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VEL-FBGM-2003 FORGED BONNETLESS Y-PATTERN, INCLINED 45º BOLTED BONNET & WELDED BONNET GLOBE AND PISTON CHECK VALVES MAINTENANCE MANUAL 1 / 4 – 4” (8 –100 mm) Maintenance Manuals
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FORGED BONNETLESS Y-PATTERN, INCLINED 45º BOLTED …vel-fbgm-2003 forged bonnetless y-pattern, inclined 45º bolted bonnet & welded bonnet globe and piston check valves maintenance

Mar 14, 2020

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Page 1: FORGED BONNETLESS Y-PATTERN, INCLINED 45º BOLTED …vel-fbgm-2003 forged bonnetless y-pattern, inclined 45º bolted bonnet & welded bonnet globe and piston check valves maintenance

VEL-FBGM-2003

FORGED BONNETLESS Y-PATTERN,

INCLINED 45º BOLTED BONNET & WELDED

BONNET GLOBE AND PISTON CHECK VALVES

MAINTENANCE MANUAL1⁄4–4” (8–100 mm)

MaintenanceManuals

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TABLE OF CONTENTS

GENERAL INFORMATION PAGE

I INTRODUCTION ........................................................................................................................41.1 General Introduction ..............................................................................................................................41.2 Essential Features of Velan Valves........................................................................................................51.3 Detailed Body / Bonnet Styles ..............................................................................................................6

II RECEIVING & PREPARATION FOR INSTALLATION ..........................................................................72.1 Receiving Inspection ..............................................................................................................................72.2 Storage ....................................................................................................................................................72.3 Special Instructions ..............................................................................................................................72.4 Instructions for Check Valves ................................................................................................................7

III WARNINGS ............................................................................................................................8

IV GENERAL MAINTENANCE ..........................................................................................................94.1 Operation ................................................................................................................................................9

4.1.1 General ..........................................................................................................................................94.1.2 Smoothness of Operation ............................................................................................................94.1.3 Seat Tightness and Closing Torques ..........................................................................................9

4.2 Recommended Lubrication....................................................................................................................94.3 Packing Chamber Leakage ..................................................................................................................104.4 Disc Refinishing ....................................................................................................................................10

4.4.1 Angle for Disc Refinishing..........................................................................................................104.5 Seat Refinishing ....................................................................................................................................114.6 Seat-Disc Lapping ................................................................................................................................114.7 Tools ......................................................................................................................................................12

4.7.1 Other Tools..................................................................................................................................13

V Y-PATTERN BONNETLESS GLOBE VALVE ..................................................................................145.1 Z Type Y-Pattern Bonnetless Globe Valve ..........................................................................................145.2 Y Type Y-Pattern Bonnetless Globe Valve ........................................................................................155.3 Disassembly of Z Type ........................................................................................................................165.4 Reassembly of Z Type ..........................................................................................................................175.5 Disassembly of Y Type ........................................................................................................................185.6 Reassembly of Y Type ..........................................................................................................................19

VI GENERAL MAINTENANCE (BOLTED AND WELDED BONNET, GLOBE VALVES) ................................206.1 Operation ..............................................................................................................................................20

6.1.1 General ........................................................................................................................................206.1.2 Smoothness of Operation ..........................................................................................................206.1.3 Seat Tightness and Closing Torques ........................................................................................20

6.2 Recommended Lubrication..................................................................................................................20

VII Y-PATTERN 45º INCLINED BOLTED BONNET GLOBE VALVES........................................................217.1 Disassembly ..........................................................................................................................................217.2 Seat Leakage ........................................................................................................................................21

7.2.1 General ........................................................................................................................................217.2.2 Seat Repairs: Globe Valves ........................................................................................................217.2.3 Fitting or Repaired Parts: Globe Valves ....................................................................................217.2.4 Disc Repair ..................................................................................................................................22

7.3 Reassembly of Globe Vales ................................................................................................................227.3.1 General ........................................................................................................................................227.3.2 Torque Procedure ......................................................................................................................227.3.3 Application of Torque ................................................................................................................237.3.4 Replacement of Spiral Wound Gasket ......................................................................................237.3.5 Packing Torques..........................................................................................................................237.3.6 Packing Consolidation Method..................................................................................................23

22

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TABLE OF CONTENTS

GENERAL INFORMATION PAGE

VIII Y-PATTERN 45º INCLINED WELDED BONNET GLOBE VALVES..................................................................................24

8.1 Disassembly ..........................................................................................................................................248.2 Reassembly ..........................................................................................................................................24

IX Y-PATTERN INCLINED WELDED COVER PISTON CHECK VALVES ..............................................................................25

9.1 Disassembly Cover Removal ..............................................................................................................259.2 Seat Repairs ..........................................................................................................................................259.3 Disc Repairs ..........................................................................................................................................259.4 Fitting of Repaired Parts, Piston Check Valves ..................................................................................259.5 Reassembly ..........................................................................................................................................26

TERMS AND CONDITIONS OF SALE ....................................................................................................................27

FIGURES NUMBER PAGE

Automatic reseater machine for grinding/lapping globe seats ............................................7.2A 22Bolt tighting sequence ............................................................................................................7.3B 23Detailed body/bonnet styles ......................................................................................................1.3 6Flat bar for 1, 11/2 & 2” Y-pattern valves stem disassembly ................................................4.7H 13Guide bushing set (split guide bushing & retaining ring) ....................................................4.7G 13Inclined Check Valves, Angle of Incline and roll angle ............................................................2.4 8Packing Installed ......................................................................................................................7.3A 24Seat refinishing tool with interchangeable heads ................................................................4.7A 13Standard globe disc and flow control needle disc ................................................................4.4B 10Stem holder ..............................................................................................................................4.7D 13Stem lifting bushing ................................................................................................................4.7B 13Stem removal tool for 1/4 - 3/4” valves ....................................................................................4.7C 13Stop check disc ........................................................................................................................4.4A 10Torque wrench adapter ............................................................................................................4.7E 13Tube wrench / packing remover ..............................................................................................4.7F 13Using the seat refinishing tool ..................................................................................................4.5 11Using a socket wrench for seat-disc lapping ............................................................................4.6 12Wrench for removal of yoke bushing Y type ..........................................................................4.7I 13Y-pattern Inclined Welded Cover Piston Check Valve ..........................................................9.1A 25Y type Y-pattern bonnetless globe valve ..................................................................................5.2 15Z type Y-pattern bonnetless globe valve ..................................................................................5.1 14

TABLES NUMBER PAGE

Disc refinishing removal allowances ........................................................................................4.4 11Packing flange nut torques for bolted and welded bonnet

gate or globe valves (graphite ribbon or PTFE packing) ................................................6.1.2 20Recommended gland nut torques for graphite packing “Y-pattern” ..................................4.1.2 9Recommended lubrication ........................................................................................................4.2 9Recommended lubrication ........................................................................................................6.2 20Recommended spline bushing or backseat retainer torques..................................................5.3 17Torque Values (100%) for body/bonnet bolting ......................................................................7.3 23Y-Pattern tool kits and tool part numbers TK976 & TK576

all sizes and all classes (2680, 4500) ..................................................................................4.7 12

3

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I INTRODUCTION

4

This maintenance manual has been prepared

to help you obtain many more years of

satisfactory service from your Y-pattern globe

and check valves. It will also help you restore your

valves to the best working condition with a minimum

of time and expense.

Velan valves are designed and manufactured based

on many years of research and are constantly being

improved. Before beginning any major work, we

recommend that you carefully read this booklet at

least once to understand the valve's physical

construction. If you do not understand the reason

for the service problem, we suggest that you get in

touch with your local Velan representative, or call

the Velan Field Engineering Service Department at the

Head Office for technical assistance.

Velan Y-Pattern Bonnetless Globe Valves are

one-piece forged steel valves designed for high

pressure-temperature service. The valves have

guided Stellite 6 discs. Stellite, a cobalt, chromium

and tungsten alloy, has an average Brinell hardness

of 400, and is generally accepted by the valve industry

as an ideal hardfacing material. However, the seat

and disc are not absolutely safe from damage. If, for

example, a particle of hard foreign matter becomes

trapped between the seat and the disc and is then

pressed into the seat in service, damage could occur.

1.1 GENERAL INTRODUCTION

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INTRODUCTION I

5

1.2 ESSENTIAL FEATURES OF VELAN VALVES

Y-Pattern Globe Valves

Type of Size of Body/Bonnet Body Trim Connection Connection Class Type Style Material Material

A B C D E F G

— —

W 0 5 — 8 0 7 6 Z — 0 2 T Se.g. is a 1” socket weld A 105 bonnetless stop globe valve Z type 1690 class with TS trim as described

TYPE OF CONNECTION

A – Special B – Butt weld F – Flanged S – Threaded W – Socket weld

*SIZE OF CONNECTION

Customers have the choice of specifying valve size as part of the valve figure number (“B”) using the numbers below,or indicating valve size separately.

