevvalvedepend
dingontheflluidconditio
onandcriticaality.Asaminimumannu
ual
exxaminationo
ofshellthickn
nessandvalvveconditionshallbemadedependin
ngupontheffluid.

AINTENANC
CE
8.0 MA
a. PA
ACKINGMAIINTENANCE
Ifleakageisob
bservedthro
oughthepacking,tighten
ntheglandn
nutsslowlyandevenlyun
ntiltheleakaage
ops.Usehalfturnincrem
mentfortigh
htening.
sto

Do
onotovertigghtenpackin
ngglandnutss.Overtightteningwillin
ncreasethettorquerequiredtooperaate
th
hevalveandreducepackkinglife.

ACKINGREPLLACEMENT
PA

WARNIING:
Beeforestartingganymainteenance,deprressurize,draain,ventand
dflushthelinewithair.C
Checkthatth
he
vaalvesarenotintemperatture.Disconn
nectanyelecctricalpowerrsupply.
Faailuretodossomaycauseeseriousperrsonnelinjuryyand/orequ
uipmentdam
mage.

ebackseatposition
1.Opencompletelythevaalveuptothe
bolt.
2.Removetheenuts(19)offtheglandb
ndflange(12)andgland((11)
3.Lifttheglan
packingusinggahockingw
wire/otherdeevice.Cleanthesteman
ndstuffingbo
ox
4.Removetheewornoutp
ore.
bo
5.Repackthepackingringgsatatimeaandensureth
hattheyarefittedcorrecctlyandagainstthebotto
om.
6.Placethegland(11),glaandflange(12)intheirorriginalposition
dnut
7.Tightenlightlythegland
8.Cyclethevaalve.Pressurizetheline
wlyandeven
nlyuntilthe
eleakagesto
ops.
9.Iftheleakaggeoccurs,tigghtentheglaandnutsslow

ODYBONN
NETFLANGEGASKETMA
AINTENANCEE
b. BO
W
WARNING:
Beeforestartingganymainteenance,deprressurize,draain,ventand
dflushthelinewithair.Checkthattthe
vaalvesarenotintemperatture:DisconnectanyeleectricalPoweersupply.Faailuretodossomaycause
e
peersonalinjuryyandor/equ
uipmentdam
mage.

PREPAREDBY:D.K

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KEDBY:KMP
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ATE:01022012

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GMR

INSTTALLATIO
ON,OPER
RATIONA
AND
M
MAINTEN
NANCEM
MANUAL
GA
ATEVALV
VE

DOC
CNO

CAM
MTS0030

REV
V.NO

00

DATTE

150
022012

PAG
GENO 7O
OF11

1.Cleantheflaangesurfacee
ositiononth
hebody.Enssurethatgassketisnotsh
hiftedfromth
hecorrect
2.Placethegaasketinitspo
position.
3.Positionallthestuds/nu
uts
4.Tightenthestud/nutun
niformly,grad
duallyandcrrosswire.
bolttightenin
ngsequencee.Followthetighteningttorquegiven.
5.Followtheb
mentisinstaalledandpreessuredtighttenonceagainallthebolts.
6.Afterequipm

1. Bolttighte
eningTorque
e

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ATE:01022012

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INSTALLATION,OPERATIONAND
MAINTENANCEMANUAL
GATEVALVE

DOCNO

CAMTS0030

REV.NO

00

DATE

15022012

PAGENO 8OF11

Nominalboltsize
(inch)
1/2"

Torque
(Nm)
80

Nominalboltsize
(inch)
13/8"

5/8"

160

11/2"

2300

3/4"

275

15/8"

3000

7/8"

440

13/4"

3700

1"

650

17/8"

4700

11/8"

950

2"

5700

11/4"

1300

Torque(Nm)
1780

2. ValveTorqueandMountingofactuator
Thevalvetorquedependsuponmanyparameterslikesize,class,maximumoperatingpressure,
frequencyofoperation,fluiddetails,viscosityandflowvelocity.Pleasecontactcamtech,who
selectstheoptimumsizeofactuatorandsupplyofmountingplatesforfieldconversion.

8.1 PREVENTIVEMAINTENANCE
Allvalvecomponentshavebeendesignedtobelargelymaintenancefree.Thematerialofthemoving
partshasbeenselectedforminimumwear.Howevermalfunctioncausedbywrongoperation,lackof
maintenanceorimproperusereducesvalvelife.Allrepairandmaintenanceworkshallbeperformedby
qualifiedpersonnelfollowingallsafetyinstructions.Maintenanceintervalsshouldbeselectedbythe
valveuserincompliancewiththeapplicationcondition.

9.0 TROUBLESHOOTING
TROUBLE

Nofluidflow

FlowRatenotsufficient

PREPAREDBY:D.K

POSSIBLECAUSE

HOWTOELIMINATE

Endflangecoversnot
removed.
Valveinclosedposition.
Pipelineupstreamof
valveisblocked.

