Maintenance and repair of valves and valves

on site and in the workshop

There are various reasons why repairing valves provides many benefits, since

repair costs run to 5 35 % of the procurement price of replacement valves

it is too expensive to keep capital tied up in maintaining stocks of all replacement

the delivery times for replacement valves can be extremely long, causing major,
expensive production problems

repairing welded-in valves on site is much faster than

removing the insulation material from the valves

cutting out the valves from the pipeline system

taking the valves to the workshop

welding a replacement valve into the system after preparing the pipe ends

(if no replacement valve is available) repairing the valve, which is carried out either
by an external company in our own workshop or the external company's workshop,
including welding the valve back in again. These processes also include the
subsequent checking of the welded joints and installing the insulation.

The time taken to repair large high pressure valves may be days or even weeks. However,
repairing the valves on site reduces the time necessary to a few hours or days, as shown in
the following example:

Depending on the nature of the damage, a DN 200 300 mm high pressure slide valve can
be repaired on site within 1 -3 days. The repair of the same fault in workshop would take 3 - 4
weeks. In an electrical power station with approx. 300 MW and an average power price of
0.10 DM/kWh the cost of lost production would be 30,000 DM/hour, representing a daily loss
of 720,000 DM, and a loss of 7,200.000 DM over ten days.

HOW TO PROCEED
Preventive measures are extremely important for well-organised valve maintenance; this
means regular checking of the condition of the valves (quality of sealing, tightness of closed
valve). Valve failure / leakage can cause considerable loss of medium and can represent a
major environmental hazard or even lead to catastrophe if toxic gas escapes (SEVESO in
Italy, BHOPAL in India).
Our machines and equipment are designed for repairing damage to the sealing surfaces in
valves.
It is extremely important to act as soon as the first signs of leakage appear, because even
relatively small damage to the sealing surface can quickly develop into a major leakage,
which may then require comprehensive and expensive repairs.
There are two ways of maintaining valves:
A.

On-site repair, particularly for valves welded into pipelines, which, in most cases, is a
cheaper solution

B.

Workshop repair (partial or total repair), which is more expensive

Our comprehensive range of machines (services) covers both requirements in full.

zu A. On-site repair
1.

For globe valves (with small to medium damage to

the sealing surface) with a nominal diameter of DN 8 150 mm we use our VALVA S1 machine (VALVA
S05 for valves up to DN 50).
This machine is driven by an electric or compressed
air motor. The machines are guided by hand.

Hardened and lapped steel grinding disks are used

as tools, which are fitted with 80 - 500 grain selfadhesive grinding paper.
It is our experience that the grinding with abrasive
paper in grain 500 during the last working step results
in a surface finish which makes it unnecessary to lap
the surface.
For larger valves with a nominal diameter of up to DN
300 mm (12") the VALVA S15, DN 80 - 300 mm (3" 12") is used.
This machine operates in the same way as the
VALVA S1.

If the sealing surfaces need to be lapped, we use our

VALVA 1 machine, DN 8 - 150 mm. With this machine it
is possible to switch the spindle from the usual circular
movement to an oscillating movement for lapping (DN 8
100 mm).
The machine can be mounted on a special machine
stand for carrying out this particular work.

Disks made from grey cast iron are used for lapping. EFCOBOR lapping paste with different
grain sizes is used as the lapping medium. Generally lapping takes considerably more time
than grinding.

If lapping of valves from DN 100 mm up to DN 300 mm is

required, we use the VALVA 15 machine. A VALVA 15
must always be firmly attached to the valve housing.This
machine works in the same way as the VALVA S15, but
using planet wheels and a fixed stand or a special 3-jaw
chuck.

For valves with a nominal diameter of DN 200 to DN 600 mm (8" - 24") the VALVA 2
machine is used, and for valves with a nominal diameter of up to DN 1600 mm we use the
DN 500 - 1600 mm (20" - 64") VALVA 3 machine.

Planet wheels are used as the tools for both machines, on which planet arms with 50,
80 and 120 grinding and lapping spindles are mounted.
Here too the grinding spindles have self-adhesive grinding paper rings with various grain
sizes attached to them. Oil-thinned lapping pasted with various grain sizes is used with the
lapping spindles.
When the planet wheels rotate, due to the friction between the surface machined and the
(ball bearing-guided) grinding or lapping spindles rotate around their axis. This produces
an optimum cross-grind and keeps the sealing surface even.
Both machines must be firmly attached to the valve housing during operation.

