Dok No FRM-010-M

INSTRUCTION OPERATION Rev 00

Date 14 September 2016
PT. OHTORI INDONESIA MANUAL Page 1 of 5

Installation, Operating and Maintenance Manual.

1. Handling and unpacking guidelines

CAUTION:
Always observe the applicable standards and regulations rearding the
prevention of accidents when handling the product.

Handling guidelines
Follow these guidelines when handling the product to prevent damage:
• Use care when handling the product.
• Leave protective caps and covers on the product until installation.

Unpacking guidelines
Follow these guidelines when unpacking the product:
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, file a claim with the shipping company.

2. Lift the valve

WARNING:
Never tamper with the fasteners on the cylinder. Serious injury could result if the nuts on the cylinder tie rods are
either tightened or loosened.

CAUTION:
 Personal injury or valve damage could occurs if the valve is lifted by any part of the bevel gear assembly. The
bevel gear assembly is not designed to support the weight of the valve.
 One person should not attempt to lift cylinder-operated valves larger than 6.00 in. (15.24 cm) or
Handwheel-operated valves larger than 12.00 in. (30.48 cm).
 Use lifting equipment rated for the weight of the valve assembly.
 Do not lift the valve by the handwheel.

2.1 Raise the valve into a vertical position.

2.2 To lift larger valves, loop a lifting strap around one of the yoke legs.

2.3 Prepare the valve for lifting:

If your valve is..... Then.....

Handwheel - Loop the lifting strap under the yoke. Take care that the lifting strap does not
operated bind or tighten against any part of the handwheel. Refe to the Bevel gear-
operated valve figure below.
Bevel gear - operated Loop the lifting strap (s) under the yoke. Rfer to the Bevel gear-operated valve
figure below.
Cylinder - operated Attach two lifting eyes to the portion of the cylinder tie rods that extend above
the tp plate of the cylinder. Attach lifting hooks to the lifting eyes. Take care that
all chains are free and not bound before you lift the valve. Refer to the Cylinder-
 Dok No FRM-010-M
INSTRUCTION OPERATION Rev 00
Date 14 September 2016
PT. OHTORI INDONESIA MANUAL Page 2 of 5

operated valve figure below.

LIFT HANGER

YOKE
YOKE

FIGURE II: OPERATED VALVE

FIGURE I: HANDWHEEL OPERATED VALVE FIGURE III: GEAR OPERATED VALVE

TIE ROD

LIFT HANGER

FIGURE IV: CYLINDER OPERATED VALVE FIGURE V: WORM GEAR OPERATED

2.4 Slowly take up the slack in the lifting straps to ensure that the straps are clear and not binding
against the valve or valve top-works.

WARNING:
Never tamper with the fasteners on the cylinder. Serious injury could result if the nuts on the cylinder tie rods are
either tightened or loosened.
 Dok No FRM-010-M
INSTRUCTION OPERATION Rev 00
Date 14 September 2016
PT. OHTORI INDONESIA MANUAL Page 3 of 5

3. Storage
Valve should be stored in a covered area. If the covered area is not available water proof covering material
should be spread over the valves and the valves should be kept on a wooden pallet at least 6” (150 mm) obove
the ground level.

Do not apply tar, paint grease or any material inside the valve as this will impair the performance of the valve.

The package is designed to protect the valve only during shipping. If you are not installing the valve
immediately after delivery, then you must store it according to these requirements.
This table describes requirements for short-term and long-term valve storage.

Storage period Requirements

Less than 6 Months  Do not expose the valve to direct sunlight.
 Do not expose the valve to weather conditions.
 Do not expose the valve to temperature extremes.
 Do not stack the valves on top of each other.
 Make sure the Gate is in the Full close for GV (API 600
product) and Full open position for Through Conduit Gate (API
6D).

More than 6 months  Store in accordance with the short term action items.

 Store in accordance with OTV Preservation Product

Procedure. Contact OTV to obtain this procedure.

