USER GUIDE(E)

Product warranty

1.

Warranty period
The warranty period of delivered product shall be two years after shipment from our factory or one year after
start of trial run of the plant, whichever comes first.

2.

Warranty scope
The warranty period shall apply to our products if they are used under the specified maximum operating
conditions.
Therefore, cases to which any one of the following items is applicable shall not be covered by the warranty
even within the warranty period.
(1) Any damage or trouble caused by use beyond the specifications or selection conditions of the product or
use under unspecified inappropriate conditions or environment(2) Any damage or trouble caused by salt damage or natural disaster (such as flood, earthquake or typhoon,etc.)(3) Any damage or trouble caused by consumption of consumable components (such as seal components,
stem nuts or sliding components)(4) Any damage or trouble caused by disassembly, inspection, repair or modification performed by any
contractor other than our company(5) Any damage or trouble caused by wear, corrosion, thickness reduction, coating removal or rusting ofcomponents(6) Any damage or trouble caused by failure to carry out maintenance or inspection described in the
instruction manual or failure to detect abnormality(7) Any damage or trouble caused by improper installation, operation or handling of the product(8) Any damage or trouble caused by external factors (malfunction caused by excessively large reaction force
or vibration of piping, residual foreign substance in piping or electrical trouble)(9) Any damage or trouble caused by failure to perform maintenance or inspection suitable forhigh-frequency use(10) Any damage or trouble caused by improper thermal insulation(11) Contamination, flaws or deformation unrelated to the functions of the product(12) Any damage or trouble caused by improper storage method until start of operation(13) Any damage or trouble related to an unknown cause(14) Dirt around the floor by dripping grease applied to valve stem and bearings

3.

Warranty costs
If any trouble occurs due to any defect attributable to our company within the warranty period, we will replacewith a substitute product or repair of the product will be carried out at our cost (only in Japan).
In addition, any warranty costs shall apply only to the damaged or troubled product, and not include any of thefollowing costs induced by this damage or trouble.

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USER GUIDE(E)① Costs required for removal and installation of the product, transportation costs and standby labor costs② Compensation for lost time and operating loss caused by damage or trouble of the productIn principle, the upper limit of the warranty costs shall be within a range that does not exceed the sales
price of the valve.

4.

Discontinuation of production and change in structure, etc.
The product may be subject to discontinuation of production or change in structure, etc., without prior notice.
Parts of the discontinued product may not be supplied and the product may not be replaced with an identicalproduct.

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USER GUIDE(E)

Safety Precautions
Meanings of Displays and Symbols Used
: An immediate danger that could result in the user’s death or serious injury, if instructions are notobserved.
: A danger that could result in the user’s death or serious injury, if instructions are not observed.
: A danger that could result in the user’s injury or physical damage, if instructions are not observed.

These precautions describe important instructions regarding safety in handling valves. Please read thisInstruction Manual before using the valves to ensure your safe handling.
Make sure that the valves are always handled by licensed personnel who have received safety education andtraining.

1. Transport and Storage•

Never walk or stand under the suspended load. The accident will lead to death or serious injury.

•

Eye bolt installed on the actuator does not have capacity to hang up the whole of valve. It is provided
for actuator only. The accident will lead to death or serious injury. Never use it to hang the valve.

•

Check the mass of the valve before lifting it and use the lifting equipment suitable for the mass.
Unsuitable equipment may causes accidents such as death or serious injury.

•

Products packed in cartons may collapse due to a decrease in packing strength if made damp.
Always store packed products indoors at low humidity.

•

Never stack products unstably.

2. Installation•

Never walk or stand under the suspended load. The accident will lead to death or serious injury.

•

Eye bolt installed on the actuator does not have capacity to hang up the whole of valve.
It is provided for actuator only. The accident will lead to death or serious injury.
Never use it to hang the valve.

•

Check the mass of the valve before lifting it and use the lifting equipment suitable for the mass.
Unsuitable equipment may causes accidents such as death or serious injury.

•

When performing work, ensure safety of the surrounding environment and avoid work in unstable
places. Otherwise the worker will be get death or serious injury result from fall, misstep and touch.

•

Never use the hand-wheel as scaffolding since it rotates. This act will not only break it but also
maybe getting harm by fall.

•

Before performing any work which may catch fire such as grinder tasks or welding operations, takefire prevention measures such as by placing a noncombustible sheet around the products.

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USER GUIDE(E)
3. Operation•

Never replace or add a gland packing while the backseat is activated during operation.
The internal fluid may be ejected from the gland and result in personal injury.

•

Never touch the hot section which is 40°C or more on the valve external surface with bare hands.
When the need for making contact arises, wear heat-resistant gloves and perform work carefully
while exercising caution so as not to suffer burns.