2.
Globe valves with major damage to the sealing surface
In cases where the entire sealing surface is being replaced
(build-up welding) and the damage to the base material is
only slight, our high speed grinding machines are used.
These are firmly attached to the valve housing.
These are the EFCO machines:
VSA 05
VSA 1
VSA 2
VSA 3

Nominal diameter 20 mm - 150 mm (3/4 - 6)

Nominal diameter 50 mm - 400 mm (2 - 16)
Nominal diameter 250 mm - 800 mm (10 - 32)
Nominal diameter 500 mm - 1500 mm (20 - 60)

All VSA machines are compressed air-driven and are also

suitable for grinding conical surfaces in valve housings.

Various grinding tools are available:

Face wheels made from silicon carbide or special fused
alumina

Face wheels with adhesive grinding paper attached

EFCO-GSS grinding discs (galvanicaly bonded CBN)

Grinding cone with grinding paper sleeves

All machines can be fitted with a bore grinding device (see diagram) for grinding cylindrical
surfaces, particularly in high pressure slide valve housings.

In many gate valve housings the cylindrical

surface (3) that is used for axial sealing (so-called
siding lock) gets damaged. This surface can be
repaired in various ways. Small damage can be
ground off using the high-speed VSA machine
with the auxiliary device for the automatic grinding
of cylindrical holes. If the damage is extremely
deep, the entire surface (3) must first be turned,
(ground), then welded on, annealed and the new
sealing surface turned (ground) to the required
size.

The EFCO-TD machines developed for this purpose feature the fully automatic axial and
radial feed. As desired electric or / and pneumatic drive can be supplied.

EFCO TD-05
EFCO TD-1
EFCO TD-2
EFCO TD-3 E

diameter up to 150 mm
(up to 6)
diameter up to 400 mm
(up to 16)
diameter up to 600 mm
(bis 24)
diameter up to 400-1500 mm
(16-60) CNC-controlled

Optionally the TD-machines can be supplied with

taper turning attachment, or with high speed
grinding attachment.

The TD machine can be used for

machining of valve seats or flanges. By
means of special boring-crown the
welded joints seat ring- valve body can be
removed. (please see the drawing on the
left)

Our build-up welding machines are designed for producing build-up welds on flat, cylindrical
and conical sealing surfaces in all fittings, valves and slide valves.
These are:
EFCO-CW 1000
Automatic axial and radial build-up welding device up to a diameter of 30- 1000 mm (1
- 40) and the EFCO CW 150 machine for smaller valves (20 mm-150 mm (3/4-6)).
The CW 1000 is a unique machine world-wide because it is the only one that can
automatically produce radial, axial and conical build-up welds.
The scope of delivery also includes power sources for MIG/MAG welding and various types
of electrodes.

Small, localised damage to sealing surfaces can be easily repaired using a WIG welding
device. These devices are also in our product range.
All the devices are suitable for use on site and in the workshop.

3.

Repairing conical valve seats

These types of valves include shut-off and control valves for high pressure and high
temperatures. They are usually used to control steam and water flow in thermal power plants.
We have developed some simple and extremely efficient electrical and compressed airpowered tools for repairing this kind of valves.

These grinding tools are called the VSK tools and are
manufactured with cone angle dimensions of 30(2x15),
40(2x20), 60(2x30), 75(2x37,5) and 90(2x45) and
nominal diameters of DN 10 - 300 mm (3/8-12) as
standard.
Other cone angles and nominal diameters may be
manufactured on request.
For nominal ranges up to DN 300 mm (12), we make
use of our VALVA S15 (see photo).
Reliable, fast centring (important) is achieved using a
centring cone (1) and (for greater nominal diameters) a
three jaw chuck (2). For machining grinding paper or
abrasive cloth segments are used.
Special tools have been developed for valves from
DN 300 mm and above, these are operated with the
Valva 2 machine.
It has already been mentioned
that conical valve seats can also
be machined using our EFCO
VSA and EFCO TD machines.
We also have special tools for
machining the flange surfaces for
metallic lens seals (2x70).

