ITT FABRI-VALVE XS150 User manual

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Engineered Valves
1110 Bankhead Avenue
Amory, MS 38821
Tel: [phone]
Fax: [phone]
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Figure XS150 - ULV (Urethane Lined Valve)
FABRI-VALVE®BI-DIRECTIONAL HIGH PERFORMANCE KNIFE GATE VALVE
TABLE OF CONTENTS
0.0 GENERAL ...................................................................................................................2
1.0 INSTALLATION ...........................................................................................................3
2.0 OPERATION AND ADJUSTMENT..............................................................................6
3.0 MAINTENANCE...........................................................................................................6
3.1 Periodic Inspection.................................................................................................6
3.2 General ..................................................................................................................7
3.3 Lifting .....................................................................................................................8
3.4 Packing Adjustment ...............................................................................................9
3.5 Lubrication (Stem & Stem nut) ..............................................................................10
3.6 Electric Actuators...................................................................................................10
3.7 Seal Replacement..................................................................................................10
3.8 Setting of Valve Stroke...........................................................................................11
3.9 Transport and Storage...........................................................................................11
4. SERVICE / SPARE PARTS...........................................................................................12
4.1 Recommended Mating Flange Fasteners..............................................................12
5. EXPLODED VIEW .........................................................................................................13

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0.0 GENERAL
The latest edition of this manual can be found on the website listed on page 1 or the back page.
0.1 Safety
The safety precautions in these
operating instructions are specially
marked with the standard symbol for
danger when non-observance could
result in personal injury, loss of life
or property damage.
Non-observance of these safety
precautions can endanger the valve
and its functions.
0.1.1 Qualifications and training of personnel
The personnel responsible for operation, maintenance, inspection and assembly must be
appropriately qualified.
The operating company must precisely define the responsibilities, competence and supervision of
the personnel. If the personnel lack the necessary knowledge, they are to be trained and
instructed. If required this can be carried out by the manufacturer/supplier of the valve by order of
the operating company. Furthermore, the operating company is to ensure that the contents of the
operating instructions have been fully understood by the personnel.
0.1.2 Dangers through non-observance of the safety precautions
Failure to observe all of the safety precautions can result in the endangering of lives as well as
the environment and the valve. The non-observance of the safety precautions can lead to the
loss of all claims for damages.
0.1.3 Safety precautions for the operating company/individual operator
- If hot or cold components of the valves are a source of danger, these components must be
secured against contact by operating company.
- Contact guard for moving parts may not be removed when valve is in operation.
- Do not hang items off the valves. Any accessories must be firmly or permanently attached.
- Do not use the product as a step or hand hold.
0.1.4 Safety precautions for maintenance, inspection and assembly
Work on externally actuated valves should only be carried out when the valve is removed from
service.
On completion of work, all safety and protective equipment must immediately be fitted again or
reactivated.

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0.1.5 Unauthorized reconstruction and manufacture of spare parts
Reconstruction or modification of the valve or any component is only permissible after consulting
the manufacturer. Genuine spare parts and accessories authorized by the manufacturer serve to
maintain safety. The use of other parts can annul all liability for the consequences.
0.1.6 Inadmissible modes of operation
The operating limits given on the identification tag and in the data sheet may not be exceeded
under any circumstances.
If the product label or identification tag is missing or worn contact manufacturer at the address
listed on page 1 or the back page for specific instructions.
1.0INSTALLATION
Any flange or pipeline welding should be done prior to installation of the
valves.
Valve liner and seat can be damaged by excessive heat.
The XS150-ULV is NOT suitable for “Dead-End” service. Installation at
the end of a pipeline requires the use of a blind or “donut” flange. Failure to
do so will damage the valve liner and seat.
Valves supplied with spring to close cylinders are shipped with a gate stop
bracket. This bracket must be removed after installation of valve between 2
mating flanges. If bracket is removed prior to installation damage to liners
and seal may occur.
The XS150ULV was designed for use with metal mating flanges meeting
ANSI B16.1, either flat faced or raised face.
Fiberglass flanges: Consult with the Fiberglass Flange manufacturer to
determine if support rings are required for use with raised-faced flanges.
Rubber lined pipe with rubber lined mating flanges: Load distribution
rings are required for raised face valves if installed in this application.
Consult factory for details.

