Installation Start-up Commissioning Operation and

Maintenance Manual

KINKA KIKAI
KINKA KIKAI CO., LTD.
 - Table of Contents -
1.0 Storage

2.0 Installation

2.1 Handling

2.2 Cleaning

2.3 Installing Valve in Line

3.0 Valve Operating

4.0 Valve Maintenance

5.0 Packing

6.0 Gasket

7.0 Bolting Torque Values

8.0 Disasssembling

9.0 Application

10.0 Cautions

11.0 Parallel Slide Gate

1.0 Storage
All valves should be stored in a well-ventilated and dry area where they can be protected
from dust, rain, moisture or any weather conditions until valves are installed in line.
During storage, don't remove flange-edge protective cover or weld-end protective cover,
and moreover don't open valves.
In case that valves are to be stored separately with packing dissembled, reseal them with
valve protective cover to keep the inside of valve clean.

2.0 Installation

2.1 Handling
In handling valves, a special care must be taken not to drop them to the ground, and especially
not to damage the flange surface or weld end.
When lifting a valve, the lifting device must not be hoisted against the valve stem and handle
or actuator.
In using a sling to lift valves, be sure to rope valves, because lifting with a crate only may
be dangerous.

2.2 Cleaning
Before installing valves, be sure to remove dust, sand, scale, metal chips, burrs, or foreign
substances that may damage the valve seat.

2.3 Installing Valve in Pipe Line

When installing valves in connection line, please refer the flow direction carved on the body
of valve so that the flow direction in line is met.
Unless specially specified otherwise, gate valves may be installed in either upstream or
downstream. If the handle direction of actuator is specified, please refer to the assembly
drawing upon installation.
When welding the weld-end type valves to pipe lines, fully open disks from valve seat to
prevent arc strike before welding, and then carry out welding in accordance with relevant
welding procedures.
After valve installation in line has been completed, tightening gland nuts prevents from water
leak from gland sections due to long term storage.

3.0 Valve Operating

For hand wheel valves, turning handle clockwise and counter-clockwise indicate valve close
and valve open, respectively, which is also applicable to the gear and/or motor operated
type.In valve open/close (especially in valve open), slowly turn the handle with no excessive
force on handle. A lever, spanner, pipe wrench or other auxiliary tools to be used for tightening
valve should have a suitable length and size not to occur excessive moment or stress on valve
stem or yoke.
Do not close valve to excess.
Carefully check to see whether there is any water leakage from gasket or gland packing.
If water leak is found, loose bolts and nuts should be tightened.
Fully apply grease to grease nipples and stem threads to keep lubrication all the time.
*For Parallel Slide Gate valves please refer to Section 11 of this IOM*

4.0 Valve Maintenance

Valve assemblies are assembled in accordance with a design specification at a shop, water
leakage from bonnet gasket and gland packing may occur due to the looseness of joint
materials according to long term storage or operation and the reduction of gasket and
packing-ring airtight load, and careless control of operational part for long time may cause
malfunction. Therefore periodical thorough inspection and observation should be taken.
1. All valves shall be inspected at least once or twice a year to ensure that valve open/close
works smoothly and that there is no leak from valve. Grease nipples and stem threads
shall be kept lubrication by properly applying grease on them so that they may not be
worn or damaged due to overheat or excessive torque.
2. If any problem or damage occurs on valves, check them in the following methods:
a) Leakage from gasket
Valve bonnet joints are assembled in accordance with the design specification at a shop,
but before installing in lines, they are usually stored in a room temperature condition
for long time. Upon installation, therefore, be sure to check bonnet bolts for tightening
condition. If such a measure alone is insufficient or has no effect, dissemble the valve,
check gasket seat surface for damage, and repair or replace with a new gasket.
b) Leakage from gland packing
Gland bolts shall be tightened fully or packing ring be added. If such a measure alone
is insufficient or has no effect, dissemble the valve, replace with a new gland packing.
Excessive compression on packing may cause excessive operating torque, so special
care should be taken.
c) Abnormal operation in valve open/close
If not caused by grease, dissemble valve and inspect internal parts.
d) Leakage from valve seat
Dissemble valve, and correct the seat surface in a wrapping method.
3. For motor-operated valves, check actuator for correct operation before dissembling valve,
and if any problem occurs, contact the actuator manufacturer.
5.0 Packing
Periodically check valve packing to prevent from water leakage through valve gland packing.
Packing replacement as needed shall conform to the following procedure:

1. First, remove the internal pressure of system. If it is difficult to remove the pressure,
keep valve stem back-seated. (Gate valve, Globe valve)
2. Loosen gland bolts, and lift gland flange and packing gland to separate from stuffing
box. In case hand lifting is not possible, wire or rope may be used. At this time, gland
nuts shall be kept fastened onto gland bolts to prevent from gland nut loss.
3. With packing hook, remove old packing from stuffing box. Lantern ring shall be lifted
out by using a packing hook or bolt on tap hole located in the top of ring. Special
care shall be taken not to occur scratches or damages on stem.
3.1 (Note 1.) If space ring need it, please see below figure Note.1.