EXAMPLES: F08-2074B-13MS (valve size is part of figure number)2" F-2074B-13MS (valve size is shown separately)

01 – 1⁄4" (8 mm) 02 – 3⁄8" (10 mm) 03 – 1⁄2" (15 mm) 04 – 3⁄4" (20 mm) 05 – 1" (25 mm) 06 – 11⁄4" (32 mm)07 – 11⁄2" (40 mm) 08 – 2" (50 mm) 09 – 21⁄2" (65 mm) 10 – 3" (75 mm) 11 – 31⁄2" (90 mm) 12 – 4" (100 mm)

CLASS

2– 600 3– 1500 4– 2500 5– 4500 7– 900 8– 1690 9– 2680

TYPE

03 – Piston check 07 – Stop globe 08 – Stop check 09 – Needle

BODY/BONNET STYLE

6S – Y Pattern Bellows Sealed 6W – Y Pattern Welded 6Y – Y Pattern Bonnetless 6Z – Y Pattern (Non-Rotating Stem)(Non-Rotating Stem) Bonnet/Cover (Rotating Stem) 7Z – Y Pattern 45º (Two-Piece

Non-Rotating Stem)

BODY MATERIAL

01 – Special 02 – A105 05 – Chrome moly, F1106 – Chrome moly, F22 13 – Stainless steel, F316 34 – F91

TRIM MATERIAL

CODE DISC SEATING SURFACE SEAT SURFACE STEM

AA Special Special Special

TS Stellite 6 Stellite 6 410 CL2

MS Stellite 6 Stellite 6 SS 316B

A

B

C

D

E

F

G

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I INTRODUCTION

6

6SY-Pattern Bellows Sealed

(Non-Rotaing Stem)

6BY-Pattern 45° Inclined Bolted Bonnet

1.3 DETAILED BODY / BONNET STYLES

Velan’s range of Y-pattern valves include the following designs.

6WY-Pattern 45° Inclined Welded Bonnet

6WY-Pattern Inclined Piston Check

6ZY-Pattern (Non-Rotaing Stem)

6YY-Pattern Bonnetless (Rotating Stem)

65º 65º 65º

For bellows sealed Y-pattern valves,refer to Velan Bellow Seal Manual

VEL-BSVM-2003

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2.1 RECEIVING INSPECTION

Valves must be examined to establish that nodamage occurred during transportation. If anydamage is found, make sure that it does notimpair the operation of the valve. Seriousdamage should be reported to your local Velanrepresentative or to the Velan Service Departmentat the Head Office so that arrangement for repairscan be made.

2.2 STORAGE

Valves can be stored at any temperature in asheltered area but must be protected fromcontamination by dirt or the elements. The valve is shipped with end protectors on the inlet andoutlet which should stay in place until the valve is ready to be installed. Before installation,remove the end protectors and check theconnections for cleanliness. Visible foreign matter must be removed from end connections of weld-end valves. The weld ends must becleaned with a suitable solvent, such as acetoneor alcohol. Do not use solvents containingfluoride or chloride.

2.3 SPECIAL INSTRUCTIONS

Globe valves are usually installed with the inletbelow the valve seat. For particularly severethrottling service, we recommend that the valve be installed so that the flow enters through the top of the seat and goes down through it. This maintains the valve in a more stable position,minimizes wear and reduces the potential noise level. Valve operation is also easier because lesstorque is required to close the valve. However, itis to be noted that packing rings would besubjected to line pressure in this automation.

Globe valves should be installed and welded into the pipeline with the disc in the fully closedposition to prevent damage to the valve duringinstallation. Also, leaving the disc in the fullyclosed position helps prevent weld spatter fromfalling directly onto the mating faces of the seatand disc.

All Velan Y-Pattern Valves are tested in the factoryfor zero leakage on seat to the requirements ofASME B16.34. If any leakage occurs, it is becausethe seat has been deformed during welding on

line, foreign contaminants have been lodged in theseat interface or the motor has been set in the fieldto overthrust and has damaged the disc/seat, or ifset to under thrust, the valve would not close100% resulting in disc/seat stellite surface to bewire drawn (steam cuts). As a general rule, globevalves should be closed firmly, when welding in-line and closed lightly, when heat treatment iscarried out. The preferred orientation of a globevalve is upright. The valve may be installed inother orientations, but any deviation from verticalis a compromise. Installation upside down is notrecommended because of possible dirt build-up inthe bonnet and backseat.

NOTE: On insulation, the yoke must not beinsulated as temperature build-up in this areamight cause possible damage to the upper works(e.g. motor actuator, gear actuator, etc.), it alsoblocks access to packing bolts inspection andretorquing.

WARNING: During installation, welding andconstruction stage, the valve mid-section aroundthe packing flange and stem should be protectedat all times, as foreign debris from welding,grinding, etc., can fall in between the tapered areaof the packing flange and stem, causing extensivedamage to stem and associated parts during valvecycling. In any case, prior to cycling, the areabetween the stem, packing flange and glandbushing must be thoroughly cleaned off of allforeign matter.

2.4 INSTRUCTION FOR CHECK VALVES

All Velan inclined piston check and stop-checkvalves, when installed in vertical or near verticalline, should have fluid flow upward and the angleof incline of the line not more than 5º past thevertical in the direction of the bonnet. Wheninstalled in horizontal or near horizontal line, thevalve bonnet should be up and the angle ofincline of the line should not be more than 5ºbelow the horizontal. See Figure 2.4 for incline androll angle allowable. Consult your Velanrepresentative concerning installation other thanthat mentioned above.

All check valves must be installed with the inlet indirection of arrow. Placing a check valve in theopposite dierction to flow will prevent normaloperation of the valve.

RECEIVING AND PREPARATION FOR INSTALLATION II

7

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III WARNINGS

FOR SAFETY REASONS, IT IS IMPORTANT TO TAKE THESE PRECAUTIONS.

☛ Personnel making any adjustments on thevalves should wear safety equipmentnormally used to work with fluid in the linewhere the valve is installed.

☛ Before removing the yoke nut under pressure,the valve should be in fully open position inorder to prevent injuries (backseat position).

☛ Before removing a valve from a line, linepressure must be relieved with no exception.

☛ Velan valves can be equipped with a varietyof manual gear, electric motor, hydraulic or pneumatic actuators. Generally,all pressure must be relieved from both sidesof the valve before the actuator is removed.

☛ A valve in the fully open position(backseated), should not be jammed-tight(over-torqued), to avoid thermal binding.

It is our recommendation that the valve beremoved 1/4 turn of the handwheel from thefully open position. This will also ensure thatpacking tightness is verifiable. In gear-operated valves, because of the backlash, itis difficult sometimes to ensure this position.

☛ Valve standards, such as API and MSS,caution users that successful completion of abackseat test should not be construed as arecommendation by the manufacturer that avalve may be repacked while it is underpressure. The backseat may be used as ameans of stopping or reducing packingleakage until the packing can be replacedunder no pressure. Removal of packing withthe valve under pressure is at the owner’s risk.

☛ Velan is not responsible for automationcarried out in the field and resultingconsequences.

8

20º20º

-5º TO 95ºFROM

HORIZONTAL

VE

RT

ICA

L

VE

RT

ICA

L

20º20º

VE

RT

ICA

L

HORIZONTAL

Figure 2.4 Inclined check valve: Angle of incline and roll angle.

NOTE: All check valves should be installed at least ten pipe diameters away from upstream pumps, elbows,fittings or equipment. If closer installation is required, please consult the Velan Customer Service Manager.

WARNINGS! WARNINGS!

3 WARNINGS

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4.1 OPERATION

4.1.1 General

All valves should be checked before being put into operation and inspected regularly duringoperation. Problems should receive promptattention. As a general rule, valves should besubjected to scheduled maintenance.

4.1.2 Smoothness of Operation

Stem threads, stem nuts and other workingcomponents outside the fluid area should belubricated frequently (at least once every sixmonths). Specific lubricants and frequency ofapplication are shown in Table 4.2. Valves shouldbe opened and closed at least once a month.

IMPORTANT: Excessive handwheel effort canindicate the following:

a) Improperly lubricated or damaged valvestem.

b) Valve packing compression too tight (seeTable 4.1.2 for torque values).

c) Faulty or damaged valve parts.

Table 4.2 Recommended lubrication

4.2 RECOMMENDED LUBRICATION

SIZE TORQUEin (mm) CLASS lbf • ft (N •m)1⁄4–3⁄4 (8–20) 2680 23 (31)1⁄4–1⁄2 (8–15) 4500 48 (65)

1 (25) 2680 42 (57)3⁄4 –1 (20–25) 4500 70 (95)

11⁄4–11⁄2 (32– 40) 2680 97 (132)

11⁄4 (32) 4500 83 (113)

2 – 4 (50 –100) 2680 135 (183)

11⁄2 – 2 (40 – 50) 4500 163 (221)

2 1⁄2 – 4 (65–100) 4500 227 (308)

Note: For other packing materials and/or valve sizes, contact the Velan Field EngineeringService Department at the Head Office.