4. Repairing safety valves

Various devices and machines have been developed for making repairs in the workshop.
Our VALVA SV1 machine is suitable for machining the sealing surface of valve seats with
nominal diameters of DN 20-150 mm (3/4-6 freehand operation) on site. It is also suitable
for repairing other valves with flat seats. For the repair of safety valves in workshop a special
stationary SMS 450/750 machine was developed.
Both machines are used for the fine grinding of the sealing surface using special selfadhesive grinding foil, using which the requested surface finish can be achieved. The SMS
machine is also suitable for lapping.
The following flat lapping machines are particularly suitable for machining valve disks:
Disc size
mm

Inner diameter of
dressing rings

FLM-400

400

3 x 140

FLM-600

600

3 x 250

FLM-900

900

3 x 370

FLM-1200

1200

3 x 510

FLM-1500

1500

3 x 610

TYPE

Flat lapping machines are also suitable for lapping and

polishing mechanical seals for high pressure pumps.
The surface to be machined must be monitored at all times;
it should be checked whether the flatness and finish of the
lapped sealing surfaces is correct.
We can also supply the necessary accessories:
Monochromatic light source with optical flat glasses,
roughness measuring devices and the associated
consumable materials (silicon carbide, boron carbide,
lapping liquid etc.).

EFCO valve test stands for safety valves are built

in accordance with international standards and
requirements. In accordance with customer
requirements we also supply PC and a printer and
software for test data acquisition and test report
printing

It is often impossible to repair safety valves on site, but with the special LEGATEST device
the opening pressure of the safety valve (i.e. the force at which the valve opens) can be
measured and adjusted.

10

5. Gate valve repairs (different dimensions, pressure and design)

Our globally-renowned machines are used for repairing small to medium size damage to
sealing surfaces, gate valve wedges and flanges on site or in the workshop:
EFCO-SL 02
EFCO-SL 05
EFCO-SL 1
EFCO-SL 15
EFCO-SL 15L
EFCO-SL 2
EFCO-SL 2L
EFCO-SL 3

for DN 10-32 mm
(3/8-1 1/4)
for DN 20-80 mm
(3/4-3)
for DN 40-200 mm
(1 1/2-8)
for DN 40-300 mm
(1 1/2-12)
for DN 40-450 mm
(1 1/2-18)
for DN 200-700 mm
(8-28)
for DN 200-900 mm
(8-36)
for DN 500 bis 2000 mm
(20-80)

The EFCO SL-02 and EFCO SL-05 machines are

available with compressed air drives only, and all
other machines are available either as
compressed air or electrically powered versions.
They are also available with a rocker with a
patented digital display for indicating the
machining pressure. By means of a special
attachment EFCO-SLV it is possible to use these
machines for grinding and lapping of sealing
surfaces in globe valve bodies.
The tools used with the EFCO SL-02 and SL-05
machines are steel grinding disks, onto which selfadhesive waterproof grinding paper is applied. All
the other SL machines use planet wheels with 3 to
12 grinding spindles.
The grinding spindles are mounted in ball bearings and are radialy continuously adjustable
(depending on the diameter of the sealing surface in the gate valve). The planet wheels are
fitted with grinding spindles made from hardened steel, onto which self-adhesive grinding
paper rings are applied, or GSS disks (with galvanicaly bonded CBN), which make faster
machining possible. GSS disks are more temperature resistant and are particularly
suitable for machining extremely hard sealing surfaces.
All SL machines are also suitable for lapping. The planet wheels are then equipped with
lapping spindles made from grey cast iron. For lapping takes the oil-thinned lapping paste is
used.

11

Local areas of average damage on the sealing surfaces (approx. 0.7-1.5 mm deep) in
gate valve housings and on gate valve wedges or flanges are repaired using the WIG
welding process and then ground as per the instructions given in the above.

Gate valve wedges can be repaired (ground

and lapped) on site using the appropriate SL
machine. The universal grinding table KS-6 is
very convenient for repair of smaller gate
valve wedges (see illustration on the left).

Gate valve wedges can be repaired very efficiently

on site using the appropriate SL machine. Smaller
gate valve wedges can be machined using our
universal KS 6 grinding table.
EFCO MK adapters are enhancing the productivity
of the EFCO tools. The sealing surfaces of gate
valve wedges, in valve and gate valve housings can
also be efficiently ground (lapped) on a drill press
using a simple EFCO adapter, the EFCO ENT tilting
table and the appropriate tools of the SL machine.

