GENERAL MAINTENANCE

AND
ASSEMBLY INSTRUCTIONS
CONTROL VALVES
IN HP BYPASS SYSTEM

Bharat Heavy Electricals Limited

Tiruchirapalli

PUB.NO.7101

Index
 CONTENTS
DESCRIPTION OF WATER AND STEAM CONTROL VALVES
GENERAL
MATERIALS
MAINTENANCE
PRESSURE SEALS
GENERAL
DISMANTLING THE PRESSURE SEAL
ASSEMBLING THE PRESSURE SEAL
GLANDS
GENERAL
REPLACING THE GLAND PACKINGS, FIGURES 4 TO 13
VALVE STEMS
GENERAL
DISMANTLING AND ASSEMBLING ; ACCESS FROM NON-ACTUATOR SIDE
DISMANTLING AND ASSEMBLING ; ACCESS FROM ACTUATOR SIDE
ADJUSTING THE STEM
TIGHT-SEATING VALVES WITH ELECTRIC ACTUATORS. FIGURES. A+B
TIGHT-SEATING VALVES WITH ELECTRIC ACTUATORS. FIGURES. C+D
TIGHT-SEATING VALVES WITH HYDRAULIC ACTUATORS, FIGURES. E + F
TIGHT SEATING VALVES FITTED WITH HYDRAULIC ACTUATORS FIGURES. G + H
VALVES WITH JET CAGES
DISMANTLING THE PRESSURE SEAL AND JET BREAKER ; ACCESS FROM
NON-ACTUATOR SIDE (FIGURE. 14)
ASSEMBLING THE PRESSURE-SEAL AND JET BREAKER
INSPECTION OF THE VALVES AFTER BOILER BLOW-OUT WITH OR
WITHOUT PRIOR CHEMICAL CLEANING
INSPECTION WITH PRIOR CHEMICAL CLEANING
INSPECTION WITHOUT PRIOR CHEMICAL CLEANING
ADDITIONAL INSTRUCTIONS
POINTS TO BE NOTED DURING ERECTION AND COMMISSIONING
KEY TO PRESSURE SEAL AND GLAND BUSH TYPES

Index
 LIST OF DRAWINGS

SEAL-TYPES-FIGURE-1,2,3 .. .. BS3/A12-217

SEAL AND GLAND TYPES-FIGURE 4,5 .. .. BS3/A12-218

SEAL AND GLAND TYPES-FIGURE 5,6 .. .. BS3/A12-219

GLAND TYPES-FIGURE 8,9,10 .. .. BS3/A12-220

SEAL AND GLAND TYPES-FIGURE 11,12,13 .. .. BS3/A12-221

SEAL TYPE WITH JET CAGE-FIGURE 14,15 .. .. BS3/A12-222

Index
 GENERAL MAINTENANCE AND ASSEMBLY INSTRUCTIONS
CONTROL VALVES
1. DESCRIPTION OF WATER AND STEAM CONTROL VALVES
1.1 GENERAL
Control valves for steam generators are designed to withstand all pressure and temperature
requirements. The range consists generally of simple and similar components, for example.
- Valve body of welded design with welded or bolted seat.
- Valve stem in different shapes,sizes and flow characteristics.
- A single pressure seal (in special cases two) of simple proven design.
- Gland packing (in special cases two) with or without cooling-water connection,
depending on operating temperature. For glands under vacuum conditions there is a
connection for sealing water.
- A jet breaker or cage (only for special valves) to protect the valve body against
erosion.
1.2 MATERIALS
Different materials are used for the various valve components, depending on the operating
conditions. The valve seats are stellited in most cases. For all pressure seals, only original
material is to be used. The composition of the packing material is as follows
- Approx. 60% graphite flakes, min. size 1 mm
- Approx. 25% asbestos flakes, min. length 50 mm
- Approx. 10 to 15% cylinder oil, viscosity 30-40 Cst. at 100C.
The quality of the soft packing rings depends on the operating conditions.
2. MAINTENANCE
2.1 PRESSURE SEALS
(i) General
The pressure seal principle is the same for all valves. The components are similar throughout
the range and differ from one valve to another only in their dimensions. The principal parts of
the pressure seal are :
- Pressure-seal plug No. 21
- Pressure-seal packing No. 22
- Retainer ring No. 23
- Retainer screw No. 24
- Pressure-seal screw No. 25 or
- Pressure-seal nut No. 26
- Locking screw with spring washer No. 27
The pressure-seal must be absolutely tight during operation. If it leaks packing material is to
be added, or the packing renewed. Only a new packing can be tightened to seal successfully
again.
NOTE : When assembling do not use oil, grease or molybdenum-disulphide paste so as to
avoid carburizing difficulties when dismantling.
4

