Vag GA INDUSTRIES 517R User manual

INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
24”to 48”Figure 517R
Rectangular Port Plug Valves
TABLE OF CONTENTS
Introduction ….………………………… 1
Function ……………………....………… 1
Receiving & Storage .....……………… 1
Installation ......…………………………. 1
Operation …………........………………. 1
Valve Construction …………………….. 2
Start Up …………………………………. 2
Preventive Maintenance ....………….. 2
Trouble Shooting ...…………………… 2
Shaft Packing Replacement ………….. 2
Disassembly ....………………………… 3
Assembly ....……………………………. 3
Replacement Parts List ..……………… 3
Warranty .……………………………….. 3
Assembly Drawing/Parts Identification.. 4
234 Clay Avenue • Mars, PA 16046 USA
Telephone [phone] • Fax [phone]
E-mail: [e-mail]
Manual Number 517R-IOM-112222

1
INSTALLATION, OPERATION and
MAINTENANCE
GA Industries Figure 517R
Rectangular Port Plug Valves
INTRODUCTION
This manual will provide the information to properly install,
operate and maintain the valve to ensure a long service life.
The GA Industries Figure 517R Eccentric Plug Valves are
ruggedly constructed to provide years of trouble-free
operation with minimal maintenance.
WARNING
The valve is NOT recommended for use with
toxic or highly corrosive fluids, fuels or fluids
containing hazardous gases
The Shop Order (SO) Number, Figure Number, size and
pressure rating are stamped on a nameplate attached to the
valve. Please refer to the SO number when ordering parts.
FUNCTION
Figure 517R Eccentric Plug Valves are typically either fully
open or fully closed to isolate pipelines and equipment in
sewage and wastewater pipelines and treatment plants or on
sludge lines in water treatment plants. The valve can also
be positioned partially open to throttle flow. It can be
manually operated by turning the handwheel or 2”operating
nut on the worm gear actuator or automatically by an electric
motor, pneumatic or hydraulic actuator. The valve is
designed to accommodate solids and other matter that may
be present in sewage and sludge systems without clogging.
RECEIVING AND STORAGE
Inspect the valve upon receipt for damage during shipment.
Carefully unload all valves to the ground without dropping.
The valves should remain in a clean, dry, and weather
protected area until installed.
The valves should be stored with the plug partially open.
Replace any flange protectors that were removed for receipt
inspection.
INSTALLATION
These valves are large, heavy, and awkward to handle.
Ensure proper handling techniques are employed. Handle
heavy valves using slings around the valve body and/or by
the lifting eyes. Do not lift by the actuators or by slings or
chains through the port openings.
Prior to installation ensure all debris, packing material or
other foreign material has been removed from both ports.
Before installing, open and close the valve to ensure proper
operation. Close valve before installing in pipeline.
The valve is not designed to support adjacent equipment
and all piping must be supported to avoid imposing stress on
the valve. Do not “jack”mating pipes into position.
The valve should be oriented with the “Seat End”in the
proper direction. While the valve can operate with flow in
either direction it is typically installed with the seat end on
the downstream side of the flow.
When installed in horizontal pipes with fluids containing
suspended solids it is preferred, but not necessary, to install
the valve with the plug shaft horizontal so that the plug
rotates up and out of the flow path when open.
When installed in vertical pipes with suspended solids, the
valve should be installed with the seat end on the top side of
the valve regardless of the flow direction
Ensure mating flanges are square and parallel to the valve
flanges before tightening flange bolts. Prepare pipe ends
according to pipe manufacturer’s instructions when installing
mechanical joint end valves.
Do not backfill buried service valves until after the system is
tested.
Flanged valves should be mated with flat-faced flanges and
full-face gaskets. If ring gaskets are used the bolt material
shall be ASTM A307 Grade B (or equivalent). Higher
strength bolting should only be used with full-face gaskets.
Lubricate the bolts or studs and insert around flange. Lightly
tighten bolts until gaps are eliminated. Torque bolts in an
alternating pattern in graduated steps. If leakage occurs
wait 24 hours and re-torque the bolts but do not compress
the gasket more than 50% or exceed bolt maximum torque
rating.
Do not test systems to pressures higher than the 150 PSI
rated pressure.
Before putting into service open all valves completely and
thoroughly flush system to avoid damaging the valve seat by
closing on construction debris.
OPERATION
The Figure 517R opens and closes through a 90-degree
“eccentric”rotation. During opening, the initial rotation
causes the rubber coated plug to pull “out of the seat”and
rotation continues without seat contact minimizing wear.
When fully open the plug is out of the main flow path for low
headloss but can be positioned partially open for throttling
applications. During closing, the plug initially rotates without
seat contact but rotates “into the seat”at the end of travel
making a tight seal.

