LUBRICATED

3Z PLUG VALVES – PRESSURE BALANCED

INSTALLATION, OPERATION AND

IN-LINE MAINTENANCE MANUAL

3Z CORPORATION
652-5 CHOJI-DONG, DANWON-GU, ANSAN-SI, KOREA
(TEL) 82.2.333.1212 (FAX) 82.2.333.4111
E-mail : 3z@3zvalve.com Web:http://www.3zvalve.com

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INSTALLATION, OPERATION AND
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ISSUED OCT., 09,2001

CONTENTS
0. PREFACE 2P

1. STORAGE 3P

2. INSTALLATION 3~4P

3. OPERATION 4~5P

4. IN-LINE MAINTENANCE 6~12P

5. THE CAUTION CLAUSES TO USE THE TOOLS 12P

FOR MAINTENANCE AND REPAIR

6. IN CASE OF LIFTING UP OR PUTTING DOWN A 13P

PLUG VALVE THE MIDDLE OF MAINTENANCE
AND REPAIR

7. THE AFFIRMATION AFTER THE MAINTENANCE 13P

AND REPAIR

8. EXPLODED VIEW OF 3Z LUBRICATED VALVE 14P

9. CUTTING VIEW OF 3Z LUBRICATED VALVE 15P

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0. PREFACE.

A plug valve should be managed properly in the each stage of transportation, installation, operation, and
maintenance. Also, it depends on the managing status of a supervisor and a operator that the plug valve
might raise high efficiency or not.

If a worker is conscious of the safety with all his heart, an accident could be prevented completely. Please,
keep in your mind the guiding principle of this manual, and the damage of lives or equipments will be never
caused.

This manual show a person in charge the installation, operation, maintenance, and repairs for a plug valve
as well as some special subject for safety, which and practiced thoroughly.

However, it is impossible that this manual can cover all kinds of the unexpected accidents. Therefore, this
manual being applied substantially, it is essential to take proper measure that comes form the experience
and common idea the worker.

Safety is the best.

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1. STORAGE

If the 3Z Lubricated Plug valves are not going to be installed immediately, we recommend that they be
stored undercover in a clean and dry place. Flange, weld and thread protectors should be left in place.

2. INSTALLATION

A. Preparation for installation

A plug valve being carried, a rope, wire, and shackle should be strong enough to sustain the total weight.
A plug valve should be installed with the firm pipe line.
Move the valves as close as possible to the installation site before removing packing and end protectors.
After removing packaging, clean end connections to remove any unwanted paint or rust inhibitor. Ensure
that the valve is fully open. Inspect the internal bore of the valve. If there is excess sealant visible around
the plug ports, this should be scraped out. If the valve has been in storage for over 12 months we
recommend that additional valve sealant be injected prior to operation.

B. Installation Configuration
3Z lubricated plug valves have bi-directional sealing capabilities. Therefore, except on valves with two
different end connections or where there are space constrictions that dictate hand wheel position, the valves
can be installed in any position, horizontal, vertical or at any angle in between.

C. Lifting into Position

Valves should always be lifted using suitable mechanical lifting
equipment operated by trained personnel. Chains, slings and
other lifting equipment should be regularly inspected. Do not
lift valves using the sealant fittings, gear unit, hand wheel or
wrench. Chains or slings should be fixed around the valve
body.

D. Flanged Connections
Selection of gaskets and bolting is the customer responsibility
but as a minimum they should meet the requirements of ANSI
B16.5. Flanges should be pulled together evenly by tightening opposite pairs of bolts.

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F. Threaded Connections
As 3Z lubricated valves have steel bodies, pipe wrenches can safely be used to grip the valve body
adjacent to the connection, while tightening it. The threads are suitable for forming dry seals so the use of
thread sealants is at the customer discretion.

3. OPERATION

A. Principle
3Z lubricated valves are quarter turn valves, i.e. they have a 90-degree rotation of the plug in operating from
fully open to fully closed. This operation is always clockwise to close, when viewed from above the valve
stem. Maximum operating torque occurs during approximately the first 15 degrees of plug rotation when
opening the valve from the fully closed position. Past 15 degrees the down the line seal is broken and the
run torque drops to approximately 40% of the break torque, on a well-maintained valve.

B. Operating Wrench Operated Valves INDICATOR

Wrench operated valves have an arrow shaped position

indicator fitted over the stem. The plug port is aligned to the GLAND
arrow points in the direction. When the arrow points across
the line of the pipe, the valve is closed. The indicator
PLUG
should not be removed as it also functions as the open and
close stop by coming into contact with the stop pin adjacent
to the stem.