Table 4.1.2 Recommended gland nut torques for graphite packing rings “Y-pattern”

PART LUBRICATION APPLICATION FREQUENCY

Stem threads Exxon: Ronex MP, Castrol MP or Directly to threads When threads appear dryequivalent MP group (up to 650°F) Ronex Extra duty 2 (above 650°F)

Yoke nut Exxon: Ronex MP, Castrol MP or Inject through Concurrentlyequivalent MP group (up to 650°F) grease fitting with stemRonex Extra duty 2 (above 650°F) at hub of yoke thread lubrication

Spline bushing Sure Turn No. 1548016 Directly to threads At valve assembly

All threaded parts - Anti-seize compound No. 425-A (Crane) Thin coat on threads On valve assembly onlyexcept stem and or equivalentyoke nut - Nickel Anti-Seize to MIL-A-90TE or MOLYKOTE P37

Recommended lubricant subject to change without notice. For nuclear valves contact Velan Field Engineering Service Department.

4.1.3 Seat Tightness and Closing Torques

Even a new valve with seating faces lapped toperfection and a full seat-disc contact will bepressure-tight only if sufficient stem load isapplied. The minimum stem load for each size ofvalve varies with operating pressure, but shouldbe known by the operating personnel in order toseat the valve properly. Over-torquing up to 25%will not damage the valve.

9

GENERAL MAINTENANCE IV

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Figure 4.4A Stop check disc

271⁄2°

121⁄2°

4.3 PACKING CHAMBER LEAKAGE

If the valve is leaking around the stem and/oraround the outside diameter of the split glandbushing in the back seated position, the valveneeds to be disassembled and the stem and/orstellite backseat must be refinished or replaced.

If the valve is leaking around the stem and/oraround the outside diameter of the split glandbushing in the partially open position, tighten thegland bolting. If this does not stop the leakage,proceed with Steps 1 through 5, as follows:

STEP 1

Release line pressure and remove handwheelassembly, packing flange. See DisassemblyProcedure on pages 16 and 18 according to valvetype.

STEP 2

Examine valve stem and packing chamber bore for grooves and scratches. Clean and smoothsurfaces. Polish stems that may have scratches upto 0.005” (0.13 mm) deep with extrafine emerycloth. Otherwise replace stem.

STEP 3

Reinstall stem/disc assembly. Follow ReassemblyProcedures on pages 17 and 19 according to valvetype to complete repacking and to completereassembly.

NOTE: Velan recommends use of precompressed packing rings.

4.4 DISC REFINISHING

Minor damage can be repaired by machining the disc.

Clean the surface, then chuck the stem-discassembly in a lathe and center the disc on thecircular guides. See the diagrams at right for discrefinishing angles. Do not remove more than theamounts shown in Table 4.4.

The disc is now ready for final lapping with seat(see pages 11 and 12).

NOTE: If the disc is severely damaged, itshould be replaced.

4.4.1 Angle for Disc Refinishing

Figure 4.4B Standard globe disc and flow control needle disc

10

Figure 4.3

IV GENERAL MAINTENANCE

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11

Figure 4.5: Using the seat refinishing tool

VALVE SIZE ALLOWANCES PER SIDEin (mm) in (mm)

1⁄4–3⁄4 (8–20) 0.020 (0.5)

1– 4 (25 –100) 0.030 (0.75)

Table 4.4: Disc and seat refinishing removal allowances

4.5 SEAT REFINISHING1. Disassemble valve (see pages 16 and 18).

Select the proper head for the seat refinishingtool. Minor damage can be repaired with thelapping head, but use the cutting head first ifthere is severe damage. Remove the screw onthe end of the tool with a small Allen key,position the cutting or lapping head andtighten the screw.

NOTES:

a) If valve is not in an upright position, use theyoke bushing to hold the tool in place.

b) Total angle for seat (stop check disc)refinishing 60°.

c) Total angle for seat (standard globe andneedle disc) refinishing 30°.

2. Use an air motor for cutting and lapping if youhave one. Place the air motor adapter on theend of the tool. If you don't have an air motor,you can use a ratchet and socket wrench, butthe repair will take longer.

If you are using the cutting head

Insert the seat refinishing tool into the valvebore. Rotate the tool using either a socketwrench or an air or electric motor whileapplying light pressure on the tool. Shouldthe refinishing tool bind, reduce the pressureon the tool and try again. Remove the tool andinspect the seat area. Repeat if necessary.When all damage is removed use the lappinghead.

If you are using the lapping head

Lightly coat the lapping tool head withmedium coarse lapping compound. Insert theseat refinishing tool into the valve bore.Rotate the tool using either a socket wrench oran air or electric motor while applying lightpressure on the tool. Remove the tool andinspect the seat area. Repeat if necessary.When all visible damage is removed, clean offall coarse compound grit and finish lapping

the seat with fine lapping compound. Seatlapping can also be done using abrasive paperwith the lapping head, use course 60 grit toremove the damage and 220 grit for the finalfinish. Lapping with abrasive paper makes acleaner and faster finish.

3. Use a portable vacuum cleaner to removeloose chips. The valve is now ready for seat-disc lapping.

4.6 SEAT-DISC LAPPING

After seat refinishing or when a new orreconditioned disc is used, the disc and the seatshould be lapped together to create a perfectsealing contact. Seat-disc lapping can also beused to eliminate minor seat and/or disc damage.

Use an air or electric motor for lapping if you haveone. Place the air motor adapter on the end of thetool. If you don't have an air or electric motor, youcan use a ratchet and socket wrench, but the repairwill take longer.

1. The valve should be completely disassembledincluding the packing rings, backseat andspline bushing.

NOTE: For Y type valves only, slip an O-ringover the end of the stem and into the groovebetween the disc and the stem to prevent thedisc from rotating during lapping.

2. Apply a small amount of lapping compoundto the disc contact face. Insert the stem in the body.

GENERAL MAINTENANCE IV

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12

Cl. 2680 Cl. 4500 Cl. 2680 Cl. 4500 Cl. 4500 Cl. 2680 Cl. 4500 Cl. 2680 Cl. 4500DESCRIPTION QTY 1⁄4 – 3⁄4" 1⁄4 –1⁄2" 1" 3⁄4 –1" 11⁄4 " 11⁄4 –11⁄2" 11⁄2 – 2" 2– 4" 21⁄2 – 4"

8–20 mm 8–15 mm 25 mm 20– 25 mm 32 mm 32– 40 mm 40– 50 mm 50–100 mm 65–100 mmTK976-0.75 TK576-0.50 TK976-1.00 TK576-1.00 TK576-1.25 TK976-1.50 TK576-2.00 TK976-4.00 TK576-4.00

Seat refinishing tool (Fig. 4.7A) 1 1682-928 1682-887 1682-929 1682-949 1682-883 1682-930 1682-951 1682-878Lapping head (Fig. 4.7A) 1 1682-907 1682-890 1682-908 1682-907 1682-922 1682-891Cutting head (Fig. 4.7A) 1 1682-937 — 1682-938 1682-937 1682-939 1682-892Stem lift bushing (Fig. 4.7B) — 1682-995 1682-993 1682-992Stem removal tool (Fig. 4.7C) 1 1963-007 — — —Stem holder (Fig. 4.7D) 1 1682-840 1682-839 1682-838 1682-837Torque wrench adapter 1 1682-814 1682-812 1682-810 1682-808(Fig. 4.7E)Tube wrench/packing remover 1 1682-816 1682-817 1682-818 1682-819(Fig. 4.7F)Guide bushing set (Fig. 4.7G) 1 1682-813 1682-811 1682-809 1682-807Wrench for stem (Fig. 4.7H) 1 — 1682-087 1682-087 1682-087Crescent wrench for yokebushing “Z” style (Fig. 4.7I) 1 1682-876 1682-875 1682-874 1682-873

Crescent wrench for yokebushing “Y” style (Fig. 4.7I) 1 1682-084 1682-085 1682-086 1682-802

Bar (Fig. 4.7F) 1 1682-709 1682-710 1682-711 1682-712Packing washer hook 2 1682-850 1682-850 1682-850 1682-850(Not shown)O-ring (Not shown) 5 RXXX-309 RXXX-313 RXXX-317 RXXX-320

Adapter (air motor/ratchet) 1 1682-849 1682-848 1682-846 1682-845(Not shown)

Table 4.7 Y-Pattern tool kits and tool part numbers TK976 and TK576 all sizes and all classes (2680, 4500)

3. Insert one or two packing rings to center thestem for the lapping operation. Use the stem,without the backseat or other parts on it. Slipthe packing rings over the stem and down intothe body.

