Valve Servicing Procedure 01

MUSHTARI MAINTENANCE SERVICES SDN. BHD.
STANDARD OPERATING PROCEDURE
Title : Date :
Gate, Globe & Check Valve Servicing Procedure 8/5/2017
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1.0 INTRODUCTION
This procedure is guideline Gate, Globe &Check Valve Assembly &Maintenance
2.0 APPLICABLE CODE / STANDARD
This Valve Assembly and maintanance Procedure is carried out and in accordance with the following standard:
API Standard 598 - Valve Inspection and Testing

API Standard 602 -Compact steel gate valve-flange ,threaded, welding and extended body
API 6D -Specification of pipeline valve, end closuse,connectors and swivel
ASME B16.34 - Valve-flange threaded and welding end.
3.0 VALVE TYPE
1. GATE VALVE
Gate Valve comprises of taper wedge, situated in between two-body seat rings, having
included angle of 8 to 10 range. Guide ribs provided in the body, for smooth vertical movement
secures wedge. Spindle is engaged to the wedge, ‘T’ head self aligned joint. Spindle is engaged in
the yoke sleeve by suitable threading. Rotation of hand wheel in clockwise direction causes the
yoke sleeve to rotate and spindle moves in the downward direction along with the wedge to close
the valve. Gate valves are used for on-off service where full flow with minimum pressure drop is
desired in full open condition. Gate valves are not recommended for throttling service. These
valves are to be used either fully closed or fully open position.
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2. GLOBE VALVE
Globe valve comprises of round shape taper or regulating type disc. The disc is attached to the
Spindle by self-aligned swivelling joint. Vertical movement of disc along with spindle is
governed by rotation of hand wheel, directly fitted on spindle. Spindle is engaged in the yoke
nut on the bonnet top by suitable threading. Clockwise rotation of hand wheel leads to closing
of the disc. Globe valves are normally used for controlling the flow where certain pressure
drop is permitted. These valves can be used for on-off service also.
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3. SWING CHECK VALVE

Swing Check valve is self-operation non-return valve. Disc opens in the direction of flow and
returns back on body seat when flow stops and seals with seat ring against back-pressure.
Disc is secured in hinge; bracket & pin arrangement, which is self-aligned type and moves
inside body cavity. In larger sizes, hinge pin projects out of body to accommodate balance
weight or dashpot arrangement.
4.0 MAINTENANCE
1. DISMANTLING AND SERVICING INSTRUCTIONS FOR GATE VALVE
A. SERVICING
1. Loosen the body/bonnet joint stud/nuts and remove from body, loosen the eye bolt nuts,
rotate the hand wheel in clockwise direction. Wedge will come down to closed position.
Further rotate the hand wheel in same direction, bonnet assembly will rise in upward
direction. Continue the same till spindle comes out of threaded portion of yoke sleeve.
Lift the bonnet assembly to separate it from body. Hold the spindle portion above body
with left hand and pull it upward by hammering gently on topside of body surface beyond
gasket area. The spindle along with wedge will come out of body. Observe the condition
of seat portion and interior portion of body.
2. Clean body interior portion and seat surface thoroughly with suitable cleaning liquid
check up for any scratches on seat ring surfaces. Minor scratches should be removed by
lapping with emery paste with the help of body seat lapping fixture.
3. If the scratches are deep which cannot be removed by lapping, further machining may be
required. Threaded seat rings are machined with ‘Right Hand’ threading and can be
removed from body with the help of lugs provided. Where seat rings are seal welded to
the body, complete body should be loaded on machine for further rectification.
4. Similarly minor scratches on wedge surface should be removed by lapping with emery
paste.Deep scratches should be removed by machining and lapping. In case wedge
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surface is heavily damaged the entire seat surface should be machined and machining and
lapping should follow one layer of hard facing weld deposition as per body size.
5. Remove old gland packing from bonnet stuffing box. Clean the bonnet surface from
inside; lap the degree surface of back seat bush with the help of suitable fixture or by
spindle itself. Clean threaded portion of the spindle. Polish the non-threaded portion of
spindle on lathe machine or grind if possible. Clean threaded portion of yoke sleeve and
apply grease with the help of grease gun through grease nipple provided on the bonnet
top.
6. Change the body bonnet joint gasket and assemble the valve. Put new gland packing of
required size and quality into the stuffing box with open end 180 with respect to each
other. Tighten eyebolt nut equally on both sides. Lubricate the spindle-threading portion
and operate the valve 2/3 times.
B. PROCEDURE FOR REPAIRS TO SEAT AND WEDGE/PLUG SURFACE
1. In case the leakage persists, open the body/bonnet joints and see if there is damage on the
wedge surface. To repair this type of damage following procedure is to be adopted.
2. For repairs by deposition of 13% chrome by welding the thickness of layer required is
1.6mm minimum.
Welding Rod used:
3. The surface should be covered uniformly with complete metallurgical bond between the
surface to be deposited and alloy.
C. DEPOSITION OF COBALT BASED ALLOYS FOR STELLITING ON THE

