| GENERAL |
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CONGRATULATIONS
ON HAVING BOUGHT OSWAL VALVE. WE ASSURE THE SATISFACTORY
PERFORMANCE OF OUR VALVE. HOWEVER PROPER STORAGE,
NEAT INSTALLATION, GENTLE OPERATION & TIMELY
MAINTENANCE ENHANCES VALVE PERFORMANCE AND LIFE. |
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UPON RECEIPT, INSPECT THE
VALVE FOR ANY SHIPPING DAMAGE. |
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AS PER
THE PACKING SLIP PLACED INSIDE THE BOX, VERIFY
THE GOODS RECEIVED ITEMS PACKED LOOSE WITHIN THE
BOX ARE IDENTIFIED IN THE PACKING SLIP. CHECK
FOR SHORT SUPPLY IF ANY. |
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| STORAGE AND PRESERVATION |
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VALVE
IS GENERALLY WRAPPED AND PROTECTED FROM DAMAGE
DURING SHIPMENT. THIS WRAPPING & PROTECTION
SHOULD BE LEFT IN PLACE UNTIL THE VALVE IS TO
BE INSTALLED. VALVES SHOULD, WHERE POSSIBLE, BE
STORED IN A CLEAN, DRY ENVIRONMENT. |
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CAUTION:
- AVOID THE ENTRY
OF DIRT, SEDIMENTATION GRIT & OTHER FOREIGN
PARTICLES ON SEATING & SEALING SURFACE, FLANGE
FACE OR THREAD SURFACE. |
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| VALVE MARKING |
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EACH
VALVE HAS THE IDENTIFICATION INFORMATION PLATE
RIVETED / FASTENED ON THE FLANGE / TO THE SIDE
OF THE VALVE BODY. MATERIAL TRACEABILITY MARKING
ARE MARKED ON THE VALVE BODY. |
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| GENERAL INSTRUCTION |
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WEAR ALL NECERRARY PERSONAL
PROTECTIVE EQUIPMENT. |
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NEVER REMOVE OR MAINTAIN A
VALVE OR JOINT UNLESS THE LINE HAD BEEN FULLY DRAINED
OR DE-PRESSURISED |
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ALWAYS OPERATE THE VALVE TO
THE OPEN POSITION TO ENSURE THAT NO TRAPPED PRESSURE
EXISTS WITHIN THE CAVITY. |
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NEVER
HANDLE THE VALVES THAT HAVE BEEN USED ON HARMFUL
SUBSTANCES UNLESS THEY HAVE BEEN COMPLETELY DECONTAMINATED
AND & CERTIFIED SAFE TO HANDLE. |
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ALWAYS USE CORRECT LIFTING
METHODS & EQUIPMENTS WHEN INSTALLING, REMOVING
& MAINTIANING THE PRODUCT. |
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| INSTALLTION |
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VALVE
CAN BE INSTALLED IN ANY POSITION. HOWEVER AVOID
STEM POSITION DOWNWARD. IT IS RECOMMENDED TO MOUNT
THE VALVE STEM IN VERTICLE POSITION |
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PRIOR
TO INSTALATION, PIPELINES SHOULD BE THROUGHLY
FLUSHED, CLEANED FREE FROM WELD SLUGS, RUST, SCALES
& OTHER DUST INSIDE PIPING & ON FLANGE
SURFACE. |
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PIPELINE SHOULD BE ALIGNED
PROPERLY SO THAT PIPELINE WEIGHT & STRESSES
ARE NOT TRANSFERRED TO THE VALVE. |
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VALVES SHOULD BE THOROUGHLY
CLEANED AT FLOW PASSAGE, STEM PORTION BEFORE INSTALLATION. |
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IF THE VALVES ARE STORED FOR
LONG TIME, THEY MUST BE CLEANED, LUBRICATED, &
TESTED PRIOR TO INSTALLATION. |
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TIGHTEN THE GLAND PACKING
UNIFORMLY BEFORE INSTALLING & AFTER TRIAL OPERATION. |
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QUALIFIED WELDER MUST PERFORM
WELDING OPERATION & THE WELDING PROCEDURE IN
ACCORDANCE WITH ASME BOILER & PRESSURE VESSEL
CODE. |
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SITE
STANDARDS FOR INSTALLATION OF THE VALVES MUST
BE FOLLOWED WHERE SUCH STANDARDS DO NOT EXIST,
THE FOLLOWING GUIDELINES MUST BE USED, |
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FLANGED END VALVES |
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PIPEWORK
SHOULD HAVE CORRECT GAP TO ALLOW THE VALVE
FACE TO FACE LENGTH PLUS ASSEMBLED GASKET
MATERIAL THICKNESS. |
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BE SURE THAT FLANGE
GASKET & FASTENERS ARE SUITABLE FOR OPERATING
CONDITION. |
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INSERT
THE VALVE (FULLY OPEN) ALONG WITH GASKET
BETWEEN MATING FLANGE, ALIGN THE FLANGE
BOLT HOLES & HOLD IT IN PLACE, |
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HOLD THE NUT FIRST,
INSERT BOLT & FINGURE TIGHT FIRST. |
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USE TWO SPANNERS TO
TIGHTEN THE JOINT IN SEQUENCE AS SHOWN. |
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|
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BUTT WELD END |
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KEEP THE
VALVE IN OPEN POSITION |
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SPACE THE JOINT APART.