4. Rotate the stem with an air or electric motor orsocket wrench, applying light pressure to thestem. Remove stem and check periodically.When the seating faces are perfectly smooth,clean them with acetone or equivalent. Thevalve is now ready for reassembly.

4.7 TOOLS

Y-Pattern Bonnetless Globe Valve Tool Kits areavailable for all valve types and sizes. Tool kit numbers as well as item numbers forindividual tools are shown in Table 4.7.

Figure 4.6: Using of socket wrenchfor seat-disc lapping

IV GENERAL MAINTENANCE

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Hollow cap screw

Figure 4.7A Seat refinishing tool with interchangeable heads

Figure 4.7D

Stem holderFigure 4.7C

Stem removal tool for 1⁄4 - 3⁄4" valves

Figure 4.7G

Guide bushing set

Figure 4.7F

Tube wrench/packingremover with bar

Figure 4.7E

Torque wrench adapter

4.7.1 Other Tools

Other tools and materialsyou should have readybefore beginning repairson these valves:

• large screwdriver

• hammer or mallet

• torque wrench

• set of Allen keys

• acetone or equivalentwith socket wrenches

• coarse and fine lappingcompound

• lathe

13

GENERAL MAINTENANCE IV

Figure 4.7H Wrench for 1”, 11⁄2” & 2” Y-pattern valves stem disassembly.

Figure 4.7I Cresent wrench for removal ofyoke bushing “Y” & “Z” styles.

Cuttingend

Split Guide Bushing

Retainer Ring

Figure 4.7B Stem liftbushing (Y-pattern MOVvalves)

Cuttinghead

Lappinghead

Seatrefinishingtool

Bar

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14

QUICK & EASY DISASSEMBLY NO WELDS TO REMOVE

5.1 Z TYPE Y-PATTERN BONNETLESS GLOBE VALVE

HANDWHEEL

NAME PLATE

STEM NUT (YOKE NUT)TAB WASHER

YOKE BUSHING

THRUST BEARING

O-RING

PACKINGFLANGE

SPLIT GLANDBUSHING

PACKING RING

PACKING WASHER(JUNK RING)

SPLINE BUSHING(BACKSEAT RETAINER)

SNAP RING

KEY

O-RING

GREASEFITTING

STEM

GLAND STUD

HOLDER

DISC

SEAT

BODY

BACKSEAT

GLAND NUT

DUST COVER

GREASE RETAINER

SNAP RING

INDICATOR

NOTE: Live-loadingdiagram, see page 15.

V Y-PATTERN BONNETLESS GLOBE VALVES

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LIVE-LOADING AVAILABLE

15

HANDWHEEL

YOKE BUSHING

BACK SEAT

BACKSEAT RETAINER

PACKING WASHER(JUNK RING)

PACKING RING

SPLIT GLAND BUSHING

PACKING FLANGE

HANDWHEEL NUT

NAME PLATETACK WELD

BODY

SEAT

DISC

HOLDER

GLAND STUD

GLAND NUT

STEM

DISC SPRING“BELLEVILLE

WASHERS”

GUIDE BUSHING

PACKING FLANGE

Y-PATTERN BONNETLESS GLOBE VALVES V

5.2 Y TYPE Y-PATTERN BONNETLESS GLOBE VALVE

LOOK WASHER

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16

5.3 DISASSEMBLY — Z TYPE IMPORTANT: Release line pressure.

1. Remove packing gland nuts and studs,loosening both sides equally. If valve is fittedwith live-loading, remove guide bushing andspring washers (Belleville washers). Raisepacking flange and remove split gland bushing.

2. With the tip of a screwdriver,bend the square end of thetab washer up and the curved end down to free the yoke bushing.

EMERGENCY PROCEDURE:

If the stem absolutely refuses to unscrew usingthe torques specified, proceed as follows:

1. Place tube wrench/packing remover withthe cutting edge first over stem and intothe packing chamber.

2. Place guide bushing set into top of valve(slip split guide bushing onto tubewrench/packing remover, screw on retainerring and hand tight).

3. Use the cutting end of the tubewrench/packing remover to removepacking.

4. Remove guide bushing set, pull up the tooland remove packing rings.

5. Use the packing washerhooks to fish outthe packing washer under the packing.

6. Insert the crowned end of the tubewrench/packing remover in valve body. Use a metal bar through the top holes of the tube wrench/packing remover tounscrew the spline bushing counter-clockwise.

NOTE: Velan recommends the use of tool kits listed on pages 12 and 13 for thebest maintenance results.

3. Make sure the valve is almost closed, but nottight on the seat. Use a crescent wrench tounscrew the yoke bushing counterclockwise(with the handwheel still attached). Should theyoke bushing bind, close the valve a little.Continue to unscrew the yoke bushingcounterclockwise.

4. Remove stem nut by turning clockwise thanremove the handwheel.

5. Grip grease retainer and push it up to force thethrust bearings and stem protector up and outof the body.

6. For 1 - 4" valves:

While the stem is in full open nearbackseated position, insert thesquare of the flat bar wrench to thesquare end of the stem. Turncounterclockwise until the splinebushing begins to move. NOTE:

If turning reasonably freekeep on unscrewingcounterclockwise. Ifdifficult to move,turn a few moretimes back and forthand unscrewsomemore,do this until itis free to turn.Once fully

Figure 5.3A

unscrewed liftthe entire stemassembly withpacking and discout of the valve body.If difficult to lift out use the stemlifting bushing, turn counter-clockwise until it is completelylifted and free to pull out. (ifunable to unscrew the stem,see Emergency Procedure).

For 1⁄4 - 3⁄4" valves:

Screw stem removal tool on the end of the stem until it bottoms, thenback off two turns. Use an adjustablewrench to tighten the hollow cap screw against thestem. Continue the same procedure as for 1 - 4” valves.

WARNING: Do not apply the full force of awrench, on stem square.

Figure 5.3B

Figure 5.3C

V Y-PATTERN BONNETLESS GLOBE VALVES

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17

continue to tighten until torque value shownin Table 5.3 is obtained.

NOTE: Velan recommends the use of the tool kits listed on pages 12 and 13 for the bestmaintenance results.

5. Insert packing washer, chamfered edge down.Then insert the set of precompressed packingrings one at a time, beginning and endingwith the braided rings.

NOTE: Velan recommends the use ofprecompressed packing rings.

6. Slip split gland bushing under packing flange, one half at a time, chamfered edge up.Lubricate gland studs with anti-seizecompound, pass them through packing flange and thread on the gland nuts, tightening bothsides equally (hand-tight). For live-loaded valves, reinstall the disc springs and guide bushings onto the studs tightening both sides equally (hand-tight).

NOTE:

The gland bushing should engage into the packing chamber by 1⁄8” (3 mm) min.

7. Place grease retainer inside yoke and pushdown over stem with the crowned end of thetube wrench/packing remover. Drop in oneset of thrust bearings (washer - bearing -washer).

If Handwheel, Stem Nut and Yoke Bushing

are Disassembled:

Install upper thrust bearing (washer - bearing -washer) on stem nut. Lightly press yoke bushing over bearing (threaded side downtowards bearing). Install key and handwheel with nameplate. Secure with snap ring tohold handwheel in stem nut.

4. Insert the tube wrench/packing remover intothe body over the stem, crowned end down.Insert a metal bar through the holes in thetube wrench/packing remover and start totighten the spline bushing. Then place torquewrench adaptor into the tube wrench/packingremover. Align holes to insert a round barthrough both parts. Use a torque wrench and

Y-PATTERN BONNETLESS GLOBE VALVES V

Figure 5.4B

5.4 REASSEMBLY — Z TYPE 1. Slip backseat onto stem, chamfered edge

down. Then slide spline bushing onto stem,crowned edge up.

2. Lubricate spline bushing threads (see Table 4.2for Recommended Lubrication). Place packingflange under yoke, flat side up. Insert stemassembly through packing flange and intobody.

3. Thread in splinebushing a fewturns, then pull up firmly on stemwith one handwhile using anadjustable wrenchto continuetightening thespline bushingclockwise againstthe backseat. If the splinebushing doesnot engage easily, insert crowned end of thetube wrench/packing remover to engage splinebushing threads into the body.