Index
(ii) Dismantling the pressure seal
If the valve is to be dismantled, it is advisable if possible to loosen the pressure-seal screw 25
or the pressure-seal nut 26 by one turn, before the boiler is shut down, i.e., as long as the full
operating pressure is being applied to the seal 21.
It is essential to ensure before dismantling-that the valve is de-pressurized and properly drained.
If the valve must be dismantled during service, it is essential to ensure, before dismantling,
that the isolating valves are closed tight and the valve properly drained.
If the isolating valves do not shut tight, the dismantling must be postponed until the next
boiler shut-down.
(a) Valves with pressure seal on non actuator side see Figures 1,2 and 3
- Remove locking screw 27.
- Unscrew pressure-seal screw 25 with percussion spanner.
- Loosen and remove the retainer screw 24 with the special spanner. If it will not
loosen easily use a soft-headed heavy hammer and if necessary apply rust-softening
penetrating oil to the threads.
- Clean and lubricate the thread of retainer screw 24 and mating thread with
molybdenum-disulphide powder.
- Screw retainer screw 24 back completely, then loosen it one turn.
Replace the pressure-seal screw 25, or the pressure-seal nut 26. Continue turning the
screw 25 or the nut 26 to lift the pressure-seal plug 21 until the retainer ring 23 is just
against the retainer screw 24. Then loosen the pressureseal screw 25 or the pressure
-seal nut 26 by several turns.
- Repeat the whole procedure, i.e. loosen the retainer screw 24 by two turn etc., until
the retainer screw 24 has come completely out of the valve casing -Remove the
pressure-seal screw 25 or the pressure-seal nut 26 together with retainer screw 24.
- Screw eyebolt into the pressure-seal plug (in place of pressure-seal screw 25) and
carefully lift the plug out of the valve together with packing 22 and retainer ring 23
either by hand, or with a chain block (depending on the weight).
(b) Valves with gland in the pressure seal on the non actuator side -
Figures 4, 12, 13
- If fitted, remove the clamping screw or retainer 89, then the packing nut 81.
- Dismantle the pressure-seal as per (a) above.
(c) Valves with gland in the pressure-seal on the actuator side - Figure 5
The actuator must be dismantled to gain access to the pressure-seal. Firstly the electric cables
must be disconnected if there is no convenient handling space nearby. The amplifier must be
switched off.
- Remove coupling between valve stem and actuator.
- Loosen the connecting bolts, lift the actuator and lantern off the valve body. Remove
packing nut 41.
- Unscrew the pressure-seal nut 26.
- Dismantle the pressure seal as per (a) above.

Index
(d) Valve with glands in the pressure-seal and with cooling-water jacket on the
actuator side-Figure 6
- Dismantle actuator as per description (c) above.
- Remove packing nut 41.
- Remove locking screw 27 and unscrew the pressure-seal nut 26.
- Remove water connections and dismantle cooling-water jacket.
- Dismantle pressure seal as per (a) above.
(e) Regarding the packing 22, there are 3 possibilities
Case Condition of Packing 22 Procedure
1 Cold pressed, the packing Remove carefully and
material soft and in good insert again undamaged
condition
2 Seal tight during operation. Remove carefully and
The packing highly com- reinsert undamaged. Add
pressed due to pressure and make-up packing
temperature
3 The seal was not tight during Re-pack
operation. Packing damaged
(iii) Assembling the Pressure Seal
Before re-assembling, all parts are to be carefully cleaned and lubricated only with
molybdenumdisulphide powder. The valve seats are, if necessary, to be separately ground and
lapped.
NOTE : Oil, grease or molybdenum-disulphide paste is not to be used as this will cause
carburization which will make the next dismantling very difficult
Just before re-assembly, check that the housing and especially the seating surfaces are
completely clear of dirt and hard particles. The re-assembly is in the reverse order to the
dismantling.
(a) For Figures 1. 2 and 3
- Replace pressure-seal plug 21. (Figure 2: The piston ring gaps must be spaced at
1800 and the rings centered).
- If necessary replace the pressure-seal packing 22 (see table above). The Packing is to
be evenly inserted, layer by layer to be tamped down with a copper or similar bar. It
is important that this be done with the greatest care. For type and weight of material
see under Section 1.2 and also Technical Data .
- Fit retainer ring 23 and retainer screw 24, screw in until the ring shoulder is tight
against the housing. Then loosen 1/8th turn to make later removal easier.
- Screw in pressure-seal screw 25 and tighten.
IMPORTANT: As soon as and as long as, the valve is under pressure, the pressure seal
screw 25 must be tight against the retainer screw 24. If not, it must be
immediately tightened.