12

On-site repair in severely damaged gate valve housings

If deep local damage has occurred to the
sealing surface in gate valve housings, the
repair should be made as follows: local buildup welding using the WIG process (no
annealing required), then grinding the entire
sealing surface using our high-speed HSS
grinding machine for nominal diameters of:
HSS 05
HSS 1

DN 80-300 mm (3-12)
DN 200-600 mm (8-24)

Repairs to large areas of damage:

first remove the old damaged sealing surface
by grinding on the HSS machine, then heat
the gate valve to the required temperature as
per the manufacturer's instructions, weld on
the new sealing surface surface (a new
machine for on-site welding of sealing
surfaces in gate valve housings is being
developed), anneal,
allow to cool and then grind the new sealing
surfaces on the HSS. The entire process is
complicated but still the only alternative.
The HSS machines are delivered with
pneumatic motors.
The following types of grinding tools can be
supplies
Face wheels made from silicon carbide or
special fused alumina
Grinding cone or cylinder with grinding
paper sleeves
EFCO-GSS grinding discs (galvanicaly
bonded CBN)

13

HSS-1
GmbH&CoKGDren
Maschnr.
Baujahr
enbau
Maschinh
100527-52305
Postfac
Germany

If you wish to accelerate this process, we recommend our new gate valve lathes (pic.1)
(in test stage):

EFCO-TSD 1
for DN 200-300 mm ( 8-12)

50
40
30
20
10
0

EFCO-TSD 2
for DN 300-400 mm (12-16)

pic.2

These machines can also be

used to crop the housing
seat rings in high pressure
gate valves using the
optional accessory (pic.2).

pic.1

6.
On-site flange machining on fittings, valves, pipelines, heat exchangers, boilers and
columns.
Our outer diameter mounted machines are ideal for machining the sealing surface of any
flange:
EFCO-TDF 05
for diameter of 0- 250 mm
(0-10)
EFCO-TDF 05A
for diameter of 0- 250 mm
(0-10)
EFCO-TDF 1
for diameter of 0- 500 mm
(0-20)
EFCO-TDF 1A
for diameter of 0- 400 mm
(0-16)
EFCO-TDF 2
for diameter of 300-1200 mm
(12-48)
EFCO-TDF 3
for diameter of 700-2000 mm
(28-80)
and under development:
EFCO-TDF 4
for diameter of 1300-3000 mm
(52-120)
These machines are robust and still relatively light. They are driven by electric or
compressed air motor.
14

Chapter B. Valve repairs or maintenance in the workshop

All the above-described machines can also be used in the workshop.
The first phase of a valve repair in the workshop is sorting the valves, then dismantling,
marking and visual inspection (locating defects). The standard tools are required for this
operation. Hydraulic or pneumatic screw drivers and nut splitters (also in our product range)
are very useful.
Then the valve must be cleaned. For this purpose one or more of thee following procedures
can be used:
1.
Sand or shot blasting (with glass pearls or steel balls)
2.
High pressure cleaning (water or steam)
3.
Washing with chemical solutions in special automatic machines
4.
Mechanical cleaning
Then the valves are sorted into two groups: One group containing valves where welding and
turning are not required, and the other group containing valves requiring these operations.
The valves in the first group can be machined using our stationary grinding and lapping
machines:

EFCO SM 450 for valves up

to DN 300 mm (12)
EFCO SMS 450 for safety valves up to DN 200 mm (8)
EFCO SM 750
to DN 500 mm (20)
EFCO SMS 750 for safety valves up to DN 350 mm (14)

The machines are suitable for repairing any

valves, gate valve housings and gate valve
wedges up to the above-mentioned nominal
diameters. The repair is made using the
same tools as those used with the mobile
machines.

SM 750
For repairing valves with flat and conical
seats up to DN 150 we recommend the
VALVA S1 hand machine and the VSK
tools for conical valve seats.

EFCO SM-SMS 450

15

The following repair procedure for the valves belonging to the second group where the
build-up welding (stelite or some other material) is required

removing of the old sealing surface by turning

build-up welding
thermal treatment - annealing
machining (turning) to restore the original dimensions of the sealing surface

For machining the special CNC turning machine with precision tilt table (accuracy 5) are
used:
EFCO SPM-600
with swivelling table 800 x 800 mm
for low pressure valves up to max. DN 500 mm
for high pressure valves up to max. DN 300 mm
EFCO SPM-800
with swivelling table 1000 x 1000 mm for turning
for low pressure valves up to max. DN 600 mm
for high pressure valves up to max. DN 500 mm
For larger valves up to DN 1500 mm we have a
special machine in our product range:
The machine is manufactured as per customer
requirements, consisting of:
Machine bed with stable cast structure, precision
cross-tilting table with appropriately sized surface.
The above-described TDE-3 machine is mounted
on the machine bed. In this way the system can be
used for both stationary and on-site machining.

