TULSA VALVE

P.O. Box 35
Cleveland, Oklahoma 74020

By-Pass Style Pig Valve

IOM - Installation, Operation & Maintenance

Doc. No.: IOM-ByPass.01

Date: 3/28-2008

Contents:
Installation

Operation

2-3

Bill of Materials

4 -5-6

Maintenance

7-8

Installation:
Install the valve in the system using the proper size
and type mating flanges and Ring Type Gaskets. The
Launch/Receive direction and Catcher Side is noted
on the Cover of the Gear Operator, See diagram B
for details. The valve orientation is dependent on
whether the valve will be used as a Receiver or a
Launcher. If the valve is to be a Receiver, the Closure
(5)/Davit Assembly (28) should point down (6:00) to
the ground, see launch/receive Procedures. If the
valve is to be used as a launcher the Closure,
(5)/Davit Assembly (28) should point up (12:00) towards the sky, see launch/receive Procedures. Ample
Clearance above and below the valve is required to
install and/or remove the pig.
General Diagram A

Never hold or lift the valve by the Davit Assembly.

Never hold or lift the valve by the Gear Operator.
Use the flange bolt holes or put straps between the
flanges and the bonnet around the valve body. The
valve is not balanced and care should be taken
when lifting to prevent the valve from shifting or spinning around. Use proper lifting equipment and techniques.

Side of Ball that

Pig Catcher is on

Side of Ball that is

open to Launch or

Diagram B

After the valve is installed, the closure and davit assembly should be fully operated to ensure it is in
proper working condition. The gear operator is set at
the factory. Before applying pressure to the valve
verify that the Ball is in the open position (Diagram B
indicator is horizontal). Verify that the Equalization
valve (26) is closed. Verify that the bleed fittings (23)
are closed. Verify that the Closure (5) is screwed
down tight ( a few light knocks on the closure lugs
with a striking hammer should be sufficient). Rotate
the ball by turning the Gear hand wheel. Counterclockwise to accept or discharge a pig and clockwise
to launch or Receive.

Tulsa Valve reserves the right to change designs, materials or specifications without notice or without obligation to install such changes on products
previously or subsequently sold. 12/1/2002 Tulsa Valve Phone: 918-358-3494

Page 2 No.: IOM-ByPass.01

T U LS A VA LVE BY -P AS S S TY LE P IG V A LVE - I NST A LLAT I ON, OPE RA T I ON A ND MA I NTE NA NC E

Operation:
The Tulsa Valve By-Pass Style Pig Valve is designed to be used as either a Launcher or a Receiver. The Installation determines how the valve will be used. Below are basic diagrams outlining
the steps required to either Launch or Receive. Note: Not all assemblies have Gear Operators.

Launching Procedures
Before opening any fittings or closures, first review the orientation of the ball using the Indicator
plate shown in diagram B on page 1. The Indicator diagram must be as shownHorizontal (inline
with the valve flow bore). Follow the instructions below carefully and read the Caution notes.

FIG 1

FIG 2

Vent Fittings

FIG 3

After VerifyDavit Hand wheel

ing the Ball
Position and
Closure
that
the
equalizer
valve
is
Pig
closed (turn
Bonnet
Clockwise
until
it
stops), Open
Pig Chamber
one or both
vent fittings
to
relieve
pressure in
the
Pig
Open Closure by turning both the
Chamber. Caution: Fluids or gases will
Closure and the Davit Hand wheel
be released to atmosphere when openCounterclockwise until released from
ing vent fittings unless other precautions
Bonnet threads. When Closure is
or connections are made.
above the Bracket rotate out of position to expose the Pig Chamber.
See Caution notes.
Install the Pig in the Chamber.

Equalization Valve
FIG 4

Verify
Closure
seals are clean
and undamaged.
Rotate Davit and
Lower
Closure
onto
Bonnet
Threads. Thread
Closure
Clockwise until it is
completely down
against the Bonnet Face. The
Davit hand wheel
should also be
completely down.
Closure should be tightened snugly using a
striking hammer. Close Vent Fittings. Open
Equalizer Valve by turning T handle counterclockwise.

FIG 5

After the Pig

Chamber
Gear Hand
pressure is
equalized
with the line
pressure,
Rotate
the
Ball by turning the Gear
Hand wheel
Counterclockwise
until it stops
(about
60
turns).
The
Indicator will be vertical. The pig will drop
into the ball bore. Close the Equalizer
Valve prior to launching.

FIG 6

To Launch Pig turn Gear

Hand wheel Clockwise until
it stops (about 60 turns).
The pig is launched. Caution: Pig Chamber is still
under pressure.