Index
 (b) For Figures 4,12 and 13.
- Assembly of the pressure seal is as for Figures 1, 2, 3 (Pressure-seal nut 26 instead
of pressure-seal screw 25.)
- Packing nut 81 fitted.
(c) For Figure 5
- Assembly of the pressure-seal as for Figures 1, 2, 3
(Pressure-seal nut 26 instead of pressure-seal screw 25)
- Fit pressure nut 41.
- Replace actuator and lantern onto valve body.
- Fit coupling between valve spindle and actuator.
- Re-connect electric cables.
- Adjust valve spindle as given in Section 2.4.
(d) For Figure 6
- Assembly of the pressure-seal is as given in Figures 1, 2, 3.
- After the retainer screw 24, fit the cooling disc.
- Tighten pressure-seal nut 26 and fit locking screw 27.
- Fit packing nut 41.
- Replace actuator and lantern onto valve body.
- Fit coupling between valve spindle and actuator.
- Reconnect electric cables.
- Adjust spindle as given in Section 2.4.
2.2 GLANDS
(i) General
The gland in principle is the same for all control valves. The gland components are similar
throughout the range and differ from one valve to another only in their dimensions.
The principal parts of the gland are
Packing nut (Part No. 41)
Gland flange with or without locking device (Part No. 42)
Gland bush (Part No. 43)
Packing rings (Part No. 44)
Packing spacers (Part No. 45)
Guide bush (Part No. 46)
Lantern ring
(only for valves with sealing-water connection) (Part No. 47)
Extractor ring (Part No. 48)
Clamping screw with spring washer (Part No. 49)
Check for leaking glands regularly. To ensure a long life of the gland packings, do not
overtighten them. If a packing has leaked for some time, complete replacement is necessary.
7

Index
 (ii) Replacing the Gland Packings, Figures 4 to 13
- Remove the coupling between valve stem and actuator (if necessary).
- Remove packing nut 41 (81) after removing the clamping screw 49 (89), if one is
fitted, or flange 42 and gland bush 43 (83).
- Add or replace packing.
For gland packing material see under Technical Data
- When the gap between the shoulder of the gland bush and the valve housing becomes
less than 10 mm, and the remaining packing is in good condition, it is better to add
new packing rings than to replace the complete packing.
- Remove the packing rings 44 (84).
- Withdraw lantern ring 47 and other packing rings (if fitted).
- If necessary remove guide bush 46.
- Before assembling all dismantled parts and the inside of the gland housing must be
cleaned thoroughly. Lubricate well with molybdenum-disulphide powder before
re-assembly.
- The assembling sequence is the reverse of the dismantling, whereby care should be
taken that when tightening the packing nut 41 (81) should be screwed in by at least
4 complete turns.
- After assembly re-adjust stem (if coupling between stem and actuator had been
removed).
NOTE : When repacking the gland it is not necessary to dismantle the coupling. The packing
rings can be angle cut, wound around the stem and pressed into the packing recess.
2.3 VALVE STEMS
(i) General
The valve stems differ in size, shape and method of guidance. These characteristics vary
according to requirements, medium, and operating conditions.
(ii) Dismantling and assembling ; access from non-actuator side Figures. 1, 2, 3 or
4,12,13
- Dismantle the pressure-seal plug as per item (ii) of Section 2.1 - description Figs. 1,
2, 3 or 4, 12, 13.
For valves with valve cover (30)
First loosen the bolts 31 and then lift the cover 30 off and the gasket 32.
- With the aid of the actuator press the stem out as far as possible
- Screw eyebolt into upper end of valve stem ; lift the stem vertically out of the valve
body by hand or by means of a chain block.
NOTE : Before removing, clean the coupling end of the stem so that the gland packings will
not be damaged.
- The assembling sequence is the reverse of the dismantling order. Before assembling,
all dismantled parts have to be cleaned thoroughly and lubricated with molybdenum
-disulphide powder. The seating surfaces in particular must be free of loose, hard
particles.