For build-up welding we use the above-described equipment, also for on-site machining.
For build-up welding it is important to preheat the valve body (base material) to the
appropriate temperature and to cool it down in the annealing furnace after welding.
Our product range includes an annealing furnace.
After all the components have been machined and re-checked, installation and sealing takes
place. Our product range also contains the tools and machines that are needed to
manufacture gaskets and prepare the gland packings.

16

After the assembly the valves one

or more of the following tests are
to be performed
Body test to prove its mechanical
strength, spindle leakage test,
sealing test ...
The opening pressure of safety
valves is also tested.
EFCO is providing the equipment
to perform these.
(photo left: semi-automatic test
bench PS-15 A)

The test benches supplied are custom made units

optimised to fulfil the requirements of a particular
customer. The units with clamping forces ranging
from 7,5 up to more than 1000 tons were built.
EFCO test benches are designed for testing of
globe valves, slide valves, check valves, control
valves, ball valves and safety valves with air,
nitrogen or water.
The valves with flanges, treaded or butt weld ends
can be clamped. The production program comprises
stationary, transportable, vertical, horizontal, manual
and automatic units.
(photo right: transportable test bench PS-T 10)

17

Consumables and tools

Our product range also includes the consumables that are required for repairing valves:
a) various grinding materials:
grinding paper, grinding foil, grinding cloth (self-adhesive / non-self-adhesive )
b) Abrasive wheels:
grinding shot, GSS grinding disks (cubic-crystalline boron nitride in a galvanic bonding)
c) Lapping pastes with various grain sizes and all the consumables that are required for
lapping and polishing machines, and also diamond lapping paste and emulsion
d) Tools for all our mobile and stationary lathes
e) Gaskets
f)

Dye penetration spray

g) Complete sets of tools for on-site machining

Our companys strength lies in having highly qualified personnel and maintaining continuous
contact with our customers.
We have a great deal of expertise in our valve repair department and are available to our
customers for advice. We develop and process projects for valve maintenance for all power
stations, industrial areas, companies, countries and small workshops based on specific
requirements and requests. We also provide our customers with in-house or on-site training.
If required we can also supply our specialists for longer periods for commissioning our
machines on customer sites.

If limited funds are available for purchasing equipment, we can advise our customers
concerning the order in which the equipment should be procured.

We also provide individual, fully

equipped mobile workshops on the
basis of customer requirements and
requests.

18

We also manufacture grinding and lapping machines for repairing plug valves up to
DN 250 mm to order.
We also supply special machines for grinding and honing spheroids up to DN 250 mm that
can be mounted on conventional lathes.

For power stations and shipbuilders we

manufacture special KDM coupling hole lathes
for boring holes in turbine, gear-box, generator
and ship couplings.

We supply special machines for

machining pipe ends and cutting pipes
with diameters between 20 and
1600 mm.

We have solved many different kinds of problem that have occurred during our on-site
machining activities and have developed special machines to meet these requirements. We
are convinced that we can solve your problems!
Ask us about them and pay us a visit!

In constant aim to improve our products, we preserve the right to change the technical
specification without prior notice.
19

G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

page 3/15

GROUP 1A
FLAT SEAT VALVES

1.1 stop valve DN 10-50

check valve DN 10-50
1.9 regulating valve DN 300

1.3 HP stop valve

1.5 HP check valve
DN 10-50

1.2 stop valve DN 50-1200

1.4 check valve DN 50-250

procedure

1
2
3

grinding

repair machines

1.10 HP regulating valve

DN (
)

EFCO
surfac
e

1.8 quick acting valve

DN 50-500

20

25

50

80

100

150

200

300

400

500

600

800

On
site

In
shop

1600

l
l
l
l
l
l
l

1600

l
l
l
l

l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l

1000 1200 1500 2000

SLIGHT TO SEVERE DAMAGE

lapping

VALVA-S05 / S05-S
VALVA-S1
VALVA-1
VALVA-S15
VALVA-15
VALVA-2
VALVA-3
MK-2 + tools + ENT-1/2
MK-3 + tools + ENT-2/3
MK-5 + tools + ENT-3/4
SM-450
SM-750
SPM-600
SPM-800
VALVA-1
VALVA-15
VALVA-2
VALVA-3
MK-2 + tools + ENT-1/2
MK-3 + tools + ENT-2/3
MK-5 + tools + ENT-3/4
SM-450
SM-750
SPM-600
SPM-800