NOTICE.1. Wrench operated valves should b operated

with the correct size of 3Z wrench. Do not force valves
that will not operate readily and use pipe wrenches to
operate 3Z plug valves.

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C. Operating Gear Operated Valves GEAR BOX INDICATOR

All worm gear operators used by 3Z have visible arrow
type position indicators on the top of the gear housing.
The position indicator arrow points to these at the fully
opened or closed positions.

NOTICE.2. Gear operators should be fitted with the

correct size of hand wheel as supplied by 3Z valves.
Gear operators are always clockwise to close and this
is indicated by the arrow on the close indicator in the
center of the hand wheel. The number of turns
required to open or close the valve varies with the gear
operator fitted.

NOTICE.3. Valves that are installed in locations where unauthorized personnel can interfere with them
should normally have the wrench or hand wheel removed, be locked with suitable locking devices or be
chained through the hand wheel to prevent operation.

D. GENERAL NOTICE
1) No one may carry a plug valve except the practiced expert.
2) If a plug valve has a locking device, only the concerned operator or the supervisor should keep the key.
In case the device wants repairs, it should be done right away.
3) Never take away any attached tag or device from a plug valve nor any function could be removed at
discretion.
4) Whatever slight defect if detected in plug valve, the operation should be stopped.
5) The application terms must be observed; for example, the pressure limitation and the application for
material.
6) In accord with the manual, the inspection of the function should be carried out periodically any always
right before the operation of a plug valve.
7) Never convert a plug valve
8) Should keep the forbidden clause in mind.
9) Should keep the safety regulation in mind.

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4. IN-LINE MAINTENANCE

There are four maintenance operations that can be carried out on 3Z lubricated plug valves while in-line and
on service. With these operations, except in cases where the plug becomes heavily eroded, corroded or
damaged, 3Z valves can be fully maintained in-line for many years of trouble free service.

4-1 Injection of Valve Sealant

The reason for injecting valve sealant onto the valve seats of 3Z lubricated plug valves is to maintain the
bubble tight shutoff capabilities and to ensure smooth operation of the valve.

EQUIPMENT NEEDED
High Pressure Sealant Injection Gun with Pressure Gauge (cf; CLIMAX No. 10516-S)

Plug Valve Sealant (suitable for service)

A. Frequency of Sealant Injection (recommended)

Service Conditions
1) All valves should be injected with appropriate sealant after valve installation to the process line.
2) Infrequent operation, valve either fully opened or fully closed.
Non-abrasive gases or liquids.
Every 50 operations, minimum once per year.
3) Infrequent operation, valve either fully opened or fully closed. Abrasive gases or liquids.
Every 25 operations, minimum of 2 times per year.
4) Throttling services and abrasive slurries
Every 10 operations, minimum of 4 times per year

B. Sealant Injection Equipment

All 3Z lubricated plug valves are fitted with "Giant Button Head Sealant
fittings, unless the customer specifies special fittings such as sub-sea. To
inject sealant into 3Z valves, a high pressure sealant gun with a giant button
head coupler is required. The gun should also have a pressure gauge
reading to at least 10,000 psi.
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NOTICE.4. Do not attempt to use low pressure lubricant guns on 3Z lubricated valve.

C. Valve Sealants & Lubricants

Only sealants recommended for use in TAPER plug valves should be used. 3Z can supply sealants
suitable for most services and there are other manufactures who also make good sealants. If you already
have a particular valve sealant in use at a facility, we will advise on the suitability of it for it's use in 3Z
lubricated plug valves, on a particular service.

NOTICE. 5. Do not use the following types of sealant : Sealant supplied by cylindrical/parallel plug valve
manufacturers, commercially available lubricating grease such as bearing grease, and sealants with high
levels of bentonite clay filler such as Rockwell/Nordstrom NO.555.

D. Injecting Sealant
The following instructions should be used in
conjunction with the sealant gun manufacturers
instructions. Sealant can be injected with the valve
in line and on pressure.

1) Plug Position
If possible the valve should be either fully opened
or fully closed. This ensures that all four sealant
grooves on the plug are connected to the sealant
supply. If the valve is partially open, injection is
less effective as only two of the grooves are
connected to the supply.

2) Sealant Fitting
Identify and clean the giant button head fitting on the valve. In particular scrape off any paint build-up

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away from the small hole in the end of the supply.