4. After the removal of packing, wash grease or dust

off the stem, stuffing box and gland and check for cleaning condition. If necessary,
clean the inside by air.

5. Packing shall be inserted one by one, when

packing ring edges or corners may not be damaged, cut or overlapped. Where one-cut
packing ring is used, packing ring shall be inserted into stem with packing ring twisted
as shown in Figure in the right side to prevent from extreme distortion or severe damage.
At this time, each cut section should be overlapped by 120.
 6. When seating packing in packing insertion, any apparatus having a sharp point must
be prohibited. With a packing iron as shown in Figure in the right side, packing ring
shall be seated firmly in place. For leak-off type, packing ring shall be inserted fully
into the lower part of ring so that lantern ring is located on leak-off position. After
packing is filled into the stuffing box, uniformly tighten gland nuts that packing gland
becomes concentric with valve stem. When tightening packing gland and gland flange,
care should be taken not to lock or damage the valve stem.
7. Operate valve two or three times to check that valve stem is locked.
8. After the valve operation test, fasten again the gland nuts to perfectly compress packing,
and if clearance allows, one packing ring may be added.
9. Valve stem shall be separated properly from back seat to prevent from packing dry.
10. To keep a sufficient air tightness on packing, it is recommended to replace
packing every two years.

6.0 Gasket
Periodical inspection should be conducted to check valve bonnet gaskets for water leaks due
to loose bolting according to the internal pressure of piping system, and if required to replace
gasket, conform to the following procedure:
1. First, remove the internal pressure of system.
2. Loosen bonnet bolt/nuts, separate bonnet from the body of valve, and remove old gasket.
At this time, care should be taken not to damage seats.
3. After the removal of gasket, wash grease, dust or foreign substances off gasket seats
and check for cleaning condition.
4. Place a new gasket into the gasket seat of valve body flange, and carefully push bonnet
assembly into the body, when valve actuator shall be checked for correct direction.
5. Clean bonnet bolts/nuts before the use, and coat bolt/nut surfaces with a lubrication
oil of high quality. Damaged bolts/nuts should be replaced with new ones.
6. In this procedure, it is very important to tighten valve body and bonnet bolts by a specified
torque in accordance with the specified procedures. Applicable and recommended
maximum bolt torque is shown classified by bolt size in the Table 1 below.
7. When tightening nuts, fasten uniformly and diagonally in the proper order as shown
in the Figure with torque given at first and then torque increased gradually, and
repeat the previous steps.
8. Flange face shall be kept parallel and all bolts shall be given a uniform tension.

7.0 Bolting Torque Values

It is recommended that bolt torques of all bolts undergo a regular inspection every six months
and that bolted bonnet valves have the torque values provided in the Table 1 below.
 < Table 1. Maximum Bolt Torque (ft-lb) >
The torque values indicated in the Table 1 below are provided for guidance in field works,
assuming that friction coefficient is 0.2 in which bolt materials as designated have no damage.
Bolt A193
A193 A564 A453
Material B8 & B8M
B7 & B16 Type 630 Type 660
Bolt Size (Class 1)
5/16-18 11 6 18 13

3/8-8 19 11 32 24

1/2-13 47 27 78 58

5/8-11 95 54 155 115

3/4-10 170 96 280 200

7/8-9 270 155 450 330

1-8 400 230 670 190

1-1/8-8 600 340 980 720

1-1/4-8 840 480 1370 1020

1-3/8-8 1140 650 1860 1380

1-1/2-8 1500 860 2460 1820

1-5/8-8 1950 1100 3170 2340

1-3/4-8 2450 1400 4000 2960

1-7/8-8 3030 1730 4980 3680

1-8 3700 2120 6095 4500

8.0 Disassembling
Where valve dissembling is needed to replace valve gasket, always refer to the assembly
drawing as specified, and first of all, check the following items:
1. Completely remove the internal pressure of system.
2. For replacement, prepare spare parts such as packing ring and gasket.
3. Make sure that valve open/close is smooth.
In particular, wedge-gate valve may be inverted in the left and right sides of wedge at assembly
or dissembling. Therefore, with color marking or other methods, special attention should
be paid not to occur such case.
In case of valve disassembling for repair, please contact and consult with our company
or the agency that you purchased this product before starting the disassembly. KINKA
disclaims all the responsibility for problems that may be caused without prior agreement
with KINKA KIKAI INTERNATIONAL.