G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

DN (
)

EFCO
surfac
e

procedure

repair machines

20

25

SLIGHT
1
2
3

high-speed VSA-05
grinding
VSA-1
VSA-2
VSA-3
SPM-600
SPM-800

2
3

1
2
3

TD-05
TD-1
TD-2
TD-3 E
SPM-600
SPM-800
TDF-05
TDF-05A
TDF-1
TDF-1A
TDF-2
TDF-3
TDF-4
high-speed VSA-05
grinding
VSA-1
VSA-2
VSA-3
SPM-600
SPM-800

50

TO

80

100

SEVERE

150

200

300

400

500

600

800

1000 1200 1500 2000

On
site

In
shop

l
l
l
l

l
l
l
l
l
l

l
l
l
l

l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l

DAMAGE

250

u
u

RENOVATION
1
2
3
4

page 4/15

turning

OF

SEALING

FACES

R E S P.

SEATS

(RESURFACING)

150

250
250

700
1300

250

u
u

3000

l
l
l
l
l
l
l
l
l
l
l

G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

DN (
)

EFCO
surfac
e
4

repair machines

procedure
high-speed VSA-1
grinding
VSA-2
VSA-3
SPM-600
SPM-800

page 5/15

20

25

u
u

Lapping can be replaced by grinding (using micron abrasives).

Application:
Performance:

with grinding head (optional)

With bore grinding device (optional)

-machining of many small valves

-drive with more power
-double quantity of tooling ( grinding discs, pin wrenches)

50

80

100

150

200

250

300

400

500

600

800

1000 1200 1500 2000

On
site

In
shop

l
l
l

l
l
l
l
l

G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

page 6/15

To this we recommend our micro abrasives:

EFCO - new procedures

GROUP 1B

P 500 = 3 0 Micron

Superfinish grinding instead of lapping

(with VALVA-S05 and VALVA-S1)
our test results point out that comparable surface
roughness can be achieved by superfinish grinding
instead of lapping.

VALVES WITH FLAT SEATS

SAFETY VALVES

P 1200 = 15 Micron
P 1600 = 9 Micron

Rz 1,2
Roughness Rz

0,7

..
0,5

Ra 0,1
Ra

0,06

..

0,04

For repairing safety valves, manufactures

recommendations must be observed!

safety valve DN75-700

DN (
)

EFCO
surfac
e

procedure

grinding

2
3

turning

repair machines

20

25

50

80

100

150

200

300

400

500

600

800

1000 1200 1500 2000

On
site

In
shop

l
l
l
l
l
l

l
l
l
l
l
l
l
l
l
l
l
l

S E A T D A M A G E
VALVA- S05-S
VALVA-S1 (VALVA SV-1)
VALVA-1
(lapping)
VALVA-S15
VALVA-15
(lapping)
VALVA-2
(lapping)
MK-2 + tools + ENT-1/2
MK-3 + tools + ENT-2/3
SMS-450
SMS-750
SPM-600
SPM-800

350

RENOVATION OF SEALING SURFACES

2
3

for working the surfaces 2 and 3, see table on page 3

RENOVATION OF SEATS AND SAFETY VALVE TAPERS

lapping

FLM - 400
FLM - 600
FLM - 900
FLM-1200
FLM-1500
FLM-1800

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G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

GROUP 2

For working sealing seats

2 and 3 see table,
page 3

VALVES WITH
CONICAL SEAT

2.3 regulating valve

2.2 HP stop valve

2.1 low pressure stop valve

DN (
)

EFCO
surfac
e

procedure

repair machines

20

25

SLIGHT
1

grinding

VALVA-S1 + VSK-tools
VALVA-S15K + VSK-top segm.
VALVA-2 + VSK-top. segm.

high-speed VSA-05
grinding
VSA-1
VSA-2
VSA-3
grinding
VALVA-S1 + VSK-tools
VALVA-S15K + VSK-top segm.
VALVA-2 + VSK-top segm.