Tulsa Valve reserves the right to change designs, materials or specifications without notice or without obligation to install such changes on products
previously or subsequently sold. 12/1/2002 Tulsa Valve Phone: 918-358-3494

T U LS A VA LVE BY -P AS S S TY LE P IG V A LVE - I NST A LLAT I ON, OPE RA T I ON A ND MA I NTE NA NC E

Receiving Procedures

Page 3 No.: IOM-ByPass.01

FIG 7

Before opening any fittings or closures, first review the orientation of

the ball using the Indicator plate shown in diagram B on page 1. The
Indicator diagram must be as shownHorizontal (inline with the valve
flow bore). Follow the instructions below carefully and read the Caution
notes.
Equalization

CAUTION NOTES
Opening any fittings or closures is dangerous. Make sure to follow all
safety precautions when operating this valve. Take measures not to
pollute the atmosphere or ground when opening the vent, drain fittings
or closure. These valves are under high pressures so re-verify that the
pig chamber is vented before opening closure. Improper use may result in serious injury or death.

FIG 8

To receive pigs the valve

must be installed as
shown and the ball open
to flow. The catcher must
be down stream to allow
the pig to enter fully into
the ball cavity.

After the pig

has entered
the ball cavity the valve
is ready to
remove the
pig.
First
verify that
the
vent
FIG 9
fittings are
closed and
the closure
is installed correctly. Then open the
Equalization valve by turning T handle counterclockwise and allow the
pig chamber pressure to equalize
with the Pipeline pressure.

Once the Pig

has entered
the
Pig
Chamber
rotate
the
ball by turning the gear
hand wheel
clockwise
FIG 11
(about
60
turns) until it
stops. Close
the equalization valve by turning the T
handle clockwise until it stops. Open
one or both vent fittings to relieve pressure in the Pig Chamber. Caution: Fluids or gases will be released to atmosphere when opening vent fittings
unless other precautions or connections are made.

Vent Fittings

After the Pig

c h a m b e r
pressure
is
equalized,
rotate the ball
by turning the
gear
hand
wheel count e r cl o c k wi s e
FIG 10
(about
60
turns) until it
stops. The Pig
will fall into the
pig chamber when completely rotated.

Open Closure by turning both the

Closure and
the
Davit
Hand wheel
Counterclockwise
until
reFIG 12
leased from
B o n n e t
threads.
Caution closure may drop suddenly if Davit hand
wheel is rotated to far down. When
Closure is below the Bracket rotate out
of position to expose the Pig Chamber.
Caution fluids or debris will be released. Pig will fall out of chamber.

Verify Closure seals

are
clean
and
undamaged.
R o t a t e
Davit and
raise Closure inline
FIG 13
with Bonn
e
t
Threads.
Thread Closure Clockwise until it is
completely up against the Bonnet
Face. The Davit hand wheel should
also be completely up. Closure should
be tightened snugly using a striking
hammer. Close Vent Fittings. Valve
is ready to receive the next pig.

Tulsa Valve reserves the right to change designs, materials or specifications without notice or without obligation to install such changes on products
previously or subsequently sold. 12/1/2002 Tulsa Valve Phone: 918-358-3494

8a

General Section
25

7a

Detail E
18
13
13

17

22

12

10

16

19

14

Detail G

7a

Detail F

27

24

28

General Assembly Drawing of

By-Pass Valve with Davit and
Gear Operator

Tulsa Valve By-Pass Style

Pig Valve:

20

21

29

Detail D

11

26

23

23

15

T U LS A VA LVE BY -P AS S S TY LE P IG V A LVE - I NST A LLAT I ON, OPE RA T I ON A ND MA I NTE NA NC E

Page 4 No.: IOM-ByPass.01

Tulsa Valve reserves the right to change designs, materials or specifications without notice or without obligation to install such changes on products
previously or subsequently sold. 12/1/2002 Tulsa Valve Phone: 918-358-3494

T U LS A VA LVE BY -P AS S S TY LE P IG V A LVE - I NST A LLAT I ON, OPE RA T I ON A ND MA I NTE NA NC E

Page 5 No.: IOM-ByPass.01

Generic Bill of Material

Use the Assembly drawing and the Bill of Materials shown to reference parts. The repair and
maintenance procedures reference these Item numbers. The recommended spare parts are
listed in the Bill of Material.
For other materials and part numbers consult the Factory.