CO-AXIAL WITH 2-3 mm GAP |
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AFTER FINISHING WELDING
CLEAN THE PIPELINE & VALVES BY FLUSHING
OR PIGGING TO REMOVE IMPURITIES. |
|
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WARNING |
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ALL INSTALLATIONS
SHALL BE PROVIDED WITH PRESSURE RELIEF DEVICES
IN ACCORDANCE WITH THE REQUIREMENTS OF THE PRESSURE
EQUIPMENT DIRECTIVE 97/23/EC. PROPER INSTALLATION
PRIOR TO INITIAL OPERATION IS THE USERS RESPONSIBILITY.
THE INSTALLATION SHALL ALSO BE PROTECTEDAGAINST
EXCESSIVE PRESSURE WHERE HAZARD DUE TO FIRE EXISTS. |
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| OPERATION, INSPECTION
& MAINTAINANCE |
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OPERATION |
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FLUSH
THE PIPE LINE CAREFULLY WHEN VALVE IS MOUNTED
TO REMOVE ALL POSSIBLE IMPURITIES. BEFORE
FLUSHING KEEP THE VALVE OPEN FULLY. |
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VALVES SHOULD BE OPENED
& CLOSED SLOWLY TO AVOID HAMMERING EFFECT
ON THE VALVE AND PIPELINE. |
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VALVES SHOULD BE USED
IN ACCORDANCE WITH THE PRESSURE / TEMPERATURE
CHART. |
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ANY
MEDIA WHICH MAY SOLIDIFY, CRYSTALLIZE OR
POLYMERIZED SHOULD NOT BE ALLOWED TO STAND
IN THE CAVITY SINCE THIS MAY DETRIMENTAL
TO VALVE PERFORMANCE AND LIFE |
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|
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PERIODIC INSPECTION AND
MAINTAINANCE |
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ANNUAL INSPECTION
SHOULD BE MADE TO CHECK UP VALVE BODY, DISC,
AND STEM IF WORN OR PITTED, SUBSTITUTE NEW
ONE. |
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IT IS RECOMMENDED TO
REPLACE SEAT, BODY GASKET, STEM PACKING, WASHERS,
UNLESS THE PARTS ARE IN GOOD CONDITION. |
|
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LUBRICATION |
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WHEN
LUBE FITTINGS ARE PROVIDED, VALVE SHOULD BE LUBRICATED
PERIODICALLY. STEM THREADS MUST BE BRUSHED WITH
LUBRICANTS TO AVOID DAMAGE AND EXCESSIVE TORQUE
FROM DEVELOPING. VALVE SHOULD NEVER BE OPERATED
WITHOUT LUBRICATED STEM THREAD OR YOKE SLEEVES |
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| DISASSEMBLY |
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FOR
SAFETY & PROTECTION, IT IS IMPORTANT THAT
THE FOLLOWING PRECAUTION BE TAKEN PRIOR TO REMOVING
THE VALVE FROM SERVICE OR BEFORE DISASSEMBLY OF
THE VALVE. |
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DISASSEMBLY |
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WEAR ANY
PROTECTIVE CLOTHING OR EQUIPMENT NORMALLY
REQUIRED WHEN WORKING WITH THE MEDIA INVOLVED. |
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DE-PRESSUIREIZE
ALL THE LINES & DRAIN THE SYSTEM FLUID.
