Installation, Operation &

Maintenance Manual

Gate Valve
P/N:BB5895368Y1A
3 ANSI 600 Class Screwed to NPT (F) Ends

&

P/N:BB5895366Y1A
2 ANSI 600 Class Screwed to NPT (F) Ends

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Factory Address: W-96, MIDC, Rabale, Navi Mumbai 400701, INDIA. Tel/Fax: +91 (22) 27604649 / 4654
Email: info@vibafluidcontrol.com WEB: www.vibafluidcontrol.com

1.0 Storage

On receipt check that the valves and accessories are intact. Ensure that the valve is fully closed position.
End protectors on either side of the valve should be kept intact and removed only at the time of
installation
Valve should be stored in a covered area. If the covered area is not available then water proof covering
material should be spread over the valves and valves should be kept on the wooden pallet at 6 (150mm)
above the ground level.
Do not apply tar, paint, grease or any other material inside the valve as this will impair the performance
of the valve

2.0 Construction

VIBA Gate valves are of Sturdy design and give tight sealing against varied pressure and temperature of
the line fluid.
Gate Valves are of Outside Screw and Yoke (OS&Y), Bolted Body & Bonnet Joint & Flexible Wedge Type.
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.

3.0 Installation
3.1 Preparation for Installation

Move the valves as close as possible to the installation site before removing packaging and end protector.
After removing the end protector, check the inside of the valve and remove any rust inhibitor or dirt. If
the valves have been in storage for a long period then clean the stem threads and apply fresh grease.

3.2 Pre-commissioning Tests

All valves are factory tested in accordance with the relevant testing standards as mentioned in the
product catalogue / Test inspection Certificate.
Wherever valves are required to be re-tested before installation, ensure that proper test rig is available at
the site. Valves should be tested as per the relevant testing standards only and avoid testing at higher
pressure then recommended in the standards.

3.3 Installation Configuration

For best performance it is recommended that the Gate Valves are installed vertical with stem operating
end at the top, horizontal or at any angle in between.
VIBA Gate valves have bi-directional sealing capabilities and therefore can be installed in any direction.

3.4 Lifting to Position

Valves should be lifted using suitable mechanical equipment. Mechanical equipment used for lifting the
valves shall be regularly inspected. Do not attempt to lift the valve by applying load on the Hand wheel,
Gear Unit, Actuator or By-Pass piping. Chain and Slings shall be fixed around the Valve body.

Page 2 of 5
Factory Address: W-96, MIDC, Rabale, Navi Mumbai 400701, INDIA. Tel/Fax: +91 (22) 27604649 / 4654
Email: info@vibafluidcontrol.com WEB: www.vibafluidcontrol.com

3.5 Make End Connections

VIBA Gate vales are offered with flanged, Butt Weld, Socket Weld and Screwed Ends as per the
customers requirement.
The ends are machined in accordance to the standard specified in the product catalogue / drawing / test
inspection certificate.
On Site installation team shall ensure valves are properly installed on to the pipe line to suit the ends of
the Valves.

3.6 Installation of Valve Operator

As a standard VIBA Gate Valves are supplied with Hand wheel for manual operation.
Optionally valves are fitted with Gear unit or Actuators as per customers requirement.
Whenever the Gate valves are supplied with Actuators, it is factory fitted and tested. It is strongly
recommended that the actuator setting be not disturbed or altered. Refer the actuator O&M manual for
any alteration required for site condition.

3.7 Start Up

All Valves should be checked for operation before start up by rotating the hand wheel or by actuator if
applicable.
The pipe line should be cleaned by flushing thoroughly with water or air. The valves should be either fully
open or fully closed position to avoid damaging of gate seating by the debris that are flushed out.
Some pipelines are required to be flushed out at very high speed (such as steam blow in turbine inlet), in
such cases particles in the pipeline might damage even the body seating. Use metal protectors around the
body seating to prevent damage.

3.8 Commissioning Test

Valves are to be tested as per relevant testing standard only. Do not test the valves on higher pressure
then it is recommended by standard.
If there is operational requirement to test the valves at higher pressures, temperatures or duration then
the test parameters should be specified and clarified with VIBA prior subjecting the valves to such tests.