Item

Qty

Description

Spare Parts

Assembly

Body Machined

WCB/WCC

Bonnet/Closure Machined

WCB/WCC

Ball Finished

Closure Machined

Stem

Yes

316 SS

Seat

Yes

DELRIN (Celcon)

7a

Seat Carrier (8 and larger)

316 SS

Yes

Standard Material

CF8M/316 SS
WCB/WCC

Bonnet (Stem)

1040/1045 CS

8a

Baffle Plate

316 SS

Retaining Ring (Ball/Baffle Plate)

316 SS

10

Body/Bonnet O-ring

Yes

Buna N

11

Bonnet/Closure O-ring

Yes

Buna N

12

Bonnet (Stem)/Body O-ring

Yes

Buna N

13

Stem O-ring

Yes

Buna N

14

Seat Carrier O-ring

Yes

Buna N

15

Closure Gasket (O-ring)

Yes

Buna N

16

Body/Bonnet Gasket

Yes

Buna N

17

Bonnet (Stem) Gasket (O-ring)

Yes

Buna N

18

DU Stem Bearing

Yes

DU

19

Thrust Bearing

Yes

PEEK

20

Varies

Body Studs

ASTM A 193 B7

21

Varies

Body Nuts

ASTM A194 2H

22

Varies

Bonnet Bolts- Socket Head Cap

ASTM A193 B7

23

Bleed Fitting 1 NPT 4006-BV10N8-80

4140 Nace

24

1" NPT Pipe Plug

4140 Nace

25

Wave Spring

17-7 PH

26

Equalizing Valve

CS

27

Handle (not shown)

CS

27

Gear Operator

DT-90

28

Davit Assembly

29

1-8 UN Socket Head Cap screw 1.25 LG

CS

Tulsa Valve reserves the right to change designs, materials or specifications without notice or without obligation to install such changes on products
previously or subsequently sold. 12/1/2002 Tulsa Valve Phone: 918-358-3494

T U LS A VA LVE BY -P AS S S TY LE P IG V A LVE - I NST A LLAT I ON, OPE RA T I ON A ND MA I NTE NA NC E

Page 6 No.: IOM-ByPass.01

Davit Assembly
The Davit should not need to be serviced or lubricated. The main lifting and turning components
are either Teflon Composite bearings or Xylan Coated for lubricity and corrosion protection. Use
the drawing and Bill of Material when referencing the Davit and its components.
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
18

QTY.
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1

19

20
21
22
23

4
4
1
1
15

12

DESCRIPTION
Bracket
Lock Nut
Shaft
Washer/Spacer
Pivot Base
Pivot Tube
Pivot Shaft
Pivot Shaft plate
Pivot Hub
Pivot Bearing
Pivot Thrust Bearing
Pivot Shaft plate top
Pivot Arm
Hub
1-8 UN X 1.5 LG bolt
Handle wheel Assembly
3/4-10 UNC X 1.25 LG Socket Head Cap
Screw
3/4-10 UNC X 2.5 LG Hex Head Cap Screw
3/4-10 UNC Hex Nut
Lock Nut O-ring
Washer/Spacer Lock Pin
11

MATERIAL
CS
1018 CS
1018 CS
1018 CS
CS
CS
1018 CS
CS
1018 CS
DU
DU
1018 CS
CS
1018 CS
18-8 SS
IRON

COATING
XYLAN
XYLAN
XYLAN
XYLAN
XYLAN
XYLAN
XYLAN
XYLAN

XYLAN
XYLAN
XYLAN

18-8 SS
18-8 SS
18-8 SS
Nitrile
SS

18

10

11

14

13

8
7
6

3
22
23

20
5
21

19

Tulsa Valve reserves the right to change designs, materials or specifications without notice or without obligation to install such changes on products
previously or subsequently sold. 12/1/2002 Tulsa Valve Phone: 918-358-3494

T U LS A VA LVE BY -P AS S S TY LE P IG V A LVE - I NST A LLAT I ON, OPE RA T I ON A ND MA I NTE NA NC E

Page 7 No.: IOM-ByPass.01

Gear Installation and Removal

When installing or removing the gear operator follow these instructions. Standard tools are required such as Allen keys, crescent wrench, and a screw driver. When removing the Gear, it
should be noted that the gear segment must be rotated. If the ball must stay in its present position, the Key will have to be removed first prior to rotating the gear segment. Gear must be lubed
prior to using.
To Remove Gear:
Mounting Bolts
Step 1: Remove Indicator Cover.
Step 2: Remove Gear Cover
1
4
Step 3: Remove Key if required
Step 4: Remove Bolts 1,2 and 3
Step 5: Rotate Gear Segment by
turning handwheel to expose Bolt 4
3
2
Step 6: Remove Bolt 4
Step 7: Slide Gear off Valve Shaft
Gear Mounted on
Gear Mounted on Valve
Retain Grease Lubrication for reValve with indicator
with cover removed
installation.
cover removed.
Worm Gear

Handwheel Shaft

Gear Lubrication
required.