Index
 - Lower the stem into the valve body and fit coupling.
- Install the pressure seal plug as described under item (iii) in Section 2.1 description
for figures 1, 2, 3 or 4, 12, 13 or fit the valve cover 30 with gasket 32 and secure with
bolts 31.
- Adjust the stem as per Section 2.4.
- Tighten the gland nut.
(iii) Dismantling and assembling ; access from actuator side-Figure. 5 or 6
For these valves, it is necessary to remove the actuator before dismantling the stem. Firstly
the electric cables must be disconnected if there is no convenient handling space nearby. The
amplifier must be switched off
- Dismantle the coupling between valve stem, and actuator rod.
- Loosen the connecting bolts and lift the actuator off.
- Dismantle pressure-seal plug as per item (ii) of Section 2.1 description Fig. 5or 6.
(For valves with cover 30 (instead of a pressure-seal) loosen screw 31, remove cover
30 and gasket 32 (see code sheet)).
- Screw eyebolt into upper end of valve stem, lift the stem vertically out of the valve
body, by hand or by means of a chain block.
NOTE : Before removing clean the coupling end of the stem so that the glandpackings will
not be damaged.
- The assembling sequence is the reverse of the dismantling order. Before assembling,
all dismantled parts have to be cleaned thoroughly and lubricated with molybdenum
-disulphide powder. The seating surfaces in particular must be free of loose, hard
particles.
- Replace the stem in the valve body.
- Depending on which is fitted, install the pressure-seal plug as described under item
(iii) of Section 2.1 description Fig. 5 or 6, fit the valve cover 30 with gasket 32 and
secure with bolts 31 and lock washer
- Assemble (if necessary) the gland packing as per item (ii) of Section 2.2.
- Adjust the stem as per Section 2.4.
- Tighten the gland nut and secure, if parts are provided.
2.4 ADJUSTING THE STEM
(i) Tight-seating valves with electric actuators. Figures. A+B
- By turning the handwheel, move actuator to full-open position. Adjust the position
indicator to maximum reading.
- Loosen coupling screws and then turn stem just far enough out of the coupling so
that the position 0 on the indicator is not reached when the valve is then fully
closed by hand.
- By turning the handwheel, open the valve, screw the stem one, turn into the coupling
then close valve, repeat the whole procedure until the position 0 on the indicator
corresponds exactly with the closed position of valve.
IMPORTANT : Do not turn valve stem on seat; it might damage seating surface.
- By turning the handwheel, open valve a little and tighten the coupling screws. Check
feedback transmitter.
9

Index
 FIG A FIG B

(ii) Tight-seating valves with electric actuators. Figures. C+D

FIG. C FIG.D

- By turning the handwheel, move actuator to full-open position. Adjust the position
indicator to maximum reading.
- Loosen coupling screws and then turn stem just far enough into the coupling so,
that the position 0 on the indicator is not reached, when the valve is then fully
closed by hand.
- By turning the handwheel, open the valve, screw the stem one turn out of the cou-
pling then close valve, repeat the whole procedure until the position 0on the indica
tor corresponds exactly with the closed position of valve.
IMPORTANT : Do not turn valve stem on seat; it might damage seating surface.
- By turning the handwheel, open valve a little and tighten the coupling screws. Cheek
feedback transmitter.

(iii) Tight-seating valves with hydraulic actuators, Figures. E + F

FIG .E FIG. F

- Move hydraulic actuator to full-open position.