3) Fill the Gun

Ensure that the gun is filled and primed with a suitable plug valve sealant. Follow the gun manufacturers
instructions to fill the gun. Giant Button Head
Coupler

4) Attach the Gun

Slide the button head coupler on the end of the gun hose, over the valve gaint button
head fitting, ensuring that the lip of the coupler fits into the groove in the fitting. If the
gun has an isolating valve on the coupler or elsewhere, open this valve.

Giant Button Head

Fitting

5) Start Pumping
Inject sealant either by pumping the handle on a manual gun or connecting the air supply to the pneumatic
gun. The pressure gauge needs to be monitored during the sealant injection process. For sealant to flow
onto the valve seats, enough sealant at sufficient pressure has first to be injected to overcome the line
pressure, to fill any cavities in the sealant chamber and grooves and to overcome the resistance to flow
through the valve sealant system.

Sealant is flowing onto the seats when the pressure gauge on the gun is significantly higher than the line
pressure and falls slowly. On low pressure 3Z or valves off pressure, a minimum of 2000 PSI sealant
pressure is needed to ensure proper injection of sealant onto the seats.

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With a valve that is regularly injected with sealant, the sealant pressure will quickly build up. A valve that
has not been well maintained could require a significant amount of sealant to be injected before pressure
builds up and sealant flows onto the seats.

6) Disconnect
After sufficient sealant has been injected, relieve the internal pressure in the gun and disconnect it from the
giant button head fitting.

NOTICE.5. The lubricant gun should not be connected or disconnected while it has internal pressure.

4-2 STEM PACKING ADJUSTMENT

All 3Z lubricated plug valves are fitted with an emergency stem packing fitting. In the unlikely event of a 3Z
lubricated valve developing a stem leak, this fitting can be used to inject stem packing into the stem area
and reseal the valve stem. This can safely be done with the valve under pressure.

NOTICE.6. Never attempt to replace the stem packing in bolted gland 3Z lubricated valves while under
pressure.

. When a plug valve is separated from the pipeline, after identifying that the pressure inside the connected
pipelines as well as the plug valve is removed completely, the instruction of the manual should be
observed. Allen Head Needle Valve
. Upon getting rid or the pressure inside a plug valve, the signal
WARNING should be given on it.
. It is impossible that the fluid and pressure is resupplied in the
line, which have been separated once, without the permission
of either the concerned expert or the supervisor.
. If valve has been used on hazardous fluids, make certain it
has been thoroughly cleaned before disassembly.
. Should wear the safeguard during cleansing a plug valve.

EQUIPMENT NEEDED
Allen key wrench (to fit stem packing injector) or
High Pressure Stem Packing Injection Gun with Pressure
release (CLIMAX NO. 10516).
Stem Sealing Compound for 3Z Lubricated Plug Valves.

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The stem packing injector fitting consists of an outer hexagonal shaped casting, that is screwed into the
valve body. Inside it is a check valve and stem packing is forced through it with an allen head needle valve
that threads into the end of the casting. Stem packing injectors on 3Z lubricated plug valves are preloaded
at the factory with sufficient Stem Sealing Compound to reseal small leaks.

a. Injecting Stem Packing Allen Head Needle Valve

To inject the stem sealing compound already in the fitting, into the valve
stem area, insert and Allen head wrench into the Allen head needle
valve, in the end of the stem packing injector and rotate it clock wise
until it becomes hard to turn. Normally only 1-3 turns will be possible.
A maximum torque of 10 foot pounds onto the Allen head wrench is all
that is required to sufficiently inject the stem packing. Or use high-
pressure stem packing injection gun with pressure release to inject stem
packing.

NOTICE.7. Operating the valve during the injection of stem sealing

compound can assist in resealing the valve stem.
Allen Head Wrench

b. Reloading the Stem Packing Injector

If the needle valve bottoms out inside of the stem packing injector and the stem is still leaking, more stem
packing needs to be loaded into the stem packing injector. This is done by backing out the needle valve,
putting in a new piece of stem sealing compound into the fitting and screwing the needle valve back in.

NOTICE. 8. Never unscrew the stem packing injector fitting out of the valve body while the valve is under
pressure.

4-3 ADJUSTMENT OF PLUG ADJUSTING BOLT

All 3Z lubricated plug valves have a plug-adjusting bolt that is present at the factory to position the tapered
plug in optimum contact with the tapered body, i.e. the valve will seal off bubble tight and be of benefit to
adjust the plug into or out of the body seat.

EQUIPMENT NEEDED
Adjusting crescent wrench.
Hammer & steel punch (to loosen cap over adjustment screw).