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14” – 24” valves should be installed in a “stem vertical”
position when in a horizontal pipeline. Accelerated wear
will occur on the seal if the valve is installed in any other
orientation:
Fabri-Valve XS150 ULV Recommended Flange Gaskets
Note: The XS150 includes an integrated O-ring seal. Flange Gaskets are not
required. In some cases a gasket may be used if the o-ring is damaged or missing.
Standard
Flat Face VALVE Flanges Optional Raised Face VALVE Flanges
Mating Pipe Flanges
Standard
Installation
NO Flange
Gaskets
NON-Standard
Installation
Compressible
Gasket with each
mating flange
Standard
Installation
NO Flange
Gaskets
NON-Standard
Installation
Compressible
Gasket with each
mating flange
Standard Metal Raised
Faced Pipe Flanges OK Not Recommended (1) OK Not Recommended (1)
Metal Flat Face pipe
flanges OK OK
only with full face gasket OK
Not Recommended (1)
Rubber-lined pipe and
end flange OK OK
only with full face gasket Not
Recommended (1) Not Recommended (1)
Fiberglass or Plastic
Flat-Faced pipe
flanges OK OK
only with full face gasket Not
Recommended Not Recommended
(1) OK with Load Distribution Ring
1.1 Check to ensure that the o-ring face seal on each face of the valve is in place and undamaged.
The use of flange gaskets may affect valve performance and shorten the life of
the valve liner.

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1.2 The valve should be tightened between flanges using appropriate fasteners for the service, in
compliance with applicable piping codes and standards.
1.3 Bolt the valve to the mating flange using proper size bolts and/or studs. If stainless bolts or studs
are used, lubricate threads to prevent galling.
Recommended fasteners are listed in Section 4.1
1.4 When tightening flange bolts, work from side to side in an alternating sequence to ensure even
compression of the O-ring or gasket. See Figure 1
1
8
3
52
7
4
6
FIGURE 1: FLANGE BOLTING SEQUENCE
1.5 If there is seepage past the chest seal upon installation, the valve may have been subject to wide
temperature variations during shipment. Leak tight performance can be restored by the simple
packing adjustment procedure in the Maintenance Section 3-4.
NOTE: All valves are pressure and seat tested before shipment.
1.6 If the valve is installed in horizontal position and an actuator is included with the valve, support of
the actuator may be required. Consult the factory for technical advice.
1.7 Air operated valves must be supplied with clean, dry, regulated air.
WARNING: MATING PIPE FLANGES SHOULD BE TIGHT AGAINST THE
VALVE FLANGES TO PROPERLY ENERGIZE THE O-RING FLANGE SEAL.
PROCESS PRESSURE SHOULD BE BROUGHT UP SLOWLY TO CHECK FOR
LEAKS BETWEEN THE VALVE AND PIPE FLANGES. SERIOUS INJURY OR
DEATH COULD RESULT FROM MEDIA LEAKAGE BETWEEN THE PIPE
FLANGES AND THE VALVE.
WARNING: VALVES THAT ARE SUPPLIED WITH CYLINDERS ARE SIZED
FOR A SPECIFIED PRESSURE. EXCESSIVE PRESSURE COULD RESULT IN
SERIOUS PERSONAL INJURY OR MAY CAUSE DAMAGE TO THE VALVE
AND/OR CYLINDER. AIR REGULATORS AND AIR FILTERS ARE AVAILABLE
FROM YOUR ITT DISTRIBUTOR.