- Remove coupling between valve stem and actuator.
-. Check that hydraulic actuator is in the full-open position.
- Replace the coupling between actuator and valve stem.
- Adjust the position indicator to the maximum reading.
- Turn the stem far enough out of the coupling so that the position 0 on the indicator
is just not reached when the valve is in the fully closed position.
- Tighten the coupling bolts and move the valve to the closed position.
WARNING : Do not operate the hydraulic actuator when the coupling bolts are loose.
Otherwise, there is a danger that the thread of the valve stem will be stripped.

10

Index
 - Re-open the valve and loosen the coupling bolts. Then turn the stem one turn into
the coupling and re-tighten the coupling bolts.
- Close the valve again and repeat the whole procedure until the position 0 on the
actuator indicator corresponds exactly with closed position of the valve.
IMPORTANT : Do not turn valve stem on seat, it might damage seating surface.
- Check feedback transmitter.
(iv) Adjusting the stem for tight seating valves fitted with hydraulic actuators as
indicated by Figures. G + H
Fig.G Fig.H

- More the hydraulic actuator to full open position

- Disconnect coupling between valve stem and actuator.
- Chock that hydraulic actuator is in the full-open position.
- Replace the coupling between actuator and valve stem.
- Adjust the position indicator to the maximum reading.
- Turn the stem far enough into the coupling so that the position 0 on the indicator
is just not reached when the valve is in the fully closed position.
- Tighten the coupling bolts and move the valve to the closed position.
WARNING : Do not operate the hydraulic actuator when the coupling bolts are loose.
Otherwise, there is a danger that the thread of the valve stem will be stripped.
- Re-open the valve and loosen the coupling bolts. Then turn the stem one turn out of
the coupling and re-tighten the coupling bolts.
- Close the valve again and repeat the whole procedure until the position 0 on the
actuator indicator corresponds exactly with closed position of the valve.
IMPORTANT : Do not turn valve stem on seat, it might damage seating surface.
- Check feedback transmitter.
ADJUSTMENT OF FEED BACK LINKAGE
Whenever actuator piston rod and valve stem are coupled together proper care should be
taken to ensure that the LEVER(in the feed back linkage) fixed to position Feed Back
Transmitter (FBT) does not foul with any one of the four pins provided on the FBT at valve
full open/close position.
The following adjustments shall be done after doing the stroke adjustment to avoid the foul-
ing.
1) Adjust the position of the slide on the lever and fix it such that the slide is at a
distance equal to valve stroke length. This shall be checked by the scale on the lever.
11

Index
 2) Keep the valve at mid position (50%) and adjust the STUD length such that the
Lever is in horizontal position (at valve 50% position).
3) Check the operation of actuator and the lever position with reference to the pins on
FBT at valve full open/close position.
3. VALVES WITH JET CAGES
3.1 Dismantling the Pressure Seal and Jet Breaker ; access from non-actuator side
(Figure. 14)
If the valve is to be dismantled, it is advisable to loosen the nut on the bolt 65 by one turn,
before the boiler is shutdown. It is essential to ensure before dismantling that the valve is
de-pressurized and properly drained.
If the valve must be dismantled during service, it must be isolated and drained. If the isolating
valves do not shut tight, the dismantling should be postponed until the next boiler shutdown.
- Loosen nut on bolt 65 and remove the cover 75.
- Push the pressure-seal plug 61 as far as possible into the valve body, so that the
locking ring segments 64 can be removed.
- Remove the pressure-seal plug 61 together with pressure-seal packing 62, retainer
ring 63 and jet breaker 9 from the valve body.
For replacement of the pressure-seal packing 62 there are three different cases which call for
the following procedure :
Case Condition of packing 62 Procedure
1 Cold pressed, the packing Remove carefully and insert again
material soft and in good undamaged
condition
2 Seal tight during operation. Remove seal carefully and reinsert
The packing highly undamaged.Add make-up packing.
compressed owing to
pressure and temprature.
3 The seal was not tight Re-pack.
during operation.
Packing damaged.
3.2 Assembling the Pressure-seal and Jet Breaker
The assembling sequence is the reverse of the dismantling order, except the re-packing of
seal. In this case it is necessary to have a pressing tool A (see Fig. 15), having an internal
diameter identical to that part of the valve body in which the pressure-seal plug 61 is fitted.
Before assembling, all parts have to be cleaned. Rub all surfaces which have metal-to-metal
contact with molybdenum-disulphide powder.
- If it is necessary (see table under Section 3.1) to replace the pressure-seal packing
62, as shown in Fig. 15, proceed as follows :
- Insert the pressure-seal plug 61 with jet breaker into the pressing tool A, then fill in
the new packing material evenly, layer by layer, around the plug and tamp it with a
copper (or similar) bar. It is important that this work is done properly. The plug and