SURFACE OR SEAT/WEDGE:
When the seat ring surface is made from alloys other than 13% Chrome use the following
procedure for stelliting
D. HARDNESS PROCEDURE.
1.Expected between 38 to 42 Rc for seat Valve seat are preheated to temp of 350 to 400
degrees centigrade through out the section of the work piece and they are, then deposited with
stellated alloys on the specified seat area using insert gas shielded plasma ARC process with
non-consumable throated (tungsten) rods.
2. The ARC is always directed towards the deposited alloys to minimize dilution. Dilution
observed is in the range of 5-8% for deposits of 2.50-mm thick using current range of 75-125
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amperes. It has to be ensured that the complete surface is covered uniformly and there is
complete metallurgical
3. bond between the surface to be deposited and the alloy. Subsequent to the deposition the
part is put in a dry lime bucket for slow cooling and also to relieve the stress. The flow of the
inert gas shield should be adequate to avoid any oxide formation and also to restore all
hardenable agents and the metallic constituents in the alloy that provide higher temperature
and wear resistance.
E. LAPPING AND FINISHING OPERATION
1. lapping compound should be used. Before starting the lapping operation on the surface of
the seat/wedge, ensure that surface is properly machined (∇∇∇ finishing), burns are removed.
Put the lapping compound on the surface of the lapping area,
2. apply it on flat metallic plate (lapping plate). For proper finish, give the equal force to all
contact area, till the surface is smoothly lapped (∇∇∇∇ finish). Clean the surface and observe
the proper matching between the contact area. Before re-assembly, ensure that the contact area
is properly matched.
F. STEM REPAIR
All the valve stems are to be repaired for the following:

♦ Straightness,
♦ Damage to head and threads,
♦ Corrosion,
♦ Pitting and taper in the portion that slides through the packing.
1. Straightness
Minimum clearance for the length of the stem when measured from a straight edge laid along
side the stem, while rotated 360. The stem should be press straightened if necessary or should
be regrounded on center less grinder.
2. Threads and head:
Thickness and smoothness of threads must ensure smooth operation within the stem nut. The
head must adequately engage the disc or plug.
3. Packing slide area:,
The area that passes through packing should be free from pits and have smooth finish.
Polishing or turning of the sliding surface within pre-decided limits can achieve this. Also the
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taper on the stem should be removed. If pits wear, taper or previous machining results in a
reduction of the stem outside diameter beyond acceptable limit from original size; the stem to
be replaced by new one.
G. IMPORTANT TIPS DURING THE RE-PACKING OF GLAND
1. While removing the old packing avoid hooks that can scratch the fine finishes of stem &
stuffing box. Soft materials such as brass or hardwood dowels are better instruments.
2. Thoroughly clean stem & stuffing box while replacing new rings.
3. Avoid handling the parts and new packing set with bare hands after cleaning, otherwise salt
is introduced which can start corrosion.
4. It is generally acknowledged that the top tow rings of packing set are most effective in
sealing the stem. Therefore, if two rings can be added to an in-service valve on back seat,
there is an excellent chance of stopping leakage.
4.2. DISMANTLING AND SERVICING INSTRUCTIONS FOR GLOBE VALVES
A. DISMANTLING AND SERVICING
1. Loosen the eyebolts/nuts; remove the body bonnet joint stud/nuts. Lift the bonnet assembly
from body. Remove tack weld locking of spindle nut to disc and take out the disc from spindle
assembly. Remove the hand wheel from spindle and take out spindle from bonnet assembly by
rotating anti-clockwise
2. Clean the spindle-threaded portion and polish or grind unthreaded portion.
Take a light cut on taper back seat portion, if damage is more. Remove old gland packing
from bonnet stuffing box. Lap the back seat portion of bonnet bush. Check the condition of
seat surface of body seat ring and disc. Minor scratches should be removed by lapping with
emery paste with the help of suitable fixtures. Deep scratches should be removed by
machining and lapping. Removal of threaded seat rings is similar to that of gate valve
3. Assemble the disc/spindle assembly as before and assemble the valve and replace the old
gasket. Add new gland packing in the stuffing box of exact size having opened ends 180 with
each other. Apply proper lubrication to spindle threading and operate the valve 2/3 times.
4.3. DISMANTLING AND SERVICING INSTRUCTIONS FOR CHECK VALVES
A. DISMANTLING AND SERVICING