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2.0OPERATION AND ADJUSTMENT
2.1 All valves are pressure and seat tested before shipment and an inspection tag is attached.
The Packing may require some adjusting after line pressure is up to normal.
Tighten the packing bolts just enough to stop leakage. All four packing screws must be
adjusted equally to maximize the life of the valve. Over tightening may cause binding and/or
rapid wear.
3.0MAINTENANCE
ALL MAINTENANCE PROCEDURES MUST BE PERFORMED BY QUALIFIED
PERSONNEL. MAINTENANCE DONE BY PERSONNEL NOT QUALIFIED TO PERFORM IT
COULD RESULT IN PERSONAL INJURY, DEATH OR PROPERTY DAMAGE.
3.1 Periodic inspection
WHEN THE PROCESS FLUID IS HAZARDOUS OR CORROSIVE, EXTRA
PRECAUTIONS SHOULD BE TAKEN. THE USER SHOULD EMPLOY
APPROPRIATE SAFETY DEVICES AND SHOULD BE PREPARED TO CONTROL
A LEAK OF THE PROCESS FLUID. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH,
AND PROPERTY DAMAGE.
Periodically inspect condition of external valve parts. Replace all parts showing excessive wear or
corrosion. Contact manufacturer at the address listed on page 1 or the back page in order to obtain
replacement parts or for specific instructions.
The “closed position” stop is set at the factory to provide tight
shutoff. DO NOT OVERRIDE. “Over-closing” the valve may cause
the gate to over-compress the seat and damage the seat.
NEVER USE UNAPPROVED MEANS OF ACTUATING THE VALVE. THE
USE OF A “CHEATER BAR” TO OPERATE MANUALLY OPERATED
VALVES COULD LEAD TO SERIOUS INJURY AND PROPERTY DAMAGE.
REMOVE ALL LINE PRESSURE BEFORE SERVICING VALVE.
REMOVE ELECTRICAL, PNEUMATIC OR HYDRAULIC POWER TO THE
VALVE ACTUATOR BEFORE PERFORMING ANY MAINTENANCE.

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3.2 General
3.2.1 Maintenance on the XS150-ULV is a straightforward procedure. To assist in the proper
assembly of the valve after maintenance, it is recommended that the user NOT make
adjustments to the stem clamp (on actuated valves) or the upper stop collar (on manually
operated valves.) This will help insure that the valve stroke is correctly set upon re-
assembly.
3.2.2 The rubber seal should be replaced whenever the urethane liners are replaced to insure
optimal performance of the valve.
3.2.3 An appropriate lubricant should be applied to the gate and seal if the valve is going to be
cycled dry. Dry cycling the valve will lead to premature seal wear and could affect smooth
operation of the valve.
3.2.4. Never remove the yoke or actuator while the valve is installed in a pipeline.
NEVER PLACE FINGERS OR HANDS INSIDE THE VALVE YOKE WITHOUT AN
APPROPRIATE LOCK-OUT DEVICE INSTALLED ON THE VALVE. EVEN IF
POWER TO THE ACTUATOR HAS BEEN DISCONNECTED, THE GATE CAN
STILL MOVE AND CAUSE SERIOUS INJURY TO FINGERS AND HANDS.
ALWAYS USE THE HANDWHEEL RIM TO OPERATE MANUALLY ACTUATED
VALVES. USING ANY OTHER PORTION OF THE MANUAL ACTUATOR COULD
CAUSE PERSONAL INJURY.

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3.3 Lifting - General
DO NOT LIFT VALVES BY THE HAND WHEEL
USE LIFTING EQUIPMENT RATED FOR THE WEIGHT OF THE VALVE
ASSEMBLY
Route lifting
strap under
yoke
Attach lifting
eyes here
DO NOT
remove or
adjust retaining
nuts