12

Index
 the tool A must be completely dry. The type and quantity of the packing material is
shown under Section 1.2. and under Technical Data of the particular valve.
- Place the retainer 63 on the top of the packing material and then screw the bolt 65,
into the pressure-seal plug 61.
- Replace the cover 75 and then compress the packing 62 as far as possible by
tightening the nut on bolt 65.
- Remove the nut on bolt 65, the cover 75 and then carefully lift the complete
pressure-seal plug assembly out of the pressing tool A.
- Insert the pressure-seal plug assembly into the valve body. Locating pin 11
correctly locates the pressure-seal plug.
- Replace the segmented locking ring 64.
IMPORTANT :The segments ot the locking ring 64 should be inserted in such a way that
the holes are visible; that is the holes point outwards.
- Insert cover 75. Tighten seal as far as possible by tightening nut on bolt 65
Pressure-seal 61 is thereby pressed towards the packing 62, or retainer ring
63. The pressure-seal must be able to pass freely through the segmented
locking ring 64.
NOTE : As soon as, and as long as, the operating pressure has been applied to the
valve, the pressure-seal bolt 65 has to be tightened to ensure that the packing
remains in the compressed condition after the operating pressure is released.
4. INSPECTION OF THE VALVES AFTER BOILER BLOW-OUT WITH OR
WITHOUT PRIOR CHEMICAL CLEANING
4.1 Inspection with prior chemical cleaning
- If the boiler has been chemically cleaned, then the pressure-seals and gland packings
of the affected valves must be replaced, in order to prevent corrosion due to residual
amounts of acid left in the packings.
- During the boiler blow-out, following the chemical cleaning particles of dirt in the
blow-out steam can cause damage to valve seats and spindles. Therefore these parts
are to be checked and, if necessary, repaired before re-assembly.
Further, the inside of the valve body is to be cleaned of any foreign particles.
4.2 Inspection without prior chemical cleaning
If the boiler is blown-out without a prior chemical cleaning, then the duration of the blowout
will be longer. Damage to the valve seats and spindle could be greater. Further it is possible
that the additives for removing the rust-protective coating of the tubes will attack the packings.
HP Bypass Valves and spray valves should not be installed in line before steam blowing.

5. ADDITIONAL INSTRUCTIONS
For certain special valves, the above instructions are not enough. For instance, the valve stem
for some valves has to be adjusted in a different way to that given under Section 2.4. For such
and other important differences from the general instruction, an additional instruction is
attached to the relevant code sheets. If, however, only a small addition to this instruction is
required then the particular code sheet will be modified.

13

Index
6. POINTS TO BE NOTED DURING ERECTION AND COMMISSIONING
(i) HPBypass valves and spray valves should not be involved during steam blow out
operation
(ii) After acid cleaning operation, all packings,gaskets and seals of the valves should be
changed if the line on to which these valves are assembled or acid cleaned.
(iii) After hydraulic testing, if long storage is expected, it is advisable to remove the
stem and the packing and cover suitably the opening caused for the above removal.
Silica Gel may be put inside the valve.
(iv) The threads to be lubricated with molybdenum-disulphide powder.
(v) Valves should be thoroughly cleaned before they are put into service.
(vi) Gland nut to be tightened to the extent necessary to stop the leakage and it should
not be overtightened.
(vii) Rubber hoses should be erected with fairly large bending radius.
(viii) Oil pipes to be supported every 2 to 3 metres.
(ix) Filling of oil into the tank should be done through a 3 micron filter.
(x) Hydraulic oil should not contain any viscosity index improver and any calcium.
(xi) When laying out the oil supply unit, it should be noted that these units are located
atleast 1.5 m below the lowest actuator. When routing the oil hydraulic pipe work, it
should be ensured that no static head of oil can occur at any servo valve. Oil supply
unit should be located such that the running length of pipe is 15 to 20m maximum
from oil supply unit to valve actuator.
(xii) Welding between two flanged surfaces SHOULD NOT be resorted to, if small leaks
of medium are found through the gasketed joints.
KEY TO PRESSURE SEAL AND GLAND BUSH TYPES
9 jet cage
11 Positioning pin
21 Pressure-seal plug
22 Pressure-seal packing
23 Retainer ring
24 Retainer screw
25 Pressure-seal screw
26 Pressure seal nut
27 Locking screw -with spring washer
29 Pin
33 Guide bush
34 Retainer nut
35 Locking plate
36 Clamping ring
41 Packing nut