Table 5.3: Recommended spline bushing or backseat retainer torques

SIZECLASS

TORQUESin (mm) lb • ft (N • m)

1⁄4–3⁄4 (8–20) 268060 (80)

1⁄4–1⁄2 (8–15) 4500

1 (25) 2680120 (160)

3⁄4–11⁄4 (20–32) 4500

11⁄4–11⁄2 (32–40) 2680150 (200)

11⁄2– 2 (40–50) 4500

2 – 4 (50– 100) 2680180 (245)

21⁄2– 4 (65–100) 4500

Figure 5.4A

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18

If Handwheel, Stem Nut and Yoke Bushing are

Assembled:

Set tab washer in place on yoke. Lubricateyoke and stem threads (refer to Table 4.2).Screw counterclockwise the handwheelassembly onto stem about half-way. Thenbegin tightening yoke bushing clockwise intotop of valve. Should the yoke bushing bind,it’s because the stem has pushed the discagainst the seat. Correct this by backing off thehandwheel slightly and continue tightening byhand. Finish tightening with a large crescentwrench, holding tab washer in position againstflat spot on yoke. Press square tab down withtip of screwdriver. On the opposite side, pressrounded edge up against yoke bushing.

8. Continue tightening packing nuts or guidebushing for live-loaded valves with a crescentwrench. Install the crescent key on the torquewrench and finish tightening the nuts to thetorques shown in Table 4.1.2.

5.5 DISASSEMBLY — Y TYPE IMPORTANT: Release line pressure.

1. Remove handwheel nut and handwheel.

2. Remove packing gland nuts and studs,loosening both sides equally. If valve is fittedwith live-loading, remove guide bushing andspring washers (Belleville washers). Raisepacking flange and remove split gland bushing.

3. Grind off tack weld between yoke bushingand yoke.

4. Make sure the valve is almost closed, but nottight on the seat. Use a crescent wrench tounscrew the yoke bushing counterclockwise.Should the yoke bushing bind, put handwheelon stem and close the valve a little. Continueto unscrew the yoke bushing counter-clockwise. Remove handwheel and yokebushing.

5. Place tube wrench/packing remover with thecutting edge first over stem and into thepacking chamber. Place guide bushing set intotop of valve (put in split guide bushing, screwin retainer ring and hand tight). Insert a metalbar through the holes in the tubewrench/packing remover, turn in a clockwisedirection while pushing bar down. This willpick up the packing rings within the spiralflutes of the tube wrench/packing remover.Pull up the tool and remove packing ringswithin the spiral flutes. Re-insert tool toremove any remaining packing rings. Aftercomplete removal of packing, remove guidebushing set, and tube wrench/packingremover. Using two packing washer hooks,insert them into the packing washer holes andpull it up over the stem.

6. Insert the crowned end of the tubewrench/packing remover in valve body. Use ametal bar through the top holes of the tubewrench/packing remover to unscrew thebackseat retainer counterclockwise. Removestem/disc assembly. The valve is now readyfor servicing.

V Y-PATTERN BONNETLESS GLOBE VALVES

Figure 5.4C

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5.6 REASSEMBLY — Y TYPE 1. Slip backseat onto stem, chamfered edge

down. Lubricate backseat retainer threads (see Table 4.2). Then slide backseat retaineronto stem, crowned edge up.

2. Place packing flange under yoke, flat side up.Insert stem assembly through packing flangeand into body.

3. Thread in backseat retainer, use the crownedend of the tube wrench/packing remover totighten the backseat retainer clockwise againstthe backseat.

4. Then place torque wrench adaptor into thetube wrench/packing remover. Align holes toinsert a round bar through both parts. Use atorque wrench and continue to tighten untiltorque value shown in Table 5.3 is obtained.

NOTE: Velan recommends the use of the toolkits listed on pages 12 and 13 for the bestmaintenance results.

5. Insert packing washer, chamfered edge down.Then insert the set of precompressed packingrings one at a time, beginning and ending withthe braided rings. Use the crowned end of thetube wrench/packing remover to tap the ringsinto place.

NOTE: If uncompressed packing is usedfollow Packing Consolidation Method (refer toSection 7.3, paragraph 7.3.6).

19

Y-PATTERN BONNETLESS GLOBE VALVES V

6. Slip split gland bushing under packing flange,one half at a time, chamfered edge up.Lubricate gland studs with anti-seizecompound, pass them through packing flangeand thread on the gland nuts, tightening bothsides equally (hand-tight). For live-loadedvalves reinstall the disc springs and guidebushings onto the studs tightening both sidesequally (hand-tight).

NOTE: The gland bushing should engage intothe body by 1⁄8” (3 mm) min.

7. Screw on yoke bushing clockwise, using alarge crescent wrench. Should the yokebushing bind, it’s because the stem hasbottomed on the seat. Correct this by backingoff the handwheel slightly. Secure yokebushing to yoke with tack weld.

8. Continue tightening packing nuts or guidebushing for live-loaded valves with a crescentwrench. Install the crescent key on the torquewrench and finish tightening the nuts to thetorques shown in Table 4.1.2.

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6.1 OPERATION

6.1.1 General

All valves should be checked before being put intooperation and should be inspected regularly duringoperation. Prompt attention should be paid whentrouble arises. As a general rule, valves should besubjected to scheduled maintenance.

6.1.2 Smoothness of Operation

Stem threads, stem nuts and other workingcomponents outside the fluid area should belubricated frequently (at least once every sixmonths). Specific lubricants and frequency ofapplication are shown in Table 6.2.

IMPORTANT: Excessive handwheel effort canindicate the following:1. Improperly lubricated or damaged valve stem.2. Valve packing compression too tight

(see Table 6.1.2 for torques).3. Faulty or damaged valve parts.

6.1.3 Seat Tightness and Closing Torques

Even a new valve with seating faces lapped toperfection and a full seat-wedge or disc contact will be pressure-tight only if sufficient stem load is applied. The minimum stem load for each size of valve varies with operating pressure in order toseat the valve properly. Slight over-torquing will not damage the valve.

CAUTION: Do not use “cheaters” on the handwheel.

VI GENERAL MAINTENANCE

GATE VALVES GLOBE VALVESSIZE CLASS STUD SIZE TORQUE TORQUE

in (mm) lb•in (Nm) lb•in (Nm)1/4 – 1/2 (8–15) 150–800 1/4 –20UNC 24 (2.7) 24 (2.7)1/4 – 3/4 (8–20) 900–1690 3/8 –16UNC 45 (5.1) 90 (10.2)3/4 –1 (20-25) 150–800 5/16 –18UNC 40 (4.5) 50 (5.6)1 (25) 900–1690 7/16 –14UNC 100 (11.3) 130 (14.7)11/4 –11/2 (32–40) 150–800 3/8 –16UNC 85 (9.6) 85 (9.6)11/4–2 (32–50) 900–1690 7/16 –14UNC 145 (16.4) 130 (14.7)2 (50) 150–800 3/8 –16UNC 85 (9.6) 90 (10.2)

Note: For other sizes and packing materials, contact the manufacturer.

Table 6.1.2 Packing flange nut torques for bolted and welded bonnet gate or globe valves (graphite ribbon or PTFE packing)

Table 6.2 Recommended lubrication

6.2 RECOMMENDED LUBRICATION

Recommended lubricant subject to change without notice.

20

PART LUBRICATION APPLICATION FREQUENCY

Stem threads Exxon: Ronex MP, Castrol MP or Directly to threads When threads appear dryequivalent MP group (up to 650°F) Ronex Extra duty 2 (above 650°F)

Yoke nut Exxon: Ronex MP, Castrol MP or Inject through Concurrentlyequivalent MP group (up to 650°F) grease fitting with stemRonex Extra duty 2 (above 650°F) at hub of yoke thread lubrication

Spline bushing Sure Turn No. 1548016 Directly to threads At valve assembly

All threaded parts - Anti-seize compound No. 425-A (Crane) Thin coat on threads On valve assembly onlyexcept stem and or equivalentyoke nut - Nickel Anti-Seize to MIL-A-90TE or MOLYKOTE P37

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Y-PATTERN 45° INCLINED

BOLTED BONNET GLOBE VALVES VII

7.1 DISASSEMBLY1. Ensure the line has been depressurized. Place

match mark on the bonnet and body.

2. Open the valve partially and remove thehandwheel nut and the handwheel.

3. Remove the body-bonnet gasket bolts and liftout the complete bonnet assembly. At thispoint remove the yoke bushing tack welds andunscrew the yoke bushing counterclockwise.

4. Remove the gland bolts and pull out the stemout of the bonnet and remove the packing outof the packing chamber.

The valve is now ready for parts replacementand or repair.

7.2 SEAT LEAKAGE

7.2.1 General

An indication that valve leakage exists after a valvehas been properly closed may be found byobserving the pressure loss in the line on the highpressure side of the valve. In the case of hot wateror steam lines, note whether the downstream piperemains hot beyond the usual length of time. Thistype of leak may be the result of a distorted seat,caused by improper welding of the valve into thepipeline, or by stress-relieving temperature that mayhave been used during installation.

Leaks can also be caused by failure to close the valvetightly, resulting in high-velocity flow through a smallopening. In spite of the fact that the hardfacingmaterial (Stellite) is corrosion- and erosion-resistant,grooves, pit marks or other surface irregularities maystill form on the mating faces. Valves which leakshould be repaired as soon as possible to preventgreater damage caused by high-velocity flow.