50

TO

80

100

150

SEVERE

200

300

400

500

600

800

DAMAGE

10
10

AVERAGE
1

page 7/15

TO

SEVERE

DAMAGE

250
10

1000 1200 1500 2000

On
site

In
shop

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RENOVATION OF SEATS AFTER HARD FACE WELDING

1

high-speed VSA-05
grinding
VSA-1
or
VSA-2
VSA-3
turning
SPM-600
SPM-800
TD-1 + taper turning tool
TD-2 + taper turning tool
TD-3 E
finishVALVA-S1 + VSK-tools
grinding
VALVA-S15K + VSK-top segm.
VALVA-2 + VSK-top segm.
turning
TDF-05
TDF-05A

250

10

250
250

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G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

3

page 8/15
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TDF-1
TDF-1A

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GROUP 3
GATE VALVES AND
SWING CHECK VALVES

3.2 gate valve flanged

3.1 HP gate valve

3.3 gate valve with seat ring

procedure

repair machines

20

25

50

80

100

150

200

300

400

TDF-2
TDF-3
TDF-4
grinding

lapping

SL-02
SL-05
SL-1
SL-15
SL-15 L
SL-2
SL-2 L
SL-3
VALVA-1/S1
VALVA-S15
MK-2 + tools + ENT-1/2
MK-3 + tools + ENT-2/3
MK-5 + tools + ENT-3/4
SM-450
SM-750
SL-1
SL-15
SL-15 L
SL-2
SL-2 L
SL-3
VALVA-1

500

600

800

1000 1200 1500 2000

700
1300

SLIGHT
1
2
5
6

3.4.2 swing check valve (min. 30)

DN (
)

EFCO
surfac
e

3.4.1 swing check valve

TO

SEVERE

40
40
450
700
900

40
40
40

In
shop

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DAMAGE

32

40

3000

On
site

450
700
900

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G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

page 9/15
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MK-2 + tools + ENT-1/2

MK-3 + tools + ENT-2/3
MK-5 + tools + ENT-3/4

DN (
)

EFCO
surfac
e

repair machines

procedure

grinding

and
lapping

20

SM-450
SM-750
SL-1
SL-15
SL-15 L
SL-2
SL-2 L
SL-3

25

50

80

100

150

200

300

400

500

600

800

1000 1200 1500 2000

40
40
40

450
700
900

On
site

In
shop

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R E N O V A T I O N O F S E A L I N G S U R F A C E S R E S P. S E A T S A F T E R H A R D F A C E W E L D I N G
1
5
6
1
5,6
2
3
4

grinding

turning

HSS-1
HSS-05
SPM-600
SPM-800
TSD-1
TSD-2

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(planed)
(planed)

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for working the surfaces 2, 3 and 4 see table , page 3

REPLACING OF SEALING FACES WITH PORTABLE BUILD_UP WELDING MIG/MAG WITH EFCO-WELDING MACHINES

with grinding head (option)

with adapter head und tilt table (option)

EFCO CW 150
EFCO CW 1000

20- 150 mm
30-1000 mm

axial up to 75 mm
axial up to 150 mm

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G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

page 10/15

GROUP 4
VALVE ACCESSORIES

4.1 wedge

4.2 disk

EFCO
surfac
e

procedure

7
8

finishgrinding

repair machines

20

25

SLIGHT

grinding

lapping

MK-2 + tools + ENT-1/2

MK-3 + tools + ENT-2/3
MK-5 + tools + ENT-4
SM-450
SM-750
SL-05
SL-1
SL-15
Sl-15L
SL-2
SL-2L
SL-3
VALVA-S1
VALVA S15
KS-6
SM-450
SM-750
SL-1
SL-15
Sl-15L
SL-2
SL-2L
SL-3
VALVA-1
VALVA-15
SM-450
SM-750

4.3 cone

DN (
)
50

TO

80

100

SEVERE

150

200

300

400

500

600

800

40
450
700
900

40
40
40

On
site

In
shop

DAMAGE

40
40

1000 1200 1500 2000

450
700
900

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G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

page 11/15

G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

DN (
)

EFCO
surfac
e

repair machines

procedure

lapping

turning

finishgrinding

grinding

20

25

50

80

100

150

200

300

400

500

600

800

1000 1200 1500 2000

On
site

In
shop
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FLM-400
FLM-600
FLM-900
FLM-1200
FLM-1500
FLM-1800

