Comeval UNIFLOW PP Series Installation guide

IOM - SLEEVED PLUG VALVES, UNIFLOW PP
©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - SLEEVED PLUG VALVES, UNIFLOW PP - Ed.16/05 Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es
INSTALLATION, OPERATING
AND MAINTENANCE MANUAL
SLEEVED PLUG VALVES
1.0 GENERAL INFORMATION ON THE MANUAL........2
2.0 NOTES ON POSSIBLE DANGERS..........................2
2.1 Signicance of symbols ..........................................2
2.2 Explanatory notes on safety information..................2
3.0 PRESERVATION, STORAGE AND TRANSPORT...2
4.0 DESCRIPTION...........................................................2
4.1 General Description..................................................2
4.2 Area of Application...................................................2
4.3 Operating principles.................................................2
4.4 Technical data – remarks.........................................2
4.5 Marking/nameplate...................................................3
5.0 INSTALLATION.............................................................3
5.1 General remarks on installation...................................3
5.2 Assembling additional modules...................................4
5.3 Requirements at the place of installation.....................4
6.0 COMMISSIONING.........................................................4
7.0 CARE AND MAINTENANCE.........................................5
8.0 TROUBLESHOOTING...................................................5
9.0 TROUBLESHOOTING TABLE......................................6
10.0 DISMANTLING THE VALVE.......................................6
11.0 WARRANTY / GUARANTEE......................................7
12.0 PARTS LIST.................................................................8
Contents
Series UNIFLOW PP

IOM - SLEEVED PLUG VALVES, UNIFLOW PP
©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - SLEEVED PLUG VALVES, UNIFLOW PP - Ed.16/05 Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es
1.–GENERAL INFORMATION ON THE MANUAL
- This Manual provides information on safely mounting and maintaining the product. Please contact the supplier or the
manufacturer in case of problems which cannot be solved by reference to this Maual.
- This Manual is binding for transport, storage, installation, commissioning, operation, maintenance or repair.
- Manual must be read before commissioning the valve.
- The notes and warnings must be observed and complied with.
- Handling and all other work must be carried out by specialist personnel, or all the activities must be supervised and
inspected.
- It is the owner’s responsibility to dene areas of responsibility and competence and to monitor the personnel.
- In addition, current regional safety requirements must be always applied and observed, also when decommisioning,
maintaining and repairing the valves.
- Any deviation from this Manual or from usual installation guidelines should be notied to us for recommendation and
approval.
- The manufacturer reserves the right to make technical modications at any time.
- This Manual complies with the requirements of EU Directives.
2. – NOTES ON POSSIBLE DANGERS
2.1 Signicance of symbols
ATTENTION!
. . . Warning of general danger
2.2 Explanatory notes on safety information
In this Manual dangers, risks and items of safety information are highlighted to attract special attention.
Information marked with the symbol above describes practices, which if fail to comply with, can result in serious injury or
danger of death for users or third parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
All other information not specically emphasized, as well as technical data in Data Sheets and product marking, must
also be observed and complied with to the fullest extent in order to avoid faults which in turn can cause serious injury to
persons or damage to property.
3. – PRESERVATION, STORAGE AND TRANSPORT
- Use proper packing for transportation.
- Keep storage protection before installation.
- Keep the valves in full open (preferable) or full close position.
- In order to prevent damage, corrosion or rust on the surface, avoid extreme temperatures (keep at 5ºC to 50ºC), avoid
high environmental humidity or corrosive environment. Keep the valves away from direct sunlight, dust, ames or rain. Do
not pile up excessive weight. In case of severe bumping inspect the material for any damage and replace if necessary.
4. – DESCRIPTION
4.1 General Description
Plug Valves are rotary isolating valves featured by a tapered or conic perforated plug with uid owing through it. Sleeved
plug valves are tted with a tapered plastic sleeve compressed between the valve body I.D and the plug O.D.
Valve diagram with parts can be seen at the last page of the Manual.
4.2 Area of Application
Sleeved plug valves are primarily used on On/O󰀨 duties being well featured by its exible sealing and large sealing area
thus ensuring a full tightness in full quarter turn stroke. Operation of the valve in intermediate position to be avoided since
this would lead to increased wear.