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If a 3Z lubricated plug valve leaks across the seats even after

injection of sufficient sealant onto the valve seats and it is very
easy to operate, then the plug is probably out of adjustment (not
in close enough contact with the body seat) and needs to be
adjusted into the tapered body seat.
Adjusting Bolt

NOTICE.9. Damaged metal seats can also produce these

symptoms.
Lock Nut Lock Bolt

If a 3Z lubricated plug valve is very hard to operate, even after injection of sufficient sealant, then the plug
could be pushed too far into the tapered body seat and needs adjusting out a little.

NOTICE. 10. Solid from clay based lubricants (555 type) or from the line media (slurries, etc) can also
make the valve hard to turn.

A. Adjusting the Plug Adjusting Bolt

This operation can be carried out with the valve on pressure.

B. Expose the Adjusting Screw

First identify the lock nut that protects the plug-adjusting bolt. It is always located in the center of the valve
cover. Remove the lock nut by unscrewing it (counterclockwise viewed from below the valve).

C. Adjusting into the Tapered Seats

To adjust the plug into the body seat, use an adjustable crescent wrench to tighten the plug-adjusting bolt
until it becomes significantly harden to turn. It should take no more than one turn to tighten the plug-
adjusting bolt, unless the plug-adjusting bolt has been slackened off. Once the adjusting bolt feels tight
enough, back it off by 1/8th of a turn.

NOTICE.11. Do not over tighten the plug-adjusting bolt as this. Will jam the plug into the body seat.
After adjusting the plug-adjusting bolt, refit the lock nut but do not over tighten it.

D. Adjusting out of the Tapered Seats

To adjust a seized or hard turn plug out of the body taper, slacken off the plug adjusting bolt by 1/4 turn then
inject sealant into the valve and this should ease the plug out sufficiently to make it operate smoothly.

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NOTICE. 12. Do not remove the plug-adjusting bolt from the valve cover. After adjusting the plug-
adjusting bolt, refit the lock nut but do not over tighten it.

4-4 RENEWING OF SEALING

Most plug valves are used in applications where the flow is always in one direction. As are primarily
downstream seating, it if follows that the down stream seat takes the burnt of the wear and tear form normal
usage. Typically the downstream face of the plug erodes first and caused leakage. There can be
instances where the downstream plug seat is eroded while the upstream plug seat is still in good condition.
In such cases, by rotating the plug through 180 degrees, the good condition plug seat becomes the
downstream seat and leakage will be stopped or substantially reduced, so extending the life of the valve.
This procedure should not be undertaken with product flowing through the valve.

5. THE CAUTION CLAUSES TO USE THE TOOLS FOR MAINTENANCE

AND REPAIR

Should use the proper tools for maintenance and repair, or a plug valve might be damaged by impact and
crack.

1) A screwdriver should not be used instead of a wedge, a chisel, a punch, and so on.
2) A screwdriver could never stand for wrench.
3) Should keep the sharp tools which is apt to be cut and injured in toolbox or tool-belt; keeping those tools
in the personal pocket should be banned.
4) All of tools like a connector, a rope, and a chain should be inspected before the use.
5) When the worker is injured in the middle of handiwork, the first aid should be given right away.
6) While grinding or drilling right beside a plug valve, watch out not to even a chip enter inner part of the
plug valve.
7) During the maintenance and repair, the handy tools or the equipments including a plug valve and a
scaffold should be straightened up in order well.

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6. IN CASE OF LIFTING UP OR PUTTING DOWN A PLUG VALVE IN THE MIDDLE

OF MAINTENANCE AND REPAIR

1) When a plug valve is lifted up, with straightening your back and bending your keens, only the muscle of
legs must be used.
Don't lift it up by force with unbalanced and twisted stance.
2) Should wear a safe-shoes for the provision of the unforeseen accident like slipping or dropping in the
middle of conveyance.
3) Keep yourself out of the impact point that a plug valve is hung
4) Some equipment should be furnished to prevent wire rope from being twisted and keep a Crain or
anything form being overloaded.

7. THE AFFIRMATION AFTER THE MAINTENANCE AND REPAIR

1) Should identify if all factors are set up properly before the operation.
2) A test run being carried out, all tools and equipment should be kept away form the valve.
3) Never get into production until the safety of all functions is identified.

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8. EXPLODED VIEW OF 3Z LUBRICATED VALVE

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9. CUTTING VIEW OF 3Z LUBRICATED VALVE

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