CYCLE THE VALVE SEVERAL TIMES TO RELIEVE
ANY STRESS OR PRESSURE INSIDE THE VALVE |
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KEEP
THE VALVE IN FULL OPEN POSITION. REMOVE
THE VALVE & PLACE IT ON A LEVEL SURFACE
IN VERTICLE POSITION. |
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CAUTION :- VALVES
SHOULD NOT BE DISMANTLED IN CLOSED POSITOIN. |
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DISASSEMBLY OF THE VALVE |
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FLUSH THE
VALVE TO REMOVE THE RESIDUALS IF ANY. |
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REMOVE THE COVER (02)
BY LOOSENING THE STUD/NUT (11) (12). |
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“MATCH MARK”
THE ORIENTATION OF THE BODY (01) & COVER
(02). |
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LOOSEN THE PIN PLUG
(N.S). |
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REMOVE THE HINGE PIN
(08) BY HOLDING THE DISC SUBASSEMBLY BY PROPER
EQUIPMENT. |
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REMOVE THE SPLIT PIN
FROM THE DISC |
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LOOSEN THE DISC NUT
(06) & WASHER (07) |
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DISMENTLE THE DISC
(05) FROM THE HINGE (03). AND PLACE IT ON
A CLEAN SOFT NON METALIC SURFACE |
CAUTION:
- DISC
LAPPED SURFACE MUST BE PROTECTED FROM DAMAGE
AND PLACED ON A SOFT NON METALIC SURFACE
AFTER DISASSEMBLY. |
| REMOVE
THE BODY GASKET (10) FROM THE BODY GROOVE.
|
| REMOVE THE
DRAIN PLUG (13) IF ANY. |
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|
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NOTE.
CHECK WHETHER THE SEALING
SURFACE OF THE DISC OR THE SEATRING IS DAMAGED.
IF ONLY SEATRING IS DAMAGED REPLACE THE SEATRING.
MINOR SCRATCH OR FLASHES ON THE DISC OR THE SEATRING
CAN BE SMOOTHENED WITH HELP OF GRINDING CLOTH.
CHECK
IF THE BODY GASKET IS IN PROPER CONDITION.
|
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| ASSEMBLY. |
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BEFORE
ASSEMBLY ENSURE THE COMPONENTS USED ARE SUITABLE
FOR THE VALVE REQUIREMENT. DURING ASSEMBLY CLEANLINESS
IS ESSENTIAL FOR LONG LIFE |
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FOLLOW
THE REVERSE SEQUENCE OF DISASSEMBLY.
IF PRACTICLE, LEAK TIGHTNESS & OPERATING TORQUE
SHOULD BE CHECKED PRIOR TO REFITING THE VALVE
IN LINE
|
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| RECOMMONDED SPARES
FOR 2 YEARS OF TROUBLE FREE OPERATIONS |
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VALVE QTY
IN EACH SIZE |
RECOMMENDED SPARES
SEAT / BODY GASKET / HINGE PIN
|
| UP TO 10 |
01 |
| 11 TO 25 |
02 |
| 26 TO 50 |
05 |
| 51 TO 100 |
10 |
|
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IF OTHER
PARTS ARE REQUIRED, IT IS USUALLY RECOMMENDED
THAT THE COMPLETE VALVE IS REPLACED. ALTHOUGH
PIECE PARTS ARE AVAILABLE PARTS FROM DIFFERENT
SIZED/RATED VALVES MUST NOT BE INTERCHANGED. |
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ONLY
OSWAL AUTHORISED SPARE PARTS SHOULD BE USED. IF
THE VALVE IS ALTERED IN ANY WAY, NO LIEBILITY
CAN BE ACCEPTED BY OSWAL |
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| WARNING |
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BEFORE USING THE VALVES READ
IOM MANUAL AND OBSERVE SAFETY REGULATION, AND CURRENTLY
APPLICABLE LAWS |
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INSPECT
FOR POSSIBLE TRANSPORT DAMAGE .DAMAGED VALVES
MIGHT NO LONGER COMPLY WITH THE SAFETY REQUIREMENTS
AND MUST NOT BE INSTALLED |
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TRANSPORT, INSTALLATION,
COMMISSIONING, MAINTENANCE OR REPAIR MUST ONLY BE
PERFORMED BY TRAINED PERSONNEL |
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WARNING:
FAILURE TO OBSERVE
THE OPERATING MANUAL CAN RESULT IN SERIOUS
INJURIES OR DAMAGE TO PROPERTY (EG. DUE
TO MECHANICAL, CHEMICAL, OR ELECTRICAL EFFECTS) |