Gear
Exposed Bolt
Hole

Segment

To Install Gear:
Step 1: Remove Indicator Cover.
Step 2: Remove Gear Cover
Step 3: Slide Gear over Shaft
Step 4: Align gear as shown with Hand wheel
up and to the left.
Step 5: Install Bolts 1, 2 & 3
Step 6: Rotate gear segment and install Bolt 4
Step 7: Rotate gear to line up with key way in
shaft and install the Key.
Step 8: Set Travel Stops. Install Indicator Cover.
Tulsa Valve reserves the right to change designs, materials or specifications without notice or without obligation to install such changes on products
previously or subsequently sold. 12/1/2002 Tulsa Valve Phone: 918-358-3494

T U LS A VA LVE BY -P AS S S TY LE P IG V A LVE - I NST A LLAT I ON, OPE RA T I ON A ND MA I NTE NA NC E

PAGE 8 Doc. No.: IOM-ByPass.01

Valve Assembly/Disassembly Procedures

Tulsa Valve By-Pass Style Pig Valves may be rebuilt to new condition without removing the valve from the pipeline. We
recommend removing valves from the piping if they are upside down and used for receiving. Standard shop tools and lifting equipment required. Tulsa Valve is not responsible for improper assembly or disassembly including injury, wrong materials, bad repair practices or other unforeseen actions. Consult the factory prior to working on any valve.

Reconditioning Valve
Caution! Prior to disassembly, valve must first be isolated from system pressure and flow. Also, with the valve ball at approximately half open, internal pressure must be bled to 0 psi. Finally, as a safety precaution open bleed fittings (23) and
equalizer valve (26). Use proper lifting equipment and tools when disassembling the valve. Valve components are heavy
and care must be exercised when handling components.

After observing the above caution, disassembly may begin.

Step 1: Remove the davit assembly (28), the davit locknut (item 2 on davit bill of material) must be unthreaded from closure
(5).
Step 2: Remove the closure (5).
Step 3: Remove the body nuts (21) and lift the bonnet/closure (3) off the body (2) caution the seat (7)/seat carrier (8a) is in
the bottom of the bonnet and may slip out.
Step 4: Before removing the gear, rotate the ball (4) so the flow bore is inline with the pipeline. Remove the gear assembly
following the gear removal instructions on page 7, if a mounting plate was used, remove the plate from the bonnet/stem (8).
Step 5: Remove the bonnet (stem) bolts (22) and slide the bonnet (stem) (8) off the stem (6). The stem may come out with
the bonnet (stem), this is OK. Slide the stem out of the bonnet.
Step 6: The ball (4) may now be removed. Use a heavy duty nylon type strap through the ball port to lift the ball carefully out
of the body cavity. Be careful not to bang the ball as you remove it.
Step 7: Remove the bottom seat (7) and seat carrier (7a) from the bottom of the valve body. Remove the wave spring (25)
from the bottom of the body. Clean all surfaces and inspect for damage.
If the equalizer valve or fittings need to be replaced, they may be removed at any time during the procedure.
At this point, all seals are readily accessible on the various components. Make sure all seals are removed and inspected
prior to re-building the valve. Replace any seals that are damaged or worn.

Rebuilding Valve
To rebuild the valve, first make sure all seals are in good working condition. Have grease lubricant handy and use it on all
seals. Caution: Make sure any lubricant is compatible with the Seals and the intended valve service conditions.
To rebuild the valve just reverse the instructions above. Install all o-rings and seals on the various components according to
the assembly drawing.
Step 1: Place the wave spring first then the seat carrier (no O-ring required on OD) then seat then ball in the body cavity.
Align the ball stem slot with the bonnet/stem bore to aid in inserting the stem.
Step 2: Put the other seat carrier in the bonnet/closure (this seat carrier uses the o-ring on the OD). The o-ring will hold the
seat carrier in the bonnet. Install the seat in the seat carrier (applying grease to the seat usually holds the seat in the carrier).
Step 3: Slide the bonnet/closure over the body studs and down onto the body. Make sure to align the bleed fittings and
equalizer valve according to the assembly drawing. Install the nuts and tighten to bring the bonnet down onto the body.
Step 4: Push the stem and bonnet/stem as a group into the body and into the ball slot. Use the bonnet bolts to bring the
bonnet down onto the body.
Step 5: Install the closure. Bolt the davit assembly on the bonnet/closure. Align the davit shaft with closure and tighten the
lock nut.
Step 6: Install the gear assembly as required using the gear installation instructions.
Make sure all bolts and nuts are tightened securely. Make sure all bleed fittings and the equalizer valve are installed properly. Rotate the ball to verify its operation. Unscrew the closure and lift the davit to verify they are in proper working condition
(see launching and receiving instructions for this). Test the valve prior to using in service.

Tulsa Valve reserves the right to change designs, materials or specifications without notice or without obligation to install such changes on products
previously or subsequently sold. 12/1/2002 Tulsa Valve Phone: 918-358-3494