Mission Works, Birds Royd Lane, Brighouse,

West Yorkshire. UK. HD6 1LQ

Tel: 01484 710511 Fax: 01484 713009
e-mail: uk@alco-valves.com www.alco-valves.com

MAINTENANCE INSTRUCTIONS

Needle Valve Maintenance Instructions

Copyright Alco Valves Group  2009

Revision Date Prepared by Signed by Checked by

1.0 Introduction

1.1 Alco needle valve bonnet assemblies are metal seated with a free swivel tip
configuration. The tip provides sealing on a line contact at the orifice while PTFE
or Graphite gland packings provide an adjustable stem sealing arrangement. For
maximum pressure and temperature ratings please refer to applicable General
Assembly drawing or valve data sheet. Please note that the enclosed instructions
are for a single bonnet assembly only and may be required to be repeated or
used in conjunction with other instructions dependant upon the type of valve or
manifold being refitted.

2.0 Installation

2.1 Exercise proper care and attention at the time of installation to ensure
increased probability of trouble free service from the valve.
2.2 Unpack the valve or manifold and check the nameplate or body stamping for
correct part / identification number.
2.3 Check the valve or manifold for a flow indication arrow / schematic detail or
the identified Inlet and Outlet connections. If no flow is indicated on the valve or
manifold refer to the relevant General Assembly drawing.
2.4 Immediately prior to installation check the piping to which the valve or
manifold is to be connected, for cleanliness and freedom of foreign matter.

3.0 Threaded Valve / Manifold Installation

3.1 Pipe or fittings must be made up tight. Threaded pipe joints depend on a
good intimate fit between the male and female threads. For taper threads this is
usually assisted by the use of a thread tape or sealant. Check the threads on
both the valve and the mating pipe or fitting for both cleanliness and form. Do
not use substantial wrench force particularly tapered threads until it is apparent
that the threads are properly engaged. Taper pipe threads are an inherently
loose fit at entry. Pipe / tube fittings should be assembled in accordance with the
manufacturer's instructions.

4.0 Welded Valve / Manifold Installation

4.1 Welded joints correctly made, provide a structural and metallurgical

continuity between the pipe and the valve / manifold. All welding should be in
strict accordance with the appropriate site welding codes / instructions.

5.0 Flanged Valve / Manifold Installation

5.1 Prior to assembly, the mating flanges should be checked to ensure correct
sizing and rating. Flange joints should be assembled using the correct gasket /
seal ring and bolting as specified within the relevant flange specification e.g.
ANSI B16.5.

Copyright Alco Valves Group  2009

Revision Date Prepared by Signed by Checked by

 Procedure
Ensure all parts are free from dust, grit or other foreign material. Fit new seals throughout. Alco Valves
Ltd. can supply the necessary valve repair kits. Please contact Alco Technical Sales Office.

To replace Alco Valves needle valve seals

1. Undo and remove the capscrew (12) and the locking cam (11).
2. Undo and remove the needle head from the body (1) and remove the ingress seal (13).
3. Place the needle head into a vice.
4. Undo and remove the handle bolt (8) and pull off the handle (7) from the stem (4).
5. Slacken the gland adjuster locknut (5).
6. Slacken and remove the gland adjuster (6).
7. Withdraw the stem (4) from the bonnet housing (3).
8. Prise and scrape out stem seals (10) from the bonnet housing (3) and ensure area is clean and free
from debris.
9. Place in new stem seals (10) into the bonnet housing (3).
10. Replace the stem (4) into the bonnet housing (3) ensuring the seals (10) remain in place.
11. Fasten in gland adjuster (6) against the seals to torque 25Nm.
12. Fasten gland adjuster locknut (5) against the bonnet housing (3).
13. Place the new ingress seal (13) into position over the bonnet housing.
14. Screw the needle head into body (1) and tighten to torque 80Nm.
15. Replace the locking cam (11) and the cap screw (12) onto the Alco Valves body.
16. Replace the handle (7) onto the stem (4) and tighten the handle bolt (8).

Copyright Alco Valves Group  2009

Revision Date Prepared by Signed by Checked by

 OPERATION, INSTALLATION AND MAINTENANCE INSTRUCTIONS

Safety Notes:

1. All adjustments should be carried out by qualified personnel with the valve at zero pressure.
2. End connections must not be removed from bodies.
3. Handle wrenches / Extensions must not be used to operate these valves.
4. Vent plugs must not be removed when the isolate valve is open and under pressure.
5. Head units and locking cams must not be removed once installed.
6. Maximum torque to be applied to tee-bars is 10lb ft.
7. Valves must be suitably supported in service.
8. Needle valves : No excessive forces (45nm) to be applied to the head unit.
9. Ball valves : No excessive forces to be applied to the handle/handle locking arrangement.
10. Do not paint over valve body markings.