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1. Open the cover plate by removing body-cover stud/nuts. Open two bracket bolts and take
out assembly of hinge, bracket and disc. Separate the disc by removing split pin and disc nut.
Clean the interior portion of body with cleaning liquid. Check the condition of seat ring surface.
Rectification of seat surface is same as specified in Gate and Globe Valve
2. After lapping disc & seat ring, assemble the hinge/bracket/disc assembly as before and also
Replace the old gasket. Assemble the cover plate on body and ensure that disc assembly sits
properly on seat ring and is also free to move inside body
B. MAINTENANCE OF DASH POT
1. Periodic lubricating oil should be applied on various moving part joints. Open portion of
piston rod should be kept clean.
2. Oil seals for piston rod and ‘O’ Rings for piston may need replacement over period of time
depending on frequency of use.
C. DISMANTLING OF DASH POT
1. Disengage piston rod pin attached to disc pin & lever assembly of main valve.
2. Take out dashpot by removing nut provided on pivot pin assembly.
3. Remove bolts provided on top flame and take out piston assembly from cylinder. Take out oil
from cylinder.
4. Oil seals for piston rod and ‘O’ Rings for piston may need replacement over period of time
depending on frequency of use.
5. Piston rod is threaded in the piston. Take out piston rod from piston.
6. Replace oil seal & ‘O’ Rings if required
D. GENERAL MAINTENANCE GLAND PACKING
1. The very frequent operation of the valve may lead to slight leakages through gland packing.
2. Tighten the eye bolt nuts equally on both sides to stop the leakage. This sequence should be
repeated a few more times.
3. After a period of time you may have to add one or two more gland
packing in the stuffing box. To add the gland packing rotates the hand wheel in anti-clockwise
direction in full open position. All gate and globe valves are provided with back seating
arrangement in full open position.
4. Remove the eye bolt nuts, lift the gland bush and gland flange in
upward direction and add the required nos. of gland packing.
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E. CHANGE OF GLAND PACKING
1. When the valve is kept in service or in the store for considerably long time, as the gland
packing is in compressed position for a long time, it loses its compressibility and becomes
hard. It does not hold the pressure even after further tightening. At this stage there is no
alternative than to replace the old packing with a new one.
2. The method of replacing gland packing is similar as described in 3 (a). Old gland packing
should be removed by using angular scriber and replaced with new packing of correct size
having open ends placed 180 with each other.
3. If the valve is installed in running pipeline then precautions must be taken during replacement
of gland packing under pressure. There should not be any leakage through gland when valve
is in back seat position. In may cases back seat portion of spindle and bush get damaged due
to hard foreign particles entering the pipeline and coming in contact with seat surface and
back seat area during operation of valve.
4. It is not advisable to change the gland packing if some leakage is observed in gland packing
when valve is in back seat position. In such cases valve should be dismantled and back seat
should be repaired.
F. CLEANLINESS AND LUBRICATION OF SPINDLE
1. The spindle above gland packing area is always exposed to open atmosphere where a lot of
dust and adverse weather conditions can damage the surface of spindle. For smooth operation
of valve, threaded portion of spindle must be protected from dust and proper lubrication must
be provided periodically. Grease should be applied by grease gun through the grease nipples
provided for lubrication of yoke sleeve collar.
5.0 HYDROTEST AFTER VALVE SERVICING
A. TEST FLUID
1. Water or non-corrosive liquid with a viscosity not higher than water. The test fluid temperature
shall be within the range 41◦ F (5 ◦) to 122o F (50O C).
2. For low-pressure closure, the test fluid shall be air or inert gas
3. Water used for any test may contain water-soluble oil or rust inhibitor.
4. For testing of austenitic stainless steel valves, demin water shall be used for this test.
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B. SHELL TEST
The shell test is performing to identify any leak at shell and it should be perform by following the step below:
a. Valve partially open.