4.3 Operating principles
The valves close by turning the handle 90º clockwise, with tightness achieved by friction of the plug to the sleeve. When
the handle is parallel to pipe the valve is open.
4.4 Technical data – remarks
For data such as main features, duties/limits of use, dimensions, weights, etc. refer to Data Sheet.
ATTENTION!
- Protect against external force (impacts, vibrations, etc.)
- Product parts such as levers, gears or actuators must not be used to take up external forces that they are
not designed for: e.g. do not use them as climbing aids, or as connecting points for lifting gear, etc.
- Allow only skilled personnel; suitable handling and lifting equipment must be used.
See data sheet for weights or consult manufacturer.
- Check correct position of nameplate and handle with care to avoid personnel cuttings.
Page 2

IOM - SLEEVED PLUG VALVES, UNIFLOW PP
©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - SLEEVED PLUG VALVES, UNIFLOW PP - Ed.16/05 Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es
4.5 Marking/nameplate
Nameplate description of the valve:
5. – INSTALLATION
5.1 General remarks on installation
The following points should be taken into account in addition to the general principles governing installation work:
- Valves should be installed with in open position, making sure that the parts are perfectly aligned. Tighten bolts in an
uniform and crosswise manner.
ATTENTION!
- Remove ange covers or any other remaining packing/storage protection if present.
- The interior of the valve and the pipeline must be free of foreign particles.
- Valves are normally bidirectional. Some special designs are unidirectional, in such a case please follow the arrow
in the body for ow direction.
- Lay pipelines such that damaging transverse, bending and torsional forces are avoided.
- Protect valves from dirt during construction work.
- Protect the valve soft parts from heating caused by welding works at the plant during commissioning.
- Product parts such as levers, gears or actuators must not be used to take up external forces that they are not
designed for: e.g. do not use them as climbing aids, or as connecting points for lifting gear, etc.
- Suitable materials handling and lifting equipment should be used for assembly work. During assembly work,
ensure that the valve is xed adequately. See data sheet for weights.
- Valve optimal position is horizontal with stem pointing upwards. Valves can alternatively be installed in vertical
pipelines. Try to avoid the stem pointing downwards.
- You must only operate the unmounted valve while observing all the safety measures.
- Avoid mechanical damage to the sleeve and plug during handling, storage and installation.
- Check correct position of nameplate and handle with care to avoid personnel cuttings.
- When the valve is operated, there is a crushing hazard between the plug and the sleeve. Ensure the valve is not
under operation in case hands are introduced inside the valve.
- When using the valve as an end seal, the employers’ liability insurance association of the gas and waterworks
species the use of a safety precaution such as a plug-in disc, blind ange, etc. (observe the information in EN
13857). With a medium jet that freely exists, you must secure the exit area.
- Make sure that counter-anges are compatible with the standard of the valve anges. When matching up anges,
avoid gradients, rotation and pipe misalignment that could cause pipe and valve stress and leakage once installed.
Flanges should t smoothly. Select the proper ange face gaskets according to duty and centre them on the ange
face properly. Do not force the counter-anges and do not try to tighten the bolts when a gap exists between valve
and pipe or if misalignment is observed. Tighten in a crosswise, moderate and uniform manner. During start-up
tighten again if leakage is noticed or replace gasket if necessary.
Actuator: If the valve requires pneumatic, electric or hydraulic actuators, separate actuator Manual shall be also
followed. To avoid unnecessary stress and risk of valve break, consider the weight and the relative position of
actuator to evaluate its support. Make sure that the actuator is suitable for service particular requirements, valve
adaptability, function needed, adequate torque for the valve, need for limit switches, etc. Contact our Technical
Department for advice. In case of actuator mounted, you must disconnect the energy supply before starting work.
Page 3
Mark Description
Manufacturer logo
www.comeval.es Website of manufacturer
FIG. Valve code
YY Manufacturing year
SN: ZZZZZZZ-N Batch / Serial no.