7.2.2 Seat Repairs: Globe Valves1. Disassemble the valve as described in

Disassembly of Globe Valves, Section 7.1,and inspect the disc and seat for scratches, pitting marks or other damage.

2. If there are deep pitting marks, use a cast ironlapping disc with seat angle of 15º and asuitable lapping compound to roughen thesurface first. With the use of a new, or alreadyrefinished original disc, you can use a finerlapping compound to finish lapping the discand seat together.

3. a) Use a guiding plate for the stem to maintainalignment during the lapping operation. Itcan be made from wood or any othersuitable material, to the dimensions of thegasket and the bonnet spigot. The sectionof the plate where the stem extendsthrough must be 1⁄64“ (0.4 mm) larger thanthe outside diameter of the stem.

b) If the valve has a soft-seated disc, all bodylapping must be done with a lapping discand not with a soft-seated disc

4. Evenly distribute a small quantity of lappingcompound mixed with olive oil on the twomating surfaces.

5. It is important to apply only light, even pressurewhen lapping seats and to rotate reciprocally.For best results, use an air or electric hand toolwith adjustable speed and reciprocal movement.The lapping tool should be lifted frequently andturned to a new starting position.

6. Automatic grinding and lapping of seat facescan be done by specialized equipment which can save considerable time, refer to Figure 7.2A.For major damages the use of 60-80 grit diamond or Micron alumina abrasive discs issuggested. For minor damage use 120-180 gritand for finishing 220 grit and up can be used.For further details contact the Velan FieldEngineering Service Department.

7.2.3 Fitting of Repaired Parts: Globe Valves

1. After the seating faces of the disc and seathave been relapped and cleaned with asuitable cleaning fluid, such as acetone oralcohol, the results of the lapping must beverified by a blueing test to check for fullcircumferential contact. A blueing ink shouldbe distributed smoothly and equally over theseating diameter of the disc. Slowly lower thepart into the body and find the correct matingpoint of the faces.

2. When fitting the disc, it is important that theinside diameter of the body be checked forsufficient clearance to allow the disc to movefreely up and down. A visual examination ofthe body wall is recommended. Any groovesor scratches should be polished with a fineemery cloth. It is also important to verify thatthe disc cannot be forced sideways against theoutlet side of the waterway bore and becomejammed in that position.

21

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Y-PATTERN 45° INCLINED

VII BOLTED BONNET GLOBE VALVES

NOTE: A quick test is to take the stem-discassembly and check if the disc can be rocked.The rocking will allow the disc to self-align tothe seat.

Figure 7.2AAutomatic reseatermachine for grinding /lapping globe seats

7.2.4 Disc RepairA Disc seating damage no greater than 0.005”

(0.12 mm) can be removed by lapping withbody seat, use 60 grit lapping compound toremove damage, followed by fine lapping 220grit and up for finishing.

B Damages greater than 0.005” (0.12 mm) up to0.060” (1.5 mm) should be machined followedby fine lapping (refer to Section 4.4).

NOTE: Disc and stem remains as a unit shouldstem or disc replacement become necessary, itmust be replaced as a unit.

7.3 REASSEMBLY OF GLOBE VALVES

7.3.1 GeneralThe reassembly procedures are not as detailed asthe disassembly procedures since in most casesthe reverse procedure is required.

1. The most important consideration is thecleanliness of all parts. Rust and dirt should beremoved from all parts with a wire brush oremery cloth. Oil and grease should beremoved with suitable solvents.

2. Threaded parts (cap screws, nuts, studs) mustbe well relubricated. Old grease should beremoved from the stem and stem nut threadsbefore a new coat of grease is applied.Recommended lubricants can be found in Table 6.2.NOTE: Use correct lubricant for each individual part.

3. Repaired or replaced parts must be checked to make sure that repair procedures have beendone and that replaced parts (e.g., packingrings, spiral gasket, etc.) have been checked for size so that they will fit into the valve you are servicing.

4. All orientation marks assigned duringdisassembly must be observed so that correctassembly is maintained.

7.3.2 Torque Procedure1. Clean all studs and nuts and inspect all threads

to ensure removal of all foreign matter, rust,corrosion, burrs and previous lubricant.

2. Liberally cover the cap screw (stud) threads andsurface under the nut head with anti-seizecompound FEL-PRO C5-A or approvedequivalent. Also lubricate the female threads ofthe nuts. Wipe off, with approved solvent, anyexcess lubricant that may adhere to the steelparts. Approved solvents for this work areacetone, alcohol or Freon PCA.

NOTE: The use of other solvents is notrecommended.

3. With bolts hand-tight, follow the bolt-tighteningsequence shown in Figure7.3B. The sequencedepends upon the number of bolts employedand the sketch shows only one possibletightening sequence. The bolts must betorqued to the recommended values shown in Table 7.3.

22

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Y-PATTERN 45° INCLINED

BOLTED BONNET GLOBE VALVES VII

2

41

3

Figure 7.3B Bolt tightening sequence

BOLTING MATERIALBOLT SIZE

B7, 630 6605⁄16 – 18UNC 12 (16) 10 (14)3⁄8 – 16UNC 20 (27) 20 (27)7⁄16 – 14UNC 30 (41) 30 (41)1⁄2 – 13UNC 50 (68) 45 (61)9⁄16 – 12UNC 70 (95) 62 (84)5⁄8 – 11UNC 95 (129) 85 (115)3⁄4 – 10UNC 170 (231) 150 (203)7⁄8 – 9UNC 270 (366) 240 (325)

Note: 1) All values lb•ft (Nm). Torque tolerance ±10%.2) For other sizes and bolting materials,

please contact the manufacturer.

Table 7.3Torque values (100%) for body-bonnet bolting

7.3.3 Application of Torque

When applying the torque to the bolts, each boltshould be torqued in steps of approximately 20%of the final torque. As the final torque isapproached, the required step will be much lessthan 20%.

CAUTION:

1. If tightening sequence is not followed, it is possible that the spiral wound gasket willnot be compressed evenly, causing the body-bonnet joint to leak.

2. Over-torquing could deform the bonnetflange and cause joint leakage.

3. Do not use an impacting device to draw upthe bolting on body and bonnet (cover)closures.

7.3.4 Replacement of Spiral Wound Gasket1. The gasket seating faces (the recess in the body

and the bonnet face) must first be checked forsmoothness. Scratches can normally beremoved with an emery cloth. The faces shouldthen be solvent degreased and dried beforeassembly. Approved solvents are acetone,alcohol or Freon PCA.

2. Install new spiral wound gasket between thebody and bonnet joint. The body is now readyfor installation of the bonnet assembly andtightening of the bolting in accordance with thetorquing procedure.

7.3.5 Packing Torques1. Clean all gland studs (15) and gland nuts (16).

Visually inspect all threads to ensure removal of all foreign matter, rust, corrosion, burrs andprevious lubricant.

2. Liberally cover the stud threads and the femalethreads of the nuts with anti-seize compoundFEL-PRO C5-A or approved equivalent.

3. With gland nuts (16) hand-tight, tighten them a little at a time on each side, then torque down to the correct torque in accordance with the valvetype, size and pressure class, as shown inTable 6.1.2., and use Packing ConsolidationMethod.

4. Values given in Table 6.1.2 are approximate for standard Velan valves. Whenever possible,refer to the Project Engineering drawing for aparticular valve and its torque.

7.3.6 Packing Consolidation Method

1. Insert the first packing ring, braid graphite type(end ring) and place as deep into the packingchamber as possible, followed by graphiteribbon (intermediate packing rings)refer to Figure 7.3A.

NOTE: The split lap joints of each consecutivering should be staggered at approximately 120º apart.

2. Install the last braided graphite type packingring (end ring). Lower the gland bushing andcheck for positive engagement with packingchamber.

CAUTION: Valve must be partially open whentorquing bolts to prevent damage to seatingsurface.

23

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Y-PATTERN 45° INCLINED

VIII WELDED BONNET GLOBE VALVES

NOTE: The gland bushing should enter the packing chamber as a rule of thumb approx. 1⁄8” (3 mm) minimum engagement.

3. Place the packing flange into position. Ensuregland bolt/nuts are well lubricated with anti-seize compound. Compress the packing bytightening the nuts to the torque value shownin Table 6.1.2.

4. Cycle the valve for approximately the length ofthe packing chamber, first open then close andretighten to required final torque (Table 6.1.2).Do this procedure as many times as necessary(approximately 4-5 times) until all packingbecome fully consolidated (no more loss oftorque).

NOTE: For motor operated valves (MOV) usemanual override handwheel to cycle open andclose.