b. Tight all gland packing enough to maintain pressure test
c. Apply pressure inside assemble test valve with the valve ends close
d. If pressure not drop or any leakage or no deformation detected at shell valve’s, shell test is
acceptable
C. BACKSEAT TEST
Backseat test is required for all valve, that have the backseat feature and shall be performed by following step:
a. Open valve totally and packing gland loose/packing not installed.

b. Apply pressure inside assemble test valve with the valve ends closed
D. LOW-PRESSURE CLOSURE TEST
a. Low pressure closure test shall be perform with the sealing surface clean and free from oil, grease
and sealant if necessary to prevent galling, the sealing surfaces may be coated with a film of oil
that is not heavier than kerosene. This requirement does not apply to a valve that use a lubricant as
its primary seal (for example, lubricated plug valves).
b. Low-pressure closure test will be perform by following step:
a) Install test flange one side valve(one side for inject pressure air and other side to fill with water or
any liquid that similar to other test liquid)
b) Valve fully close closed
c) Inject air pressure into valve
d) Make sure valve at vertical position (air hose at bottom valve).
e) Attach seat sealing surface at outlet flange, the valve shall be detected when bubbles observed
coming from the closure (disk, seat, and seat ring), covered with water.
f) If no bubble detected, low- pressure closure test acceptable leakage (refer table 6 for a metal-
seated valve of equivalent size and type) and repeat step a-e to other side valve.
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E. HIGH-PRESSURE CLOSURE TEST
The procedure for high-pressure closure test shall be the same as the procedure for low-pressure closure
Test except that, in the case of liquid test, leakage shall be detected when drops not bubble.
F. TEST PRESSURE
a. The shell test pressure shall be in accordance with the table below. (According API 598, Table
2-
Test shell pressure)
Shell Test Pressure (Minimum)

Valve Type Class Pounds per Square Inch Bar
Gauge (PSI)
Ductile Iron 150 400 26
300 975 66
Cast Iron 125
NPS 2-12 350 25
NPS 14-48 265 19
Cast Iron 250
NPS 2-12 875 61
NPS 14-48 525 37
Steel
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Flanged 150-2500 b
Buttweld 150-4500 b
Threadeda and socketweld 800 c
150-4500 b
Notes:
a
ASME B16.34 limits threaded-end valves to class 2500 and lower.
b
Per ASME B16.34.
c
For Class 800 valves, the shell test pressure shall be 1 ½” times the pressure rating at 100◦F (38◦C), round off
to the next higher increment of 25 pounds per square in. gauge (or 1 bar) (see table 2 of API Std 602).
b. Other Test Pressure (According API 598, Table 3- Other Test Pressure)
Test Pressured
Test Pounds per Square Inch Bar
Gauge (PSI)
Valves Except Butterfly and Check
High-Pressure closure and backseata b b