RENOVATION
7

page 12/15

lathe
SPM-600
SPM-800
MK-2 + tools + ENT-1/2
MK-3 + tools + ENT-2/3
MK-5 + tools + ENT-3/4
SM-450
SM-750
SPM-600
SPM-800
VALVA-S05
VALVA-S1
VALVA-1
VALVA-S15
VALVA-15
VALVA-2
VALVA-3
MK-2 + tools
MK-3 + tools
MK-5 + tools
SM-450
SM-750
KS-6
SPM-600
SPM-800

OF

SEATS

AFTER

HARD

FACE

WELDING

1600
450
900

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G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

DN (
)

EFCO
surfac
e
8

procedure
lapping

repair machines

turning

finishgrinding

20

25

50

80

100

150

200

300

400

500

600

800

VALVA-1
VALVA-15
VALVA-2
VALVA-3
MK-2 + tools + ENT-1/2
MK-3 + tools + ENT-2/3
MK-5 + tools + ENT-4
FLM-400
FLM-600
FLM-900
FLM-1200
FLM-1500
FLM-1800
SM-450
SM-750
SPM-600
SPM-800

RENOVATION
8

lathe
SM-750
u
SPM-600
SPM-800
VALVA-S05
VALVA-S1
VALVA-1
VALVA-S15
VALVA-15
VALVA-2
VALVA-3
MK-2 + tools + ENT-1/2
MK-3 + tools + ENT-2/3
MK-5 + tools + ENT-3/4
SM-450

page 13/15

1000 1200 1500 2000

1600

OF

SEATS

AFTER

HARD

FACE

On
site

In
shop

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WELDING

1600

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G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

DN (
)

EFCO
surfac
e
8

repair machines

procedure
finishgrinding

page 14/15

20

25

50

80

100

150

200

300

400

500

600

800

1000 1200 1500 2000

On
site

In
shop
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SM-750
KS-6
SPM-600
SPM-800

S L I G H T T O S E VE R E D E M A G E
9

grinding

VALVA-1/S1 + disk grinder

turning

lathe
SPM-600
SPM-800

15

R E N O V A T I O N O F S E A T S (R E S U R F A C I N G)

with turning head (option)

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G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

page 15/15

GROUP 5
OTHER SEALING SEATS

5.1

working of tube ends for metallic lens type gaskets (=140 to

DIN2696)

5.2 working of flanges with annular sealing groove

DN (
)

EFCO
surfac
e

procedure

repair machines

20

25

SLIGHT
1

grinding

50

TO

80

100

150

SEVERE

200

300

400

500

600

800

1000 1200 1500 2000

On
site

In
shop

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DAMAGE

VALVA-S1 + LS-tools
VALVA-S15 + LS-tools

RENOVATION OF SEALING SURFACES

turning

2
3
4

grinding

TDF-05 +taper head

TDF-05A + taper head
TDF-1
+ taper head
TDF-1A + taper head
TDF-2
+ taper head
TDF-3
+ taper head
TD-1
+taper turning tool
TD-2
+taper turning tool
TD-3 E
SPM-600
SPM-800
VALVA-S1 + LS-tools
VALVA-S15 + LS-tools

250
250

700

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In constant aim to improve our products, we preserve the right to change the technical specification without prior notice.
EFCO VALVA TEST BENCHES
(Standard- und special design)

For testing flanged and welded valves

For testing safety valves
For testing pressure regulating valves
EFCO booster units

G:\TB\TEXTE\EMPFEHLU.NG\REP-EMPF.DOC

Recommendation for the repair of valves using EFCO machines

LEGEND
VALVA
VSK-TOOLS
VSK-TOP SEGMENTS
VSA
SL
HSS
TD
TDF
TSD
FLM
KS
SM
SPM
MK
ENT
LS
KDM
PS

Portable grinding and lapping machine for valves and flanges

Special tools for grinding conical seatings
Conical top segments
Portable high-speed grinding machine for valves and flanges
Portable gate valve grinding and lapping machine
Portable high-speed gate valve grinding machine
Portable turning machine for working sealing seats and drill holes
Portable turning machine for working flanges
Portable gate valve turning machine
Stationary face lapping machine
Grinding table for wedges and disks
Stationary grinding and lapping machine
Stationary turning, grinding and lapping machine
Adapter for grinding and lapping wheels
Tilt tables
Special tools for working metallic lens type gaskets and tube ends
Flange coupling boring machine
Valve test benches

page 16/15