SValve size
C Valve class
B Body material
STEM Stem material
PLUG Plug material
SLEEVE Sleeve material
PSmax Max. pressure
TS Max. temperature at max. pressure
PS Max. pressure at max. temperature
TSmax Max. temperature
Example

IOM - SLEEVED PLUG VALVES, UNIFLOW PP
©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - SLEEVED PLUG VALVES, UNIFLOW PP - Ed.16/05 Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es
5.2 Assembling additional modules
Optional accessories (limit switches, extensions, etc.) that are supplied with valves must be tted as required for their
functions as shown in the system plan.
5.3 Requirements at the place of installation
- Aggressive environmental conditions may reduce the life span of the product.
- Consider the interaction between the system and the equipment. Foresee elements to absorb vibrations, pipe dilata-
tions, guides, anchoring and proper support according to the weight of the components.
- The system and operation protocol should be conceived in such a way to avoid high velocities and cavitation. Prevent
pulsing ow or water hammers, which are very harmful for valves and the rest of the components.
- Flooding of the product is not recommended.
- Allow enough space for valve installation, operation and maintenance.
- It is recommended to install a proper sized mesh strainer upstream the valve in order to protect seating surfaces from
abrasion or erosion that could lead to leakage.
- Planners / construction companies or the owner are responsible for positioning and installing products.
6. – COMMISSIONING
- Ensure valve surface is in good condition and retouch coating protection if any when needed.
- Valve operation, lling, warming-up and starting-up shall be gradual so as to avoid any inadmissible stress. Check for
tightness in valve connections, body/cover union, and stem, and retighten crosswise and gradually if necessary until
leakage elimination. When tightening gland packing make sure that operating torque is not signicantly a󰀨ected by over
tightening. If leakage persists surfaces should be thoroughly cleaned and new gaskets or packing rings correctly placed.
- Packing gland is tightened at factory in a moderate way to pass the pressure tests. After a while before installation, pac-
king rings experiment a relaxation and some retighten of the gland could be needed during start-up. Over tightening will
increase operating torque and will reduce life of the packing. Also after several open and close manoeuvres of the valve
the stem gains some play with the packing rings, thus packing tightness should be checked periodically and retighten
gradually when necessary.
- Once the valve installed, make an initial opening and closing operation to check its proper operability.
7. – CARE AND MAINTENANCE
The operator must dene maintenance and maintenance-intervals to meet requirements.
- Check for body and seat tightness and valve smooth operation without additional tools.
ATTENTION!
- Before commissioning the valve, check the material, pressure, temperature and other essential parameters.
Always use the product within the scope of intended service and operating duties.
- Before commissioning, make sure above chapters have been throughly followed.
- It is essential to ush the pipe system thoroughly to eliminate all the particles and impurities which could remain in
the pipes and particularly welding residue, chips, tool remains, etc. that could damage the equipment during start-
up. Ensure that during cleaning of the pipe system, any chemicals used and temperature are compatible with the
valve construction.
- Regional safety instructions should be adhered to.
- Temperatures above 50ºC or below 0ºC may cause personnel injuries if valves are touched. Ensure that the
corresponding warning signs are displayed on the valve or surrounding area, or isolate the equipment in case of
danger.
- Before commissioning a new plant or restarting it after repairs or modication, always ensure that:
- All work has been completed correctly!
- The valve is in the correct position for its function.
- Safety devices have been attached!
Page 4
ATTENTION!
- In the event of infrequent use, operate the valve as frequently as possible to avoid deposits of dirt and valve
blocking.
- When using the valve as an end seal, the employers’ liability insurance association of the gas and waterworks
species the use of a safety precaution such as a plug-in disc, blind ange, etc. (observe the information in EN
13857). With a medium jet that freely exists, you must secure the exit area.
- Before disassembling the valve, note chapters 10 & 11.

IOM - SLEEVED PLUG VALVES, UNIFLOW PP
©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - SLEEVED PLUG VALVES, UNIFLOW PP - Ed.16/05 Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es
- Check the valve surface inside and outsideand retouch coating protection if any when needed. If advanced corrosion
or erosion is observed, double check service and valve features and replace the valve properly.
- Sleeve, packing, gaskets, plug and stem can be easily dismounted by using common tools.