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3.4 PACKING ADJUSTMENT (Injectable)
3.4.1 The packing adjustments to the XS150-ULV can be made while the valve is under working
pressure. Read the entire warning below.
3.4.2 Occasionally, the XS150-ULV’s chest seal may require an adjustment. To adjust the
XS150-ULV’s chest seal, inject small amounts of the packing material through each of the
injection holes until the leak stops. Inject just enough packing to stop leakage. Over
packing the chest seal may cause undue pressure against the gate making the valve
difficult to operate and cause rapid chest seal wear. If possible, stroke the valve a few
times before injecting packing. IMPORTANT: Packing must be added evenly to all four
ports to evenly load the chest seal.
3.4.3 Determine the location of the leak and slowly tighten the nearest packing injection bolt. If
this bolt is already bottomed out, new packing will have to be injected into the seal cavity.
Slowly remove the packing injection bolt that is closest to the leak. Read the entire
warning below.
REMOVE THE PACKING SCREWS VERY SLOWLY AND WATCH FOR
ANY SIGNS INDICATING LEAKAGE PAST THE PACKING BOLT. IF
ANY LEAKAGE PAST THE PACKING BOLT IS OBSERVED WHEN THE
BOLT IS BEING REMOVED, QUICKLY SCREW THE BOLT BACK TO ITS
FULL DEPTH. THE PIPELINE WILL NEED TO BE DE-PRESSURIZED
BEFORE THE VALVE’S CHEST SEAL CAN BE REPACKED.
3.4.4 Inject small amounts of packing by placing it in the hole and slowly pushing it into the
valve.
NOTE: A simple re-packing tool will be required for packing the valve. This packing tool
can easily be fabricated on the job site. Use a piece of rod or a round shank screw driver
with the end cut off or a 3/16” Allen wrench to force the packing into the lateral seal. (The
tool diameter should be approximately 0.21”) The shank length of the tool should be at least
5” long. If you make the tool yourself, grind a small chamfer on the end of the tool to prevent
damaging the threads in the injection holes.
3.4.5 Replace the packing injection bolt and tighten until snug. Inspect for leaks. If leaks
continue, repeat step 3.4.4 until the leak stops. Care should be taken not to over fill the
lateral seal with packing as this could lead to premature failure due to wear against the
gate.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE REMOVING THE
PACKING BOLTS. WEAR PROTECTIVE CLOTHING AND EQUIPMENT
NORMALLY REQUIRED TO AVOID INJURY FROM THE PARTICULAR
FLUID IN THE LINE. WEAR PROTECTIVE CLOTHING AND PROTECTIVE
EQUIPMENT THAT SAFEGUARDS EYES, FACE, HANDS, ALL SKIN AND
LUNGS. IF THERE IS ANY DOUBT, CONTACT THE PROPER
SUPERVISOR IMMEDIATELY.

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3.5 LUBRICATION (STEM & STEMNUT)
The stem and stemnut are lubricated at the factory before shipment. However, these parts
should be lubricated periodically to prevent wear and to minimize operating forces. Some
recommended lubricants are:
CHEVRON INDUSTRIAL GREASE-MEDIUM
TEXACO MOLYTEX GREASE #2
MOLY XL 47-F2-75
FEL-PRO C5-A COMPOUND
3.6 VALVES WITH ELECTRIC ACTUATORS
Valves with electric motors should be set up as positioned limit closed.
3.7 SEAL REPLACEMENT
1. Valve must be completely disassembled to remove and replace the valve seal.
2. Clean the gate and smooth any marred or rough surfaces by using a scotch-brite pad. It
should be free of grooves and scratches. Set the gate aside until re-assembly.
3. Reassemble the valve as shown on Page 13.
4. Repack the valve by using the packing replacement procedure (See Section 3.4).
5. Replace the two o-ring seals on the flange faces by using a bonding agent such as loctite
380. Apply a small amount of glue in the groove to hold the o-ring in place during valve
intallation. Mating flanges should be metal raised face or flat faced.
6. On handwheel actuated valves, reconnect the non-rising stemnut back to the gate by using
the non-rising stemnut fasteners. There is no stroke adjustment necessary for handwheel
actuated valves. Proceed to step 26.
7. On cylinder actuated valves, insert the gate clamp bolt(s) through the gate clamp to secure
the gate into place. Adjust the stroke per Section 3.7, then continue at step 26.
8. On bevel gear actuated valves, reconnect the gate clamp back to the gate by using the gate
clamp fasteners. Adjust the stroke per Section 3.7, then continue at step 26.
9. Adjust the packing for tight shutoff when the valve is installed and pressurized to operating
pressure. See Section 3.3.
10. Maintenance manuals for cylinders, electric motors, and other accessories are available from
the factory.