Low-Pressure closure and backseata 60-100 4-7
Butterfly Valve
High-pressure closure C
Low-Pressure closure 60-100 4-7
Check Valve
High-pressure closure
Class 125 (cast iron)
NPS 2-12 200 14
NPS 14-48 150 11
Class 250 (cast iron)
NPS 2-12 500 35
NPS 14-24 300 21
Class 150 (ductile iron) 250 17
Class 300 (ductile iron) 640 44
Carbon, alloy, stainless steel and special b
Alloys.
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Low-pressure closure (See table A and B) 60-100 4-7
Notes:
a
The backseat test is required for all valves that have this feature.
b
110% of the maximum allowable pressure at 100◦F (38◦C) in accordance with the applicable purchase
specification.
c
100% of design differential pressure of 100◦F (38◦C) in accordance with applicable purchase
specification.
d
Single values shown are minimum test pressure. A range of values indicated both minimum and
maximum test pressures.
11.0 TEST DURATION
Minimum Test Duration (Second)a

Valve Size Shell Backseat Closure
(NPS”
Check Valve Other valves All Valves with Check Valves Other Valves
(API std 594) backseat Feature (API Std 594)
≤2 60 15 15 60 15
2 ½-6 60 60 60 60 60
8-12 60 120 60 60 120
≥ 14 120 300 60 120 120
Table C: Duration of Required Test Pressure
Note: a The test duration is the period of inspection after the valve is fully prepared ad is under full.
12.0 TEST LEAKAGE
12.1 For shell tests, visually detectable leakage through the pressure boundary walls and fixed body joint
is not permitted.
12.2 For backseat tests, visually detectable leakage is not permitted.
12.3 For both the low-pressure closure test and the high-pressure closure test, visual evidence of leakage
through the disk, behind the seat rings, or past the shaft seal (of valves that have this feature) is not
Permitted and structural damage is not detected. The allowable rate for leakage of test fluid at the
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seat-sealing surface interface, for the duration of the test listed in table D.
12.4 The allowable leakage rate for closure tests of valves with non-metallic (e.g. ceramic) seat material
shall be equal to that specified in table 6 for a metal-seated valve of equivalent size and type.
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MUSHTARI MAINTENANCE SERVICES SDN. BHD.

STANDARD OPERATING PROCEDURE

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2.0 APPLICABLE CODE / STANDARD

API Standard 598 - Valve Inspection and Testing

3.0 VALVE TYPE

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3. SWING CHECK VALVE

1. DISMANTLING AND SERVICING INSTRUCTIONS FOR GATE VALVE

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B. PROCEDURE FOR REPAIRS TO SEAT AND WEDGE/PLUG SURFACE

C. DEPOSITION OF COBALT BASED ALLOYS FOR STELLITING ON THE

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E. LAPPING AND FINISHING OPERATION

All the valve stems are to be repaired for the following:

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G. IMPORTANT TIPS DURING THE RE-PACKING OF GLAND

4.2. DISMANTLING AND SERVICING INSTRUCTIONS FOR GLOBE VALVES

A. DISMANTLING AND SERVICING

4.3. DISMANTLING AND SERVICING INSTRUCTIONS FOR CHECK VALVES

A. DISMANTLING AND SERVICING

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B. MAINTENANCE OF DASH POT

C. DISMANTLING OF DASH POT

D. GENERAL MAINTENANCE GLAND PACKING

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E. CHANGE OF GLAND PACKING

F. CLEANLINESS AND LUBRICATION OF SPINDLE

5.0 HYDROTEST AFTER VALVE SERVICING

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a. Valve partially open.

a. Open valve totally and packing gland loose/packing not installed.

D. LOW-PRESSURE CLOSURE TEST

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E. HIGH-PRESSURE CLOSURE TEST

Shell Test Pressure (Minimum)

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High-Pressure closure and backseata b b

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Low-pressure closure (See table A and B) 60-100 4-7

11.0 TEST DURATION

Minimum Test Duration (Second)a

Table C: Duration of Required Test Pressure

12.0 TEST LEAKAGE

12.2 For backseat tests, visually detectable leakage is not permitted.

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