- In case of body/cover leakage, dismount the cover, remove old gasket, clean sealing surfaces and use a new gasket.
- In case of seat leakage, remove the valve cover to clean the seating surfaces or grind them if necessary. When mou-
nting the cover back use always new gasket, and tighten the cover bolts evenly crosswise with moderate and uniform
torque. Retighten them if leakage is detected under pressure. If it is not possible to repair the damages replace the valve
and contact us for assistance.
- If the valve is leaking through the stem, try rst to retighten the packing gland without compromising stem smooth mo-
vement. For this purpose turn clockwise all adjusting packing gland nuts little by little by 1/4-1/2 turn, evenly crosswise
each time until leakage disappears: In this way we minimize valve operation torque increase and optimize packing life.
- If leakage cannot be corrected, old packing must be replaced. Remove packing gland, remove old packing by means of
a wooden dowel, make sure that stem and packing area are thoroughly cleaned and place new packing rings ensuring
its correct position. If stem is worn out or scratched replace it. Then place back packing gland and tighten gland bolts
moderately.
- Disassembly / Assembly can easily be done by common tools. Herewith an explanation:
Before the top-works are removed from the plug valve, the manual operator (wrench, handlever, or gear operator) should
be removed. To ensure correct orientation of the operator durning reassembly, place temporary alignment marks on
the plug stem and the operator. This should not be a scatch mark, because that could cause a leak path on the sealing
portion of plug stem.
Once the operator is removed, the stop collar and/or any associated washers can be removed from the top-works. The
gland-ange bolting should be slowly loosened before removing the cover bolting. If no gland ange exists, the cover
bolting should be loosened. With the bolting loosened, the plug should be turned and slightly raised to vent any trapped
process uid in the valve.
The plug should be lifted straight up from the body, followed by inspection for any scoring or process damage, such as
erosion or cavitation. If the plug uses O-rings or sleeves as the primary sealing mechanism, the O-rings/sleeves should
be removed. If the plug uses lubricant as a sealant, remove any residue.
All disassembled parts should be cleaned thoroughly and then visually inspected for damage or wear. All parts with signi-
cant damage should be replaced as well as all soft goods (gaskets, diaphragms, O-rings, sleeve, etc.) The body should
be examined carefully for damage, and any external areas of oxidation should be repaired and repainted.
Using new soft goods, the O-rings/sleeves, the diaphragm, and / or packing should be replaced. Before replacing the
diaphragm and packing, however, the plug stem must be checked for any surface irregularities that could damage the
soft goods during installation. Any minor irregularities in the plug stem should be lightly polished. If major scoring exists,
the plug should be replaced. The diaphragm, packing, spring washers, thrust collars, etc., should be reinstalled on the
plug stem in the same order as they were removed. The assembled plug is then placed into the body or into the sleeve
inside the body.
The cover is then replaced, making sure that the diaphragm or gasket is in place to provide a seal between the body and
cover. The cover bolting can then be reinstalled, as well as the gland-ange assembly. At this point, the cover and gland-
ange bolting should be nger-tight. In a criss-cross manner, the cover bolting should be evenly tightened to the torque
values provided by the manufacturer. After the cover bolting has been reinstalled, the plug should be rotated several
times to ensure smooth stoking as well as correct orientation of the body, sleeve, and plug ports.
- If the valve was removed from the line, it should be reinstalled, using new ange gaskets.
After any maintenance work please refer to chapters 5 and 6 for installation / commissioning.
Recommended Spare parts:
Use only original spare parts.
It is advisable to keep packing rings gaskets and diaphragms as spare parts. Type and number of each spare part to be
stored according to many factors: service level, valves quantity, etc. In many cases a good choice is to keep complete
valves as spare part.
ATTENTION!
- In the event of infrequent use, operate the valve as frequently as possible to avoid deposits of dirt and valve
blocking.
- When using the valve as an end seal, the employers’ liability insurance association of the gas and waterworks
species the use of a safety precaution such as a plug-in disc, blind ange, etc. (observe the information in EN
13857). With a medium jet that freely exists, you must secure the exit area.
- Before disassembling the valve, note chapters 10 & 11.