4. Maintenance and Check•

Before performing work, make sure that there is no residual pressure in piping. In addition, makesure that persons who are in charge of the connecting systems are kept well informed to prevent
internal fluid from flowing in from upstream or downstream during work. The worker received spurt
maybe get injury or physical damage.

•

Electric equipments such as actuator or limit switch should be treated after cut off power source.
Otherwise the worker maybe get to death or serious injury by receiving an electric shock.

•

Never touch the hot section which is 40°C or more on the valve external surface with bare hands.
When the need for making contact arises, wear heat-resistant gloves and perform work carefully
while exercising caution so as not to suffer burns.

•

With regard to the disposal of consumables, comply with ordinances enacted by your local
government and properly dispose of them. Especially, use care to prevent inhalation and diffusion
dust in gland packing or gasket, and perform the disposal of them with specified procedures.

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USER GUIDE(E)

Valve Handling
1. Transport and Storage(1) Never lift any valves by the hand-wheel, gland, stem, or yoke. The valves may be deformed or damaged
due to their mass.
(2) Eye bolt installed on the actuator does not have capacity to hang up the whole of valve. It is provided for
actuator only. Never use it to hang the valve.
(3) We carefully inspect valves after completion. After placing caps on the ends of valves and packing themin a specified manner, we deliver those valves. Therefore, you must pay close attention to prevent sand or
dirt from entering into the valves and adhering on the stem exposure part. Never remove the caps on theends until installing valves on the piping.
(4) Store (temporarily place) the valve in a clean and dry indoor area with little change in temperature. In thiscase, use a wood block, etc., to stabilize the valve for storage without directly placing it on floor.
(5) The space heater will not function when power is not connected to the electric actuator, therefore,
condensation will easily form inside the switch cover, resulting in rust and electric trouble. Store the valve
in an environment where condensation does not occur.
(6) If the valve is stored in an environment where rust is a concern because of long-term storage, apply
rust-proof oil on internal and external surfaces of the valve.
(7) With regard to the packing and gasket sealing parts, corrosion is likely to occur in contact areas due toelectric corrosion or crevice corrosion. Therefore, in the case of long-term storage, remove the packing andgasket and store them.
(8) At least once every six months, check for rust and condensation and take necessary measures.
(9) Apply recommended grease to thread parts.
(10)For gasket and gland packing, refer to Chapter 6.

2. Installation
2-1

General(1) Finished products are protected by the prescribed packing after a final check and then shipped. Therefore,
be careful not to allow any foreign matter to get inside the valves when transporting them after unpacking.
Avoid carelessly placing them outdoors or where there is a lot of dirt. In particular, be careful not toremove the caps from the ends until the time immediately before installation.
(2) Before installing a valve on the piping line, check that the valve is the specified one by its marking, valve
name, valve number, etc., on the body surface.
(3) If foreign matter remains in the piping on which the valve is installed, the valve seat surface may bedamaged and a seat leak may occur. Therefore, thoroughly clean the piping and equipment.
(4) Check the flow-direction arrow on the valve body before installing the piping.
(5) In the case of keeping heat in a valve, it is required to release heat from the stuffing box part. Therefore,
never keep heat in this part. A leak may be caused due to early deterioration in the gland packing.

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USER GUIDE(E)(6) After the completion of welding, remove slag and spatter, etc.
Carry out the welding heat input and the construction method so as to keep a temperature rise in the valve
as small as possible as a result of welding. Perform welding according to the prescribed method. In
addition, when carrying out post-weld heat treatment (PWHT), do so only for the necessary part and with
an appropriate temperature rise and drop speed.
(7) If the allowable temperature limit of the packing, gasket, rubber O-ring, etc, is exceeded due to heattransmission during welding, preheating, or PWHT, replace the parts with new ones after completion ofwork. A temperature of 200°C serves as a guide for Teflon-based parts and 350°C for graphite-based parts.
Since their sealing surfaces may be oxidized, perform appropriate maintenance.
(8) When installing valve piping, consider the operation space, maintenance space, and the installation ofchain blocks to lift heavy parts.
(9) Before performing pipe welding for gate valves or globe valves, operate the valve to attain an opening of
20% or more.
(10) Install the valve by a layout in consideration of daily walk round checks, lubrication, and maintenance.
(11) Install effective supports in piping to prevent excessive bending or twisting from acting on the valve dueto the valve outlet piping and the mass of highly-charged fluid.
(12) Make sure all fittings should be firmly fixed after water seal pipe is connected to valve.
(13) When installing the electric valve, immediately connect the power. The space heater will not function
when power is not connected, therefore, condensation will easily form inside the switch cover, resulting
in rust and electric trouble. Store the valve in an environment where condensation will not occur until
operation starts.
(14) When the stem is installed in a horizontal position, grease applied to the stem or bearing
may drip and dirty the area around the floor.