Openthevalve.
Cleanthevalve.
Cleanorreplacestrainer/otherblocking
equipment.
Inspectthepipeline

Valveisnotfullopen.
Sedimentsinsidethe
valve.
Dirtystrainer.

Openthevalve.
Cleanthevalve.
Cleanorreplacestrainer/otherblocking
equipment.
Inspectthepipeline.

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APPROVEDBY:GMR

FORMATNO:0401F12REV.NO:00DATE:01022012

INSTALLATION,OPERATIONAND
MAINTENANCEMANUAL
GATEVALVE

DOCNO

CAMTS0030

REV.NO

00

DATE

15022012

PAGENO 9OF11

Valveisleaking

Valveisnotfirmlyclosed.
Excessivedifferential
pressure.
Seatandwedgeseatfaces
damages.
Excessiveloadfromthe
pipeline.

Operatingconditionmight
beoutsidethe
Valvecannotbeoperatedorit
specification.
isdifficulttoopen/close
Bentshaftorthreads
damaged
Valvecavityclogged.

Closethevalve.
Checkthesystem.
Remachine/lapseatfaces.

Checktheline/Valve.

Checkandreplaceworn/bentparts.

10.0 VALVEDISASSEMBLYANDASSEMBLY

VALVEDISASSEMBLY
Followthefollowingstepstodisassemblethevalve.
A. BONNETASSEMBLY
1.Loosenandremovestud(16,17)
2.Liftthebonnetassembly(02)fromthebody
3.Removethebonnetgasket(15)
B.WEDGE(03)
1.Removethewedgefromthestem(06)
C.STEM
1.Removethehandwheelnut(09)bylooseninginanticlockwisedirections
2.Removethehandwheel(10)fromthestemnut(07)
3.Removethestemnutretainernut(08)fromthebonnet
4.Removethestemnutfromstembyturningclockwisedirection
5.Loosentheglandnut(19)andpullthestemfromdownsideandremoveit.

VALVEASSEMBLY
Followreversesequenceofdisassemblyandassemblethevalve

11.0 GREASESANDSPECIALTOOLS
Thefollowinggreasesorequivalentothermakecanbeusedforbearing/stem/nut/gearboxes/stem
BEACON2ESSO,MOBILELUXEP2MOBL,ALVANIAR2SUPERGREASESHELL,MULTIFAKEP2GREASE,
TEXACO
SPECIALTOOL
NoSpecialtoolisrequiredforthemaintenance.

12. RECOMMENDEDSPARES
PREPAREDBY:D.K

CHECKEDBY:KMP

FORMATNO:0401F12REV.NO:00DATE:01022012

APPROVEDBY:GMR

INSTTALLATIO
ON,OPER
RATIONA
AND
M
MAINTEN
NANCEM
MANUAL
GA
ATEVALV
VE

DOC
CNO

CAM
MTS0030

REV
V.NO

00

DATTE

150
022012

PAG
GENO 10OF11

Glandpacking(14)
Bonnetgaasket(15)

used
Note:OnllyCamtechssuppliedsparresshallbeu

ForExplossiveatmosph
here,follow
wingprecautiions/measurresshallbettaken.

1.0 MaxximumSurfaceTemperature

Valvesdonotgeenerateenergy/temperaatureonitso
own.Themaaximumsurfaacetemperaature
notdependsuponthevalve,butontheoperatinggfluidcondittion.Themaaximumoperrating
don
fluid
dtemperaturreislimitedaasperASMEEB16.34.Ho
oweverforexxplosiveatm
mosphere,wh
here

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ATE:01022012

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INSTALLATION,OPERATIONAND
MAINTENANCEMANUAL
GATEVALVE

DOCNO

CAMTS0030

REV.NO

00

DATE

15022012

PAGENO 11OF11

thesurfacetemperatureduetooperatingfluidispotentialsourceofexplosion,provide
insulation/otherappropriatemeasures.

2.0 Projectedstem
Ensurethattheprojectedstemdonottouchanypipingorotherpartthatcancreatespark.

3.0 Bearinglubrication
Bearingsareslowmovingpartsanddonotrequirelubrication.Howeverlubricationis
providedforsmoothoperation.

4.0 Dustdeposit
Removedustatregularintervalsforexplosiveatmosphere.Ensurethatdustisnotpresentin
thegapsandoutsidesurfacestoexcludethepossibilityofexplosion.Ensurethatthe
surroundingsarecleanandnoexternalpartfallonthesurface.

5.0Valvesarenotprovidedwithanyopeningorenclosureforexplosionprevention.

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CHECKEDBY:KMP

FORMATNO:0401F12REV.NO:00DATE:01022012

APPROVEDBY:GMR