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3.8 SETTING VALVE STROKE
On bevel gear actuated valves, adjust the top stroke limiter to allow compression of the
seal at the bottom of the port as follows: lower the gate until the lockout pin just clears the top of
the gate while in the lower lock-out hole. This is the proper closed position.
On cylinder actuated valves, close the valve and inspect the seal compression at the
bottom of the port. This compression should be the same as on bevel gear actuated valves.
Adjustments to seal compression can be made by either screwing the gate clamp in or out of the
cylinder rod. When the compression is set, install the gate clamp nut(s) on bolt(s) and tighten.
Then tighten jam nut against cylinder rod.
3.9 TRANPORT AND STORAGE
3.9.1 Transport
The goods have to be carefully handled in order to prevent damage. Valves to be handled with
care to prevent damage during shipping. Valves are to be lifted from pallets only as specified in
section 3.3
The end flange caps supplied are to be fitted to the valve as applicable.
3.9.3 Storage
If the valve is not to be installed immediately following delivery, it must be properly stored.
If the valve is to be stored for an extended period of time before installation, the valve
should be stored in accordance with ITT’s Long Term Storage Procedure. Contact the
manufacturer using the information on page 1 to obtain this procedure.
In general, the valve should be stored in a vertical position and in a cool, clean area to
prevent damaging effects on the chest and gate seal.
Storage should be in a dry temperature controlled enviroment. Product should not be
stacked on top of one another.
3.9.4 Disposal, Recycle or Return shipment
The personnel responsible for disposal of the product or associated components are to comply
with federal, state and local requirements.
If the return shipment is required, contact manufacturer at the address listed on page 1 for
specific instructions.
Valves must be cleaned of all hazardous material before any maintenance is performed or valve
is returned to manufacturer. An MSDS is required for all materials used in valve before it can be
returned to the manufacturer.
FAILURE TO ADJUST CLOSED POSITION PROPERLY MAY CAUSE
LEAKAGE, DAMAGE, OR PREMATURE FAILURE OF SEAL.

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4.0 SERVICE / SPARE PARTS
Size Seal Material
One Piece Perimeter & Chest Seal Packing Liner
Inches DN Aflas Viton EPDM Urethane
2 50 155512 155524 155500 137375 159800
3 80 155513 155525 155501 “ 159801
4 100 155514 155526 155502 “ 159802
6 150 155515 155527 155503 “ 159803
8 200 155516 155528 155504 “ 159804
10 250 155517 155529 155505 “ 159805
12 300 155518 155530 155506 “ 159806
14 350 155519 155531 155507 “
16 400 155520 155532 155508 “
18 450 155521 155533 155509 “
20 500 155522 155534 155510 “
24 600 155523 155535 155511 “
4.1 Recommended Mating Flange Fasteners
TABLE 1: Recommended Fasteners
Size
Inches DN Fastener
Diameter &
Thread
Total No. of
Fasteners
No. Tapped Holes
in Valve Chest Stud Bolt Length (min) Machine Bolt Length (min)
2* 50 5/8-11 UNC 8 4 3.25" 1.50"
3* 80 5/8-11 UNC 8 4 3.75" 1.50"
4* 100 5/8-11 UNC 16 4 3.75" 1.50"
6 150 3/4-10 UNC 16 4 2.75" 1.50"
8 200 3/4-10 UNC 16 4 4.25" 2.00"
10 250 7/8-9 UNC 24 8 4.75" 2.00"
12 300 7/8-9 UNC 24 8 4.75" 2.25"
14 350 1-8 UNC 24 8 5.25" 2.50"
16 400 1-8 UNC 32 12 5.50" 2.50"
18 450 1-1/8-7 UNC 32 12 6.00" 2.75"
20 500 1-1/8-7 UNC 40 16 6.25" 2.75"
24 600 1-1/4-7 UNC 40 16 7.00"" 3.00"
* denotes flat face flange style
The bolt and stud lengths below assume that the mating flange thickness meets
ANSI B16.5 for flat-faced, class-150 flanges.
If raised face flanges, load distribution rings, or support rings utilized, the fastener
lengths MUST be adjusted to maintain the desired thread engagement.
Increase or decrease fastener lengths as necessary to ensure proper thread
engagement.
Damage to the valve body may occur if a flange bolt is “bottomed out”
in a tapped hole. Use of studs is highly recommended in tapped holes.

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5. EXPLODED VIEW