04

15

16

11

12

02

13A

13B

PARTS DESCRIPTION02 - Bonnet 13A - Packing ring (braided)04 - Stem 13B - Packing ring (die-formed)11 - Packing flange 15 - Stud12 - Gland bushing 16 - Nut

8.1 DISASSEMBLY1. Ensure the line has been depressurized.2. Open the valve partially and remove the gland

bolts and the handwheel.3. Using a hand grinder carefully cut by grinding

the body/bonnet seal weld along the body upto the bonnet.

4. To unscrew the bonnet, use a pipe wrench onone yoke arm, tension well counter clockwiseand tap firmly using a brass or plastichammer.NOTE: If the bonnet has not moved, it mayindicate the weld has not been removedcompletely or sufficiently that may requiresome more grinding to remove.

5. After the bonnet assembly has beenunscrewed, the stem together with disc can beremoved through the bottom of the bonnet byturning clockwise to disengage from the yokebushing and once disengaged it can be pulledout and the packing rings can then beremoved.NOTE: If the yoke bushing needs to bereplaced, it will be necessary to grind off thetack welds and turn counterclockwise tounscrew. The valve is now ready for partsreplacement and or repair.

NOTE: Seat and disc repairs and fitting of repair parts refer to Section 7.2.

8.2 REASSEMBLY1. In general the reassembly procedure in most

cases is the reverse procedure of disassembly,refer to Section 7.3.

2. Additionally, prepare the bonnet and body forseal weld by removing remnants of originalseal weld. Screw in the bonnet metal to metaland tighten firmly. The valve is now ready forseal welding.

3. Perform seal weld as follows: For 300 seriesstainless steel valves no preheat nor postweldheat treatment (PWT) is required. For CSvalves type F11 and F22. Preheat is requiredonly, preheat to 300 - 350ºF (148 - 176ºC). Forvalves P5 and up, preheat and postweld heattreatment is mandatory. NOTE: After seal weld has cooled off, performa dye penetrate test (PT), or magnetic particle(MT).

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Figure 7.3A Packing rings installed

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Y-PATTERN INCLINED WELDED COVER PISTON CHECK VALVES IX

9.1 DISASSEMBLY - COVER REMOVAL

NOTE: Y-Pattern Inclined Piston Check cover isscrewed in and seal welded. To allow coverremoval the seal weld must be grinded off ormachined.

1. Using a hand grinder with a flat cutting wheel,cut the seal weld along the body up to to thecover.

2. To unscrew the cover, use an adjustablewrench on the cover flats, tension well counterclockwise and at the same time tap firmly ontop of the cover using a brass or plastichammer.

NOTE: If the cover has not moved, it may indicatethe weld has not been removed completely orsufficiently, that may require some moregrinding/cutting to remove.

3. After the cover has been unscrewed, thespring and disc can then be removed forinspection and/or repair/replacement.

9.2 SEAT REPAIRS

Generally seat repairs are similar to bolted bonnetglobe except the seat angle of the piston check is30º angle, refer to Section 7.2 for removalallowances. Refer to Section 4.4 and Table 4.4.

For seat lapping using automatic reseater machine,refer to Section 7.2, step 6 and Figure 7.2A.

9.3 DISC REPAIRS

Piston check disc repairs are identical to globe discrepairs, except the disc seating angle is of 271/2º.Refer to Section 7.2.4 A and B and removalallowances in Section and Table 4.4.

9.4 FITTING OF REPAIRED PARTS: PISTON CHECK VALVES

1. After the seating faces of the disc and seat havebeen relapped and cleaned with a suitablecleaning fluid, such as acetone or alcohol, theresults of the lapping must be verified by ablueing test to check for full circumferentialcontact. A blueing ink should be distributedsmoothly and equally over the seating diameterof the disc. Slowly lower the part into the bodyand find the correct mating point of the faces,by tapping lightly on top of the disc.

2. When fitting the disc, it is important that theinside diameter of the body be checked forsufficient clearance to allow the disc to movefreely up and down. A visual examination of

9.1 FORGED STEEL PISTON CHECK VALVES FOR HORIZONTAL AND VERTICAL LINES

Figure 9.1A Y-pattern inclined welded cover piston check valve.

Y-PATTERN INCLINED WELDED COVER PISTON CHECK VALVES IX

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26

the body wall is recommended. Any groovesor scratches should be polished with a fineemery cloth. It is also important to verify thatthe disc cannot be forced sideways against theoutlet side of the waterway bore and becomejammed in that position.

9.5 REASSEMBLY1. In general the reassembly procedure in most

cases is the reverse procedure of disassembly,refer to Section 9.1.

2. Additionally, prepare the cover and body forseal weld by removing remnants of originalseal weld. Screw in the cover metal to metaland tighten firmly. The valve is now ready forseal welding.

3. Perform seal weld as follows: For 300 seriesstainless steel valves no preheat nor postweldheat treatment (PWT) is required. For CSvalves type F11 and F22. Preheat is requiredonly, preheat to 300 - 350ºF (148 - 176ºC). Forvalves P5 and up, preheat and postweld heattreatment is mandatory.

NOTE: After seal weld has cooled off, performa dye penetrate test (PT), or magnetic particle(MT).

IX Y-PATTERN INCLINED WELDED COVER PISTON CHECK VALVES

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TERMS AND CONDITIONS OF SALE

CONTRACT: Orders are subject to acceptance bythe Velan Companies hereinafter referred to as theseller. No terms or conditions of Purchaser's ordercontrary to the Seller's terms and condition shallbe binding upon the Seller unless specificallyagreed to by the Seller in writing.

MINIMUM ORDER CHARGE: $500.00 net.PRICES: All quoted prices are subject to change bythe seller without prior notice and, unlessotherwise stipulated by Seller, are understood tobe F.O.B. Seller's plant, with delivery to carrierconstituting delivery to purchaser. Right topossession of the material to secure the paymentof the purchase price shall remain in Seller until allpayments therefore shall have been fully made.For the protection of the Purchaser and the Seller,verbal customer orders must be confirmed by aformal written purchase order. If a writtenpurchase order is not received within ten days or averbal order, product descriptions, quantities,specifications, etc., as set forth in Seller'sacknowledgement and invoice shall be conclusiveand binding on both parties. Any order that isshipped before receipt of confirmation whichmight have been entered incorrectly and wouldrequire remedial action would be for thePurchaser's account.

TAXES: All prices are exclusive of taxes. Sales,use and other taxes, by whomsoever levied, are tobe paid by the Purchaser, and unless invoiced, areto be paid by the Purchaser directly to theappropriate governmental agency.

DELIVERY: Delivery or shipment specified isSeller's best estimate and Seller shall not be liablefor delay in deliveries resulting from any causewhatsoever. Failure to ship on or near theestimated date shall not entitle Purchaser to cancelhis order without charge.

RETURN OF MATERIALS: Materials may bereturned only with prior written agreement ofSeller.

CANCELLATION: Cancellation of orders may bemade only with the Seller's written consent andPurchaser shall be subject to cancellation charges.PRODUCT WARRANTY: Seller warrants theequipment of its own manufacture to be free ofdefects in material and workmanship, undernormal use and proper operation for a period ofone year from the date of shipment from Seller'splant. Seller's obligation under warranty shall bestrictly limited, at Seller's option, to: (i) furnishingreplacement parts for or repairing without chargeto Purchaser, F.O.B. Seller's plant or (ii) issuingwritten authorization for Purchaser or others toreplace or repair without charge to Purchaser, atcosts comparable to Seller's normal manufacturing

costs those parts proven defective, or (iii) indischarge of Seller's maximum liability herewith,refunding all monies paid by Purchaser to Sellerfor the Product and, at discretion of Seller, havingthe product removed and returned to Seller atPurchaser's expense. All transportation chargesrelative to corrective work, defective parts orreplacement parts shall be borne by Purchaser.Purchaser shall give Seller immediate notice upondiscovery of any defect. The undertaking of repairsor replacements by Purchaser or its agentswithout Seller's written consent shall relieve sellerof all responsibility herewith.

Finished materials and accessories purchased fromother manufacturers are warranted only to theextent of the manufacturer's warranty to Seller.

Any alteration in material or design of Seller'sproduct or component parts thereof by Purchaseror others without written authorization by Sellervoids all obligations of Seller regarding theproduct and any associated warranty herein statedor implied.

Seller's sole liability shall be exclusively as setforth herein, and Seller shall not be liable for anyincidental or consequential damages due to itsbreach of any warranty herein contained, orotherwise. Without limitation to the foregoing, inno event shall Seller be liable for the loss of use ofthe product or of any other product, process,plant, equipment, or facilities of the Purchaser orend-user whether partially or wholly due todefects in material and /or workmanship and /ordesign of Seller's product, and in no event shallSeller be liable for removal of appurtenances orincidentals such as connections, pipe work andsimilar items of obstruction or for any costbrought about by the necessity of removing theproduct from its point of installation.