4.0 Operation

Gate Valves are multi turn valves with rising stem i.e. they require number of turns of rotation of hand
wheel for full closing or full opening of the valve. All gate valves should be used in fully open or fully
closed position only. If they are used in partial opened condition then the Gate/Wedge may
vibrate/chatter and also cause wire drawing at the seating area which will affect the life and performance
of the valve.
Hand wheel operated Gate valve close by rotating the hand wheel clock wise and open by rotating anti
clock wise.
After closing a Gate valve with sufficient force to develop shut off, ensure that the stem is backed up
slightly ( to turn) to relive stem load. This will enable the stem to expand slightly without damaging
the valve.
For Hand wheel operated valves the projection of the stem above the hand wheel indicates whether the
valve is in open or close position. For non-Hand wheel operate valves separate indicator is provide.

5.0 Maintenance
5.1 In-Line Maintenance

Gate Valves require only minimum in-line maintenance for satisfactory performance.

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Factory Address: W-96, MIDC, Rabale, Navi Mumbai 400701, INDIA. Tel/Fax: +91 (22) 27604649 / 4654
Email: info@vibafluidcontrol.com WEB: www.vibafluidcontrol.com

Check the gland eye bolts for tightness at regular intervals. If found loose tighten them evenly.
Grease the stem threads in Gate Valves as required.
Apply a drop of oil into the stem packing area to reduce the friction between stem and packing.
Grease the Yoke Sleeve in Gate Valve through the grease nipple regularly.

5.2 Routine Maintenance

5.2.1 Gland Leak

If leak persists after the gland Eye Bolt tightening then the Packing must be renewed. For this the valve
must be either in fully open position (back seated) or the pipeline must be shut off so that there is no
pressure inside the valve before the gland eye bolts are loosened.
For replacement of packing rings first remove the gland bolts and take out packing rings chamber of
stuffing box and valve stern. After checking that all sliding parts are in good condition, load new packing
rings securely.
Most of the packing rings are already cut so that they can be inserted around the stem. In case of solid
molded packing like Graphite rings, use a sharp knife and cut the ring at 30 Deg angle. Then slightly twist
the ring and insert it around the stem. Do not open up the ring as it could break.

5.2.2 Body Bonnet Joint Leak

Check the tightness of the bolting and tighten the bolts at the vicinity of the leak. If the leak still persists
then renew the Bonnet Gasket. The pipe line must be shut off before dismantling the bonnet.

5.3 Periodic Maintenance

5.3.1 Dismantling and Servicing Instructions

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.
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 lapping fixture.
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.
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 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.
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.

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Factory Address: W-96, MIDC, Rabale, Navi Mumbai 400701, INDIA. Tel/Fax: +91 (22) 27604649 / 4654
Email: info@vibafluidcontrol.com WEB: www.vibafluidcontrol.com

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.
In case the leakage persists then contact the manufacturer for further action.

5.3.2 Lapping and Finishing Operation

Only VALVEGRIND make silicon carbide (extra coarse) lapping compound should be used. Before starting
the lapping operation on the surface of the seat/wedge, ensure that surface is properly machined (VVV
finishing), burs are removed. Put the lapping compound on the surface of the lapping area, and 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 (VVVV finish). Clean the surface and observe the proper matching between
the contact areas. Before re-assembly, ensure that the contact area is properly matched.

5.3.3 Stem Repair

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

5.3.3.1 Straightness

Minimum clearance for the length of the stem when measured from a straight edge lay
alongside the stem, while rotated 360. The stem should be press straightened if necessary or
should be re-grounded on centre less grinder.

5.3.3.2 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.

5.3.3.3 Packing slide area

The area that passes through packing should be free from pits and have smooth finish. Polishing
or turnings of the sliding surface within pre-decide limits can achieve this. Also the 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.

Page 5 of 5
Factory Address: W-96, MIDC, Rabale, Navi Mumbai 400701, INDIA. Tel/Fax: +91 (22) 27604649 / 4654
Email: info@vibafluidcontrol.com WEB: www.vibafluidcontrol.com