2-2Gate Valves(1) It is recommended to install gate valves in an upright position. Inverted position is not recommended byreason of some problems (risks)-accumulation of wastes in pipe, difficult maintenance works, andgland/bonnet leakage.
(2) For valves without a flow-direction arrow display on the body or those with a double-headed arrowdisplay on the body, there is no limitation on the outlet. However, the installation direction is specified in
the case of valves with a balancing hole or balance valve on the disc, those with a bypass valve, motor
operated valves, and manually gear operated valves. Install such valves after checking the flow-direction
arrow.

2-3

Globe valves (including Angle Valves) and Flow Control Valves(1) It is recommended to install globe valves and flow control valves in an upright position. Inverted position
is not recommended by reason of some problems (risks)-accumulation of wastes in pipe, difficult
maintenance works, and gland/bonnet leakage.
(2) Please note that the fluid flow of reversely installed valves will be opposite the flow-direction arrowdisplay on the body. For reversely installed valves, the suspended plate of [INSTALLED WITH
COUNTER-FLOW DIRECTION] is placed.
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USER GUIDE(E)(3) For valves with a valve opening indicator, check the direction of the valve opening indicator. Since abonnet direction change involves bonnet bolt loosening, change the direction before the pressure testingin line. When the bonnet direction has been changed, always replace the gasket with a new one.

2-4

Check Valves(1) Always use lift check valves in an upright position and swing check valves in horizontal piping or verticalpiping (flow from downward to upward direction). However, using swing check valves in vertical piping
causes chattering. Install piping horizontally whenever possible.
(2) Secure a straight pipe length of 3D (D: nominal diameter of piping) or more ahead and behind the valve.
Directly connecting the valve to the elbow causes wear, galling, or a decrease in sealing performance due
to violent vibrations of the disc as a result of cavitation or turbulent flow.

No Good

Good

Fig. 2a Required straight pipe length at inlet and outlet sides of the valve

2-5Motor Operated Valves(1) Connect wires in electric system securely and correctly.
Incorrect wire connection may result in stem deformation or seat surface damage due to a malfunction in
the torque switches or limit switches.
(2) With regard to indoors installed valves, seal the stem cap and connector securely to prevent intrusion of
rainwater from such places.
(3) When the direction of the actuator has been changed, always re-adjust the limit switches.
(4) Testing of limit switches and torque switches should be performed in motor operation.

3. Testing and Normal Operation
3-1 General(1) Make sure that the hydraulic test pressure will not exceed the valve test pressure.
(2) When using the valve as a stop valve with pressure testing, make sure that the valve closure test pressure
will not be exceeded.
(3) If a leak is detected from the gland or gasket during a hydraulic test, immediately tighten it to stop a leak.
(4) With regard to valve opening/closing operation, the valve will normally close in the clockwise rotationand open in the counterclockwise rotation toward the hand-wheel. Check the current opening/closing
position of the valve carefully before performing operation.
(5) Before starting up the plant, tighten the gland packing. For motor operated valves, make a motor-driven
operational check after tightening.
(6) Always tighten the gland bolts gradually and uniformly. If the gland ring contacts the stem, a gland leak
may result due to damage to the stem.
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USER GUIDE(E)(7) If a leak occurs from the valve gland during operation, tighten it immediately. Leaving the condition as it
is will increase a leak as a result of lost of constituent substance, for example expanded graphite, and eventightening will not stop a leak.
(8) Use valves in a fully open or fully closed position excluding flow control valves. Using gate valves orglobe valves in an intermediate open position may cause erosion or vibration wear, resulting in disc loss
or stem breakage.
(9) With regard to manual valves installed backseat, always return the hand-wheel by 1/4 to 1/2 turns (1.5 to
4.5 turns for the gear operation type) after a fully open position. If the valve undergoes a fluid temperaturechange while the backseat is activated, a large restraining force will be produced in the backseat due to adifference in the expansion coefficient of each part. This may cause damage to the backseat or stiff
manual operation.
(10) When the pressure seal bonnet valve had been installed in pipe line newly and has been re-assembled in
the field, the bonnet lifting bolts/nuts will trend to become loose during the first pressure/temperaturerising. Therefore, tighten them by the loosened amount.