14

Index
42 Gland flange
43 Gland bush
44 Packing rings
45 Packing spacers
46 Guide bush
47 Lantern ring
48 Extractor ring
49 Clamping screw with spring washer and spring pin
50 Gland bolt with slotted nut
51 Spherical disc and socket
52 Packing retainer ring
53 Circlip
61 Pressure-seal plug
62 Pressure-seal packing
63 Retainer ring
64 Segmented locking ring
65 Pressure-seal screw
75 Cover
81 Packing nut
83 Gland bush
84 Packing rings
85 Packing spacers
86 Guide bush
89 Clamping screw with spring washer and spring pin
90 Stud with nut and locking plate
91 Castellated nut with washer
92 Packing retainer ring
94 Cap
A Compressing device for pressure-seal packing 62 (Fig 15)

15

Index
 16

Index
 17

Index
 18

Index
 19

Index
 20

Index
 21

Index
LUBRICATION INSTRUCTION
FOR
BOLTS, NUTS AND TAPPED
HOLES
USED IN BHEL VALVES

Bharat Heavy Electricals Limited

Tiruchirapalli

PUB. NO. 7136

Index
 CONTENTS
INTRODUCTION
LUBRICATION
ASSEMBLY
TIGHTENING

Index
2
INTRODUCTION
As a rule BHEL valves are subjected to extremely severe service conditions. Nevertheless, in case
of a revision it must be possible to dismantle the valves quickly and without any problems.
For ensuring this, the bolts, nuts and tapped holes must be handled with care during assembly and
lubricated according to the following instruction.

LUBRICATION
- Check bolt and nut threads as well as tapped holes with regard to cleanliness and dam-
ages.
- Lubricate tapped holes in the casing.
- Apply lubricant on bolt threads.

ASSEMBLY
- Fasten provisionally, by 2 or 4 bolts, pressure seal plug, cover or lantern.
Complete manual fastening of the remaining bolts without washer, until the bolt head is
flush on surface.
Should it be impossible to completely fasten bolt without extra effort, the tapped hole has
to be cleaned once more, checked and, if necessary retapped.
Check the bolt thread as well. In case of any damage, use a new bolt. Do not recut the
bolt thread.
- Remove bolts.
- Apply once more lubricant thoroughly onto the bolt thread.
- Lubricate the washers on both sides.
- Install the bolts with their washers.

TIGHTENING
- If the required tightening torque is approx. 500 Nm or more, in addition to the torque
wrench a torque multiplier is needed.
- Regarding amplification (ratio) as well as the correct use of the torgue amplifier, the instruction
of the manufacturer has to be followed carefully. Take care that the lever of the torque
amplifier rests against the casing as far away as possible from the bolt centerline.
Step 1
- All bolts, except those which had been fastened provisionally, have to be tightened crosswise,
with 2/3 of the required torque. Remove the bolts which had been fastened provisionally,
treat them like the others and tighten them also with 2/3 torque.
Step 2
- Tighten crosswise all bolts with 95% of the required torque.
Step 3
- Tighten crosswise all bolts with the full required torque.

Index
3
Step 4
- Repeat step 3

LOOSENING
- Before loosening the bolts or nuts, the valve has to be depressurized and drained in any
case.
- In case the bolt threads and washers are correctly lubricated, the torque should only be
slightly higher when loosening than when tightening.

LUBRICANT
- For all bolts, etc. of water and steam valves, use Molybdenum disulphide Powder.

Index
4