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DANGER:
WHEN USING UNINTENDED
MEDIA, THE MATERIAL MAY BE ATTACKED WITH
FATAL CONSEQUENCES. FOR THIS REASON, ONLY
USE MEDIA FOR WHICH THE VALVE HAS BEEN APPROVED. |
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|
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FLOW
DIRECTION: VERIFY THAT THE DIRECTION OF THE FLOW
IN THE LINE CORRESPONDS TO THE ARROW INDICATED
ON THE VALVE BODY.HOWEVER STANDARD VALVES ARE
BIDIRECTIONAL |
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HEALTH AND SAFETY |
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WHEN INSTALLING OR MAINTAINING
VALVES: |
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CONDUCT
A RISK ASSESSMENT AND ELIMINATE OR REDUCE
HAZARDS TO AN ACCEPTABLE LEVEL. |
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WORK IN ACCORDANCE WITH
SAFE SYSTEMS OF WORK. |
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OBSERVE ALL SITE HEALTH
AND SAFETY RULES IN PARTICULAR PERMIT TO WORK
AND HOT WORK
|
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NEVER MODIFY OR ALTER
VALVES UNLESS THE MANUFACTURER HAS BEEN CONSULTED |
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DUE
TO THE VARIETY OF DUTIES ON WHICH THIS PRODUCT
CAN BE EMPLOYED, IT IS THE END USER RESPONSIBILITY
TO ENSURE THE COMPATIBILITY OF THE MEDIA
WITH THE MATERIALS OF CONSTRUCTION OF THE
PRODUCT FOR EACH SPECIFIC APPLICATION |
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|
|
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REGULARLY CARRY OUT INSPECTIONS
TO DETERMINE THE TECHNICALLY SAFE CONDITIONS OF
THE INNER WALL. |
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THE
PRESSURE PEAKS OCCURRING DURING CLOSING THE PIPELINE
CAN BE VERY MUCH HIGHER THAN THE OPERATING PRESSURE.
THE VALVE SHALL BE SELECTED FOR NOT EXCEEDING
THE PERMISSIBLE OPERATING PRESSURE. |
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DANGER : |
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OPENING PRESSURIZED VALVES
CAN BE FATAL. |
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DANGEROUS
SUBSTANCES CAN LEAK FOR INSTANCE FROM RELIEF BORES
OR WHEN DISASSEMBLING THE VALVE. COLLECT AND DISPOSE
SUCH LEAKAGE SO THAT PERSONS AND THE ENVIRONMENT
ARE NOT ENDANGERED OBSERVES THE LEGAL REGULATIONS. |
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GENERAL INSTRUCTION FOR THE
OPERATION OF THE VALVE |
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DONOT USE
THE VALVE FOR PRESSURE & TEMPERATURE HIGHER
THAN SPECIFIED IN THE NAME PLATE |
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PROVIDE SUITABLE DRAINING
& VENTING IN PIPELINE IF SERVICE CONDITION
DEMANDS |
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IF OVER PRESSURE IS
EXPECTED, INSTALL PRESSURE RELIEF VALVE IN
THE PIPELINE |
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IF SYSTEM DEMANDS VALVE
POSITION, USE PADLOCK ARRANGEMENT TO AVOID
RISK & MISUSE. |
|
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ESSENTIAL SAFETY REQUIREMENTS
– WHICH ARE NOT CONSIDERED |
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TRAFFIC
WIND, EARTH QUAKE LODING |
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PROTECTION AGAINST
EXCEEDING THE ALLOWABLE LIMITS OF PRESSURE
EQUIPMENT |
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|
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ESSNTIAL SAFETY REQUIREMENTS
– WHICH ARE NOT APPLICABLE |
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DANGEROUS
DISCHARGE OF PRESSURE RELIEF BLOW-OFF |
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DEVICES TO PREVENT PHYSICAL
ACCESS WHILST PRESSURE SAFETY ACCESSORIES |
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TEMPERATURE MONITORING
DEVICE |
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PRESSURE LIMITING DEVICES |
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EXTERNAL FIRE |
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