3-2 Gate Valves(1) Always use gate valves in a fully open position. Always return the hand-wheel by 1/4 to 1/2 turns(1.5 to
4.5 turns for the gear operation type) after a fully close position.
(2) In the case of gate valves (including motor operated valves) which have an adjusting nut (generally
stopper) on top of the stem, if a seat ring leak does not stop due to line water pressure etc., remove thesplit pin and loosen the adjusting nut before tightening the valve. In this case, make sure to put theadjusting nut back to its original position after the test and fix it with a new split pin.
(3) If the isolation valve is kept on closing after a pipeline hydraulic test and the plant starts up under thecondition as it is, trapped water in the bonnet will expand due to heat transmission and abnormally highpressure will be encapsulated. This is called “excessive build up of pressure” and impossible valve
opening operation, body or bonnet deformation, or a gasket leak may result. Performing hand-wheel
operation by force under abnormal pressure rising may cause damage to the stem, disc, and other parts. In
such a case, loosen the gland packing little by little and release pressure from the bonnet carefully todecrease pressure. Doing so will make valve operation available. Not only pressure seal bonnet but alsobolted bonnet should be used care to prevent excessive build up of pressure.
(4) Always use pressure valance valves in a fully open position during operation. Handle the valves properly
so as not to perform a fully close operation by mistake.
(5) If there is a seat leak, foreign matter may be entangled between the seats. Therefore, repeat quick-opening
operation by slight lifting to blow off foreign matter without firmly tightening the disc and then perform afully close operation. Lifting the disc a little may stop a leak.

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USER GUIDE(E)
3-3 Globe Valves (including Angle Valves) and Flow Control Valves(1) Always use standard globe valves which are not of the flow control valve specifications in a fully open or
fully closed position. If such valves are used in an intermediate full position, the disc loss or stem
breakage may result due to the wear of the stem and disc.
(2) In the case of high-pressure valves of a small diameter, hand-wheel operation becomes relatively heavy.
However, this is not a malfunction. Loosen the gland bolt a little to reduce torque.
(3) When performing hand-wheel operation by using an auxiliary hand-wheel, use the one with anappropriate length specified by the plant so as not to break the stem.
(4) If there is a seat leak, foreign matter may be entangled between the seats. Therefore, repeat quick-opening
operation by slight lifting to blow off foreign matter without firmly tightening the disc and then perform afully close operation.
(5) If flow control valves are used in a throttled state, stem breakage or a gland leak may result due to strong
vibrations. Re-adjust the valve position not to cause vibrations.
(6) Valves which handle high-temperature and high-pressure saturated water, such as continuous blow down
valves, have a high risk of producing a Bishilite seat crack or erosion. Increase the check frequency todetect an abnormal condition at an early stage.

3-4 Check Valves(1) Check valves structurally sacrifice complete sealing in a fully closed position.
(2) Chattering (a phenomenon in which the disc strikes against the seat surface near a fully closed position)and fluttering (a phenomenon in which the disc is under an unstable condition and flutters in anintermediate open position) are not functionally abnormal phenomena. However, a long-term continuationof such phenomena will cause wear of the connecting parts and leakage in seats and may break them.
Take measures against such phenomena at an early stage.
(3) If the maximum line pressure is applied to the check valve outlet side, make sure that pressure is always
below the pressure during a seat ring leak test at the plant.

3-5 Motor Operated Valves(1) The drive unit is provided with a manual hand-wheel. Switching lever will enter the manual mode andmake hand-wheel operation available. Switching on the motor under that condition will automaticallychange manual to motor. (Refer to the drive unit instruction manual since some types do not perform
automatic restoration in some rare cases.)(2) Some drive unit types may reduce an operating force at a high gear ratio during manual operation or
adopt a large hand-wheel. Even if hand-wheel operation is not performed by an excessive force, breaks invalve or actuator may occur. Always disc lift must be watched during manual operation and once a goodtactile response has been provided to ensure a fully closed or opened position, never tighten further.
On an intermediate way, when operator notices abnormal operating torque, hand-wheel operation should
be stopped and the source of the trouble should be checked.

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3-6 High-Frequency Use Valves (DSS Operation Valves)
With regard to high-frequency valves or similar operational valves, it is recommended to investigate thewear progression state of stem nut and stem threads in half a year or one year after the start of the first
operation (including a trial run) and determine the check cycle for each valve.

Understand that the valves which have one or more reciprocation cycles of opening and closing every
day, such as DSS (Daily Startup and Shutdown) operation valves, are in harsh working conditions.
These valves of high operation frequency are generally motor operated valves, and the most important
precaution in maintenance is in the wear of the stem nut threads.
In order to prevent the wear of the stem side thread, soft material (copper alloy) is used on the stem nut
side. Since this stem nut of high-frequency use valves is likely to become worn, the wear-resistantmaterial recommended by the actuator manufacturer is generally used for DSS operation valves.
However, the stem nut cannot be used permanently even if this material is adopted.
The wear of the thread will always progress with operation, but the wear speed cannot be unfortunately
predicted.
That is because the following items influence the wear speed in a complicated way:
■ Slide distance (valve stroke)■ Valve installation environment■ Operation frequency■ Adhesion of wear debris■ Load during stem operation (packing resistance and inner pressure)■ Adhesion of dust and foreign matter10■Lubrication degree