Page 5

IOM - SLEEVED PLUG VALVES, UNIFLOW PP
©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - SLEEVED PLUG VALVES, UNIFLOW PP - Ed.16/05 Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es
8. – TROUBLESHOOTING
In the event of malfunction or faulty operating performance, check that the installation and adjustment work has been
carried out and completed in accordance with this Manual.
9. – TROUBLESHOOTING TABLE
Technical support always available through our website www.comeval.es or your local distributor.
10. – DISMANTLING THE VALVE
ATTENTION!
- Read chapters 10 & 11 before carrying out installation and repair work!
- Read chapter 6 before recommissioning!
Page 6
FAULT POSSIBLE CAUSE CORRECTING MEASURES
No ow
Not enough ow
Flange covers or protection not removed Clear valve entrances
Valve closed or almost closed Check valve position
Pipe system clogged Check piping system
Broken ange Bolts not properly tightened Re-align piping and t new valve
Mating anges not properly aligned
Leakage between body/
cover
Bolts loose or gasket damaged Retighten bolts or change gasket
Parts not well aligned Check alignment
Metal Sealing surfaces damaged Repair or change damaged surfaces
Leakage through the stem Normal wear after cycles or long time without
use
Retighten bolts
Packing or stem worn out or damaged Replace parts
Metal Sealing surfaces damaged Repair or change damaged surfaces
Valve not tight at closing Valve is not in closed position Check correct handle rotation
Dirt trapped between plug and sleeve Open to sweep dirty and close back
Install a strainer upstream
Seats damaged Machine plug or change seating parts
(sleeve and plug)
Plug surface damaged Repair or change plug
Too much pressure Check the system
Too high operating torque,
lever hard to turn
Packing too tight Check packing gland tightening
Packing rings damaged or with dirt Inspect and replace/clean parts
Stem is bended Replace stem
Sleeve damaged Repair or change sleeve
Too much pressure Check the system
ATTENTION!
The following points must be observed:
- Pressureless pipe system
- Medium must be cool
- Plant must be drained
- Purge pipe systems in case of toxic, corrosive, ammable or caustic media
ATTENTION!
- It is essential that the safety regulations are observed when identifying faults.

IOM - SLEEVED PLUG VALVES, UNIFLOW PP
©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - SLEEVED PLUG VALVES, UNIFLOW PP - Ed.16/05 Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es
11. – WARRANTY / GUARANTEE
- The extent and period of warranty cover are specied in the “General Sales Terms” of COMEVAL VALVE SYSTEMS
valid at the time of delivery or, by way of departure, in the contract of sale itself.
- We guarantee freedom of faults in compliance with state-of-the-art technology and the conrmed application.
- No warranty claims are accepted for any damage caused as the result of incorrect handling or disregard of operating
and installation instructions, datasheets and relevant regulations.
- This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid
down by specications or other agreements.
- Justied complaints will be eliminated by repair carried out by us or by a specialist appointed by us.
- No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is excluded.
- The warranty shall not cover maintenance work.
- Our guarantee coverage does not cover for any commissioning, maintenance or installation of the product or external
parts.
- Our guarantee does not cover products proved to have been tampered with or faulted by material wear and tear.
- The Purchaser is responsible for checking that the incoming product is received in good condition and conforms to the
ordered specications. In case of damage caused during transit it is necessary to immediately complain to the carrier
within 24 hours. After this time carriers could not assume the derived costs. In case of any deviation in relation to order
specications, please contact us.
Page 7
COMEVAL VALVE SYSTEMS, S.L. y CIA., Soc. Comanditaria
Les Rotes, 15 46540 El Puig (Valencia) España
Phone [phone] ·Fax [phone]
E-mail [email protected] -www.comeval.es

IOM - SLEEVED PLUG VALVES, UNIFLOW PP
©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - SLEEVED PLUG VALVES, UNIFLOW PP - Ed.16/05 Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es
12. – PARTS LIST
Nº PART
01 Body
02 Sleeve
03 Plug
04 Gasket
07 Cover
09 Packing
10 Gland
11 Adjusting bolts
12 Hand lever
18 Yoke
19 Worm gear
Page 8