Seller makes no warranty of any kind whatsoever,expressed or implied, other then is specificallystated herein; and there are no warranties ofmerchantability and/or fitness for a particularpurpose which exceed the obligations andwarranties specifically stated herein.

Parts furnished without charge as replacementsfor original parts under warranty are warranted forthat period of time during which the original partswarranty is effective.

ALL SHIPMENTS WILL BE F.O.B. PLANTLOCATION. SHIPMENTS WILL BE MADE VIAMOST ECONOMICAL CARRIERS UNLESSOTHERWISE REQUESTED.TERMS: NET 30 DAYSFROM DATE OF INVOICE: 11⁄2% PER MONTH OFALL OVERDUE ACCOUNTS, ALL TAXES EXTRA.PRICES SUBJECT TO CHANGE WITHOUT NOTICE.

27

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PRINTED IN CANADA VEL–FBGM–2003

MANUFACTURING PROGRAMO

Valve Product Line Size Pressure Applicablein mm Class Specifications

Forged pressure seal and bolted bonnet 2– 24 50–600 PS: ASME 600 – 4500 ASME B16.34gate, globe and check valves BB: ASME 150 –1500Small forged steel 1⁄4–2 8–50 ASME 150– 2500 API 602, 606gate, globe and check valves ASME B16.34Forged steel Y-pattern globe valves 1⁄2 – 4 15–100 ASME 900– 4500 ASME B16.34Cast steel gate, globe and check valves 2– 60 50– 1500 ASME 150– 1500 API 600Cast stainless steel 1⁄2 –24 15–600 ASME 150–300 API 603gate, globe and check valves ASME B16.34Twin flapper wafer check valves 2 – 72 50 – 1800 ASME 125 – 2500 API 594

TAPPI TIS 405-8All stainless steel knife gate valves 2– 36 50– 900 150 psiMSS SP-81

1⁄4 – 24 8– 600 ASME 150– 600 ASME B16.34Memory seal ball valve600–4000 WOG

General purpose ball valve 1⁄4 – 12 8 – 300 Up to 300 Up to ASME B16.34Metal-seated ball valves 1⁄2 – 24 15–600 ASME 150– 4500 ASME B16.34Butterfly valves 3– 36 80–900 ASME 150-300 API 609Bellows seal gate and globe valves 1⁄2 – 12 15–300 ASME 150–2500 ASME B16.34Cryogenic gate, globe, check, ball and butterfly valves 3⁄8 – 48 10– 1150 ASME 150– 1500 ASME B16.34

Velan’s valve distributors are located worldwide.

SALES OFFICES MANUFACTURING PLANTS U.S.A.Don Bowers94 Avenue CWilliston, VT 05495-9732Tel: (802) 864-3350Fax: (802) 865-3030

Paul R. Lee105 Carriage DriveHockessin, DE19707-1329Tel: (302) 239-7114Fax: (302) 239-7946

Tony Boland45 W. Franklin StreetBellbrook, OH45305Tel: (937) 848-2011Fax: (937) 848-2144

E. Harlan Dunk5409 Thornapple Ln.,Acworth, GA30101Tel: (770) 590-0909Fax: (770) 590-8144

Ronald J. Harrington43 Wyckoff AvenueWaldwick, NJ 07463-1721Tel: (201) 670-0995Fax: (201) 670-6810

Michael Midgley3160 Vera Valley DriveFranklin, TN37064Tel: (615) 599-5910Fax: (615) 599-6949

U.S.A. VELAN VALVE CORPORATION94 Avenue CWilliston, VT 05495-9732Tel: (802) 863-2561Fax: (802) 862-4014

ENGLANDVELAN VALVES LTD.Unit 1, Pinfold Road,Lakeside Business Park,Thurmaston, LeicesterLE4 8AS EnglandTel: 44-116 269-5172Fax: 44-116 269-3695

FRANCEVELAN S.A.S90, rue Challemel Lacour69367 Lyon Cedex 7 FranceTel: (33) 4-78-61-6700Fax: (33) 4-78-72-1218

PORTUGALVELAN VÁLVULASINDUSTRIAIS, LDA.Av. Ary dos Santos1679-018 FamoesPortugalTel: (351-21) 934-7800Fax: (351-21) 934-7809

ITALYVELAN SRLVia Delle Industrie 9/520050 Mezzago,Tel: (39) 039 62-4111Fax: (39) 039 688-3357

CANADAVELAN INC.7007 Côte de LiesseMontreal, QC H4T 1G2Tel: (514) 748-7743Fax: (514) 748-8635VELAN INC.2125 Ward AvenueMontreal, QC H4M 1T6Tel: (514) 748-7743Fax: (514) 748-7641VELAN INC.550 McArthur Ave.Montreal, QC H4T 1X8Tel: (514) 748-7743Fax: (514) 341-3032VELAN INC.1010 Cowie StreetGranby, QC J2J 1E7Tel: (450) 378-2305Fax: (450) 378-6865PROQUIP835 Fourth LineOakville, ON L6L 5B8Tel: (905) 842-1721Fax: (905) 849-0923

KOREAVELAN LTD.1060-4 Shingil-DongAnsan City, Kyunggi-doKorea 425-833Tel: (82) 31-491-2811Fax: (82) 31-491-2813

TAIWANVELAN-VALVACP.O. Box 2020Taichung, Taiwan, R.O.C.Tel: (04) 2792649Fax: (886) 42750855

EUROPEBrian HallVELAN VALVES LTD.Cambridge Rd., WhetstoneLeicester LE8 6LH EnglandTel: (44) 6-275-0206Fax: (44) 6-275-0224

J.C. CennacVELAN S.A.S90, rue Challemel Lacour69367 Lyon Cedex 7FranceTel: (33) 4-78-61-6700Fax: (33) 4-78-72-1218

INDIAS.GiridharB-708 VardhamanApartmentsMayur Vihar-Phase 1Delhi 110091 IndiaTel: (91) 11-2271-2196Fax: (91) 11-2275-3533

CHINASuite C-1705, Newtown88 Jian Guo RoadChaoyang DistrictBeijing, China 100022Tel: (86) 10-8580 6196Fax: (86) 10-8580 6199

JAPANTak Sakamoto4-31-3 Kamimeguro,Meguro-ku , Tokyo 153-0051 JapanTel: (81) 3-3792-1891Fax: (81) 3-3792-1891

CANADAPaul Dion /Jacques Godbout7007 Côte de LiesseMontreal, QCH4T 1G2Tel: (514) 748-7743Fax: (514) 748-8635

George S. Lysakowski871 Kowal DriveMississauga, ONL5H 3T3Tel: (905) 278-7522Fax: (905) 278-8155

Bill Patrick7127 - 56 AvenueEdmonton, AB T6B 3L2Tel: (780) 465-1122Fax: (780) 465-0403

Leo Shewchuk17 Simcrest Manor S.W.Calgary, AB T3H 4K1Tel: (403) 232-6482Fax: (403) 686-6485

MEXICO, CENTRAL & SOUTH AMERICASergio PensottiVELAN VALVE CORP.730 N. Post Oak RoadSuite 311Houston, TX77024Tel: (713) 682-1837Fax: (713) 682-6071

Charles Pogue /B. Lawson / T. Harfield /M. Tilley730 N. Post Oak RoadSuite 311Houston, TX77024Tel: (713) 682-1084Fax: (713) 682-6071

Christopher G. Hiett21931 Harborbreeze LaneHuntington Beach, CA92646Tel: (714) 965-6277Fax: (714) 965-6737

John Flynn289 Antioch RoadLake Lure, NC 28746Tel: (828) 625-9441Fax: (828) 625-9437

Joe Denny1638 Estate CircleNaperville, IL60565Tel: (630) 579-1833Fax: (630) 579-1834

David Brodnax503 Comanche TrailWest Monroe, LA71291Tel.: (318) 396-7517Fax: (318) 396-4995

SINGAPOREGary Tan18 Eastwood PlaceSingapore 486543Tel: (65) 6246-1108 Fax: (65) 6244-9791

AUSTRALIAJim Thanos25 Beagle St.,Mosman Park, Western Australia 6012Tel: (61) 8 9284-2255 Fax: (61) 8 9284-6314

DISTRIBUTIONCENTERS &SALES OFFICESU.S.A.VELCALDave Frolich537 Stone Road, Unit "A"Benicia, CA94510Tel: (707) 745-4507Fax: (707) 745-4708

VELEASTScott Stewart605 Commerce Park Drive SEMarietta, GA30060Tel: (770) 420-2010Fax: (770) 420-7063

GERMANYVELAN GmbH Wolfgang MaarDaimlerstrasse 8 D-47877 Willich Tel: (49) 2154/4938-00Fax: (49) 2154/4938-99

GENERAL INFORMATIONTel: (514) 748-7743Fax: (514) 748-8635Web: http://www.velan.com