Figure 4-20 below shows the diagram of disassembly arranged by each valve type for gasket
replacement.

Note 1. : Figure of Space Ring Installation

PACKING GLAND

PACKING

SPACER RING (1)

(1) If spacer ring have it, this should be
inserted into the bottom of stuffing box.
STEM
Fig. 4. Gate Valve of Bolted Bonnet Type (Hand Wheel)
Fig. 5. Gate Valve of Bolted Bonnet Type (Gear Operating)
Fig. 6. Globe Valve of Bolted Bonnet Type (Hand Wheel)
Fig. 7. Globe Valve of Bolted Bonnet Type (Gear Operating)
Fig. 8. Y-Stop Check Valve of Bolted Bonnet Type
Fig. 9. Check Valve of Bolted Bonnet Type
Fig. 10. Gate Valve of Pressure-Seal Bonnet Type (4" below)
Fig. 11. Gate Valve of Pressure-Seal Bonnet Type (Hand Wheel)
Fig. 12. Gate Valve of Pressure-Seal Bonnet Type (Gear operating)
Fig. 13. Globe Valve of Pressure-Seal Bonnet Type (4" below)
Fig. 14. Globe Valve of Pressure-Seal Bonnet Type (Hand Wheel)
Fig. 15. Globe Valve of Pressure-Seal Bonnet Type (Gear Operating)
Fig. 16. Y-Stop Check Valve of Pressure-Seal Bonnet Type
Fig. 17. Check Valve of Pressure-Seal Bonnet Type (4" below)
Fig. 18. Check Valve of Pressure-Seal Bonnet Type (6" over)
Fig. 19. Floating Type Ball Valves
 Fig. 20. Trunnion Type Ball Valves

9.0 Application
This product was designed to satisfy a customer-ordered specification. KINKA Valve
disclaims all the responsibility for problems that may be caused by applications
other than the use specified.

10.0 Cautions
- This valve is limited to the specified use. Otherwise, the product may be damaged or
malfunctioned.
- During normal operation, do not keep valve back seated. Backseat may be damaged.
- Do not use an excessive auxiliary operating device. Operating parts may be damaged.
- Do not use Gate valve to throttle. Operating parts may be damaged.
- Do not torque seat closed Parallel Slide Gate valves. Operating parts may be damaged.
11.0 Parallel Slide Gate valve

* WARNING THIS IS A POSITION SEATED VALVE ONLY. FAILURE

TO FOLLOW PROPER OPERATING PROCEDURES CAN CAUSE
VALVE DAMAMGE*

USE CAUTION WHEN CLOSING/OPENING THIS VALVE.

APPLYING ANY EXCESSIVE FORCE TO THE HANDWHEEL ONCE
THE INDICATOR PIN HAS MADE CONTACT WITH THE BOTTOM
OF YOKE SLOT WILL RESULT IN OVER TRAVEL OF THE PARALLEL DISC
ASSEMBLY. THIS OVER TRAVEL CAN CAUSE A SEAT LEAK, DAMAGE TO THE
DISCS / SEAT RINGS OR OTHER VALVE DAMAGE MAY RESULT.

* Assembly & Disassembly manual for PARALLEL SLIDE GATE VALVE

* ASSEMBLY
1. Spring, Spacer Ring insert into disc and disc holder then assemble it, Take both disc by
key plate then assemble stem,
2. Assembled stem-disc & disc holder into the body and bonnet insert into the body inside
3. Gasket-adapter ring-retainer set have insert into the niche of body and bonnet
* Retainer shall be push into body groove and sustain gap tolerance 3~4mm (do not lean to one side)
4. Pull bonnet up to retainer, insert bonnet clamp then assemble clamp bolt/nut
5. Insert gland packing into bonnet stem hole and assemble packing gland ring
6. Assemble gland bolt/nut
7. Clamp bolt/nut should be tighten until not rising bonnet
8. Assemble yoke to body and assemble stopper set
9. Assemble gear box & stem cover on yoke

* DISASSEMBLY
1. Disassemble gear box & stem cover
2. Disassemble stopper set & yoke bolt/nut and separate Yoke
3. Disassemble gland bolt/nut, clamp bolt/nut
4. Disassemble gland flange, packing gland ring, bonnet clamp
5. Hit and push bonnet into body inside, hit and take each retainer out
6. Yoke raise above body and raise gear box to yoke then rotate handwheel till fall bonnet out
7. Adapter Ring, bonnet gasket will take bonnet out together