WARNING
Personal injury could result from packing leakage. The valve packing was tightened before shipment;
however, the packing might require some readjustment to meet specific service conditions. Refer to the
product maintenance instructions for details on adjustmant and replacement for the packing fitted.

OPERATING INSTRUCTIONS

NEEDLE VALVES - Approximately 6 turns from open to closed, clockwise to close.

RISING PLUG VALVES -
MINI NEEDLE VALVES -
OUTSIDE SCREW & YOLK VALVES -
BALL VALVES AND MINI BALL VALVES -
Approximately 6 turns from open to closed, clockwise to close.
Approximately 4 1/2 turns from open to closed, clockwise to close.
Approximately 8 turns from open to closed, clockwise to close.
1/4 turn from open to closed, clockwise to close as standard, (i.e. Valve is
closed when handle is at 90 ° to the valve body).

NOTE - The packing on these valves is adjustable, so turns between open and closed will vary slightly from valve to valve.

All valve bodies show our company name, maximum cold working pressure, valve material, the valve part number and also
a trace code number which relates to the material certificates from the particular valve.

INSTALLATION AND MAINTENANCE INSTRUCTIONS

NEEDLE VALVES - If a new head unit is supplied, the head unit is installed as follows -

1. Ensure that the spindle is fully retracted into the head unit so the tip is hardly showing.
2. If the head unit is stainless steel, please ensure that copper lube is applied to the 5/8" UNF thread prior to engaging
the valve body.
3. Screw head unit down and torque to 65 N/Metres.
4. Replace locking cam and screw in the 5mm hole and secure.
5. Replace handle and tighten handle bolt.
6. Adjust packing if required by loosening the lock nut (bottom nut on head unit). Close the valve by turning the tee
handle in a clockwise direction until it stops. Open the valve one full turn (turn tee handle anti-clockwise). Tighten
down the gland adjuster (top nut on head unit) which compresses the packing until the valve does not feel to slack
or difficult to operate, then tighten down the lock nut.
7. If valve packing is Graphoil wait two minutes after tightening the gland adjuster and before checking valve
operation.

IMPORTANT NOTE:
Needle valves supplied with socket weld or butt weld ends, that are not of a specifically extended end
design, are supplied with loose assembled bonnets and are supplied factory set without test . The bonnets
must be removed during installation / welding process to protect the seals and replaced afterwards with
any necessary adjustment to the gland being made to suit process conditions
 OPERATION, INSTALLATION AND MAINTENANCE INSTRUCTIONS Cont.

RISING PLUG VALVE - Adjust the packing if required by loosening lock nut (bottom of head unit) and tighten down the
gland adjuster (top nut on head unit) while compresses packing until the valve feels not too slack or difficult to operate,
then tighten down lock nut.

BALL VALVES / MINI BALL VALVES - No maintenance required but repair kits can be supplied.

MINI NEEDLE VALVE - No maintenance require but repair kits can be supplied.

OUTSIDE SCREW AND YOLK VALVE -

SAFETY NOTE : These operations must be carried out at zero pressure and ambient temperature.

1. To adjust RTFE packing close the valve by turning the tee handle in a clockwise direction until it stops. Do not
exceed 10lb ft torque. Open the valve one full turn (turn tee handle anti-clockwise). The two packing nuts either
side of the spindle must be adjusted evenly to keep the gland bridge square and compress the gland packing till the
valve feels not too slack or difficult to operate.
2. If the valve packing is graphoil, wait two minutes after tightening the two nuts before checking valve operation.
Carry out operation No.1 if required.

GAUGE VALVES AND RELIEF VALVES - Are pre-set in our premises and must not be adjusted or interfered with in any
way.

SOUR GAS SERVICE

Valves can be manufactured for sour gas service in accordance with NACE MR-01-75 latest revision.

GAS SERVICE

Various soft tips can be offered for example, Peek for NACE applications as opposed to the standard hard tip.

VALVE MATERIALS

Alco Valves Ltd. Offer valves to meet customers material specifications. We do not however specify materials for
suitability with process media ourselves.

MANIFOLDS

Direct mounted manifolds are supplied as standard with high tensile carbon steel bolts and sealing kits. (other manifolds
which have vent valves are supplied with pressure plugs as standard).

MATERIAL CERTIFICATION

Valve bodies are stamped with a trace code which is linked to the material certification. Alco Valves standard material
certification is to EN 10204 3.1B. Certification is available at a nominal charge.
Test certification is also available for the hydrostatic test at 1 1/2 times the ambient working pressure, the seat test at
ambient working pressure and for ball valves a 100psi low pressure test is also carried out.

FIRESAFE VALVES

Needle and ball valves can be supplied firesafe in accordance with BS 6755 Part 2.

QUALITY ASSURANCE

Valves are manufactured to BS EN ISO 9002 levels of quality assurance.

REV.1 13.04.06 FOR FURTHER INFORMATION PLEASE CONTACT THE FACTORY