4. Installation

4.1 Carefully check valve identification against valve specification before installation. The fluid flow
direction in pipeline must be consistent with the arrow direction indicated on the body.
4.2 If there is pressure pulse/ surge source, the check valve shall be installed far away from the source.
4.3 Check the inide of bore and the sealing surface before installation, any attached dirty shall be
removed with clean soft cloth.
4.4 For valve with flange end, user shall select proper bolt, gasket according to the working temperature,
working pressure and fluid, equally fasten the bolts and nuts. Bolt shall be with full thread and 8UN
serial thread shall be used for bolt over 1 inch in diameter.
4.5 For valve with butt welding end, user shall perform welding and post welding heat treatment using
qualified WPS ad welder in accordance with the requirements of ASME Sect VIII div. 1 and or B31.3.
 Dok No FRM-010-M
INSTRUCTION OPERATION Rev 00
Date 14 September 2016
PT. OHTORI INDONESIA MANUAL Page 4 of 5

5 Valve Operation and Maintenance

5.1 The online valve shall be knocked, walked on or used as weight support.
5.2 Usually check valves have no heat insulation structure, never touch the surface of valves to prevent
burn when the valve has a high/low surface temperature.
5.3 After put into service, valve shall be checked and maintained periodically especially for the situation of
sealing surfaces and worn, and the corrosion of body. In case of such situation, valve shall be repaired
or replaced. It is suggested that inspection and maintenance of valve shall be perform every three
months provided the fluid is water or oil, every month or to local law provided the fluid is strong
corrosive.
5.4 When performing repair/ maintenance operations, user shall use valve gasket, bolt and nut of the
same size and material as the original one. Valve gasket may be ordered as spare parts for
maintenance and replacement. It is fobiddento open the bonnet or replace the bolt or nut, valve shall
be pressure tested prior to reuse..
5.5 User may repair the valve sealing surface providing a successful closure test is performed and the
sealing is ok.
5.6 Generally valve trim prefers replacement. If part produced by valve manufacturer is not available due
to emergency, user shall produce the part to OTV technical documentations. OTV takes no
responsibility for loss caused out of part produced from outsourcing.
5.7 It is not recommended for reparation of valve pressure containing part by user. If the pressure
containing part is used for a long time and consequently defection occurs and affect safety use, user
shall replace the valve with a new one.
5.8 Welding repair on valve online is forbidden.

6. Potential Failure & Troubleshooting

Failure Cause Troubleshooting

Leakage between sealing
surfaces
Operation failure
1. Dirties between sealing
surfaces
2. Sealing surfaces damages
1. Arm device in a wrong
position
2. The wear of arm, disc and
pin connection
3. Arm deformation or rupture
1. Clean sealing surface
2. Repair the sealing surfaces
Cut off the fluid and dismount
the valve, repair the valve or
replace part.

Leakage between bonnet 1. Bonnet bolts loose
flanges 2. Bonnet gasket failure
Body and bonnet broken and 1. water hammer
leaked 2. Fatique
3. Freezing broken
1. Proper tighten bonnet nuts
2. Replace bonnet gasket
1. Replace valve that exceeds
guarantee period or is found
with early fatique detection.
2. Drain away water in winter
when valve is not used.

Disc failed to open
1. Disc blocked in the body
2. Stem is overheated and
blocks the disc
1. Use proper torque
2. When the valve is closed and
the pipeline is heated, rotate
the handwheel some bit
counter clockwise for unload at
interval

7. Disposal
Dispose of this product and associated components in compliance with government and local regulations.
 Dok No FRM-010-M
INSTRUCTION OPERATION Rev 00
Date 14 September 2016
PT. OHTORI INDONESIA MANUAL Page 5 of 5

8. Return
Ensure these requirements are met before you return a product to OTV:
• Contact OTV for specific instructions on how to return the product.
• Clean the valve of all hazardous material.
• Complete a Material Safety Data Sheet or Process Data Sheet for any process fluid that could
remain on the valve.
• Obtain a Return Material Authorization from the factory.