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There are no travel stops in the valve itself. The full open
and full closed travel stops are in the actuator and are
adjustable.
On direct nut, “wrench/lever”operated valves, ¼ turn of the
wrench/lever clockwise closes the valve and
counterclockwise opens the valve.
On gear operated valves, turning the handwheel or operating
nut clockwise closes the valve and counterclockwise opens
the valve.
VALVE CONSTRUCTION
The standard Figure 517R Eccentric Plug Valves have an
epoxy lined and coated cast iron body and cover, a pure
nickel weld overlaid body seat and a ductile iron plug with
Buna-N rubber facing.
Refer to the List of Materials submitted for the order if non-
standard materials were provided.
Refer to Page 4 for details of construction and parts location.
START-UP
The valve generally does not require any calibration or
adjustment prior to start-up. The open and close travel stops
are set at the factory but may change during transportation
and handling. If the valve does not seat tightly when closed,
the close travel stop can be adjusted to allow the plug to
rotate farther into the seat.
CAUTION: Excessive closing force or travel can damage the
valve or actuator if there is debris preventing a tight seat.
Before adjusting the travel stop open the valve to flush out
any debris that may be lodged in the valve.
PREVENTIVE MAINTENANCE
Figure 517R Eccentric Plug Valves are designed to remain
in one position for long periods of time, but regular exercise
is recommended for valves that are not frequently operated.
There are no lubrication requirements.
Exposed valves should be visually inspected for leaks and
cycled close/open or vice versa under pressure at least twice
a year.
Buried valves should be cycled close/open or vice versa at
least twice a year to ensure it operates freely without
vibration.
TROUBLESHOOTING
•Leakage at Flange Joint
- Tighten bolts but do not over-torque
- Replace gasket
•Leakage at Shaft Packing
- Tighten packing gland
- Replace packing
•Seat Leakage
- Debris on seat: Open valve to flush
- Rotate farther closed: Adjust close stop
- Damaged plug: Replace
•Difficult to Operate
- Gland too tight: Loosen gland
- Grit in bearings: Disassemble, inspect, clean
or replace bearings
- WARNING
Removing the actuator from the valve or
disassembling the valve while there is pressure
in the valve body may result in injury or damage
to the valve
WARNING
Follow all applicable safety regulations and
codes and read and understand all instructions
before undertaking disassembly.
REPLACING SHAFT PACKING WITHOUT REMOVING
THE ACTUATOR
The shaft packing (8) in exposed valves can be replaced
without removing the actuator.
1. Ensure there is no pressure within the valve and
operating equipment is locked out.
2. Loosen or remove the gland bolts (12) so the
gland (11) can be sufficiently lifted to access the
packing
3. Using a pick, lift the packing rings, cutting them to
remove from the plug shaft.
4. Clean the packing box and blow out any debris
5. The packing consists of a bottom male adaptor,
several V-rings, and a top female adaptor.
6. Using a razor knife, cut the bottom (male) packing
ring on a 45-degree angle. Lubricate the ring and
install in the bottom of the packing box.
7. Cut the V-rings on a 45-degree angle, lubricate
and install with the point of the “V”pointing toward
the actuator, staggering the cut joints.
8. Cut the top (female) packing ring on a 45-degree
angle, lubricate and install.
9. Push the packing set into the packing box using
the gland until the packing set is fully seated.
10. Install and tighten the gland bolts (12) until they
just touch the gland (11) and then one more full
turn.
11. Reintroduce pressure and check for leaks. If a
leak is noticed, evenly tighten the gland bolts (12)
just until the leak stops. Excess compression will
increase operating torque and shorten the packing
life.
REPLACING SHAFT PACKING AFTER REMOVING THE
ACTUATOR
1. Scribe or mark the actuator and cover for proper
alignment upon reassembly.
2. Ensure there is no pressure within the valve and
operating equipment is locked out.
WARNING
If the valve is installed in a vertical pipe or in a
horizontal pipe with the plug shaft horizontal,
the plug may swing downward when the
actuator is removed. Rotate the plug to the
lowest position before removing the actuator
3. Remove the gland bolts (12) and gland (11). Using
a pick, lift and remove the packing rings.

3
4. Clean the packing box and blow out any debris
5. Lubricate and install the bottom (male) adaptor
ring over the shaft.
6. Lubricate and install the V-rings with the point of
the “V”pointing toward the actuator.
7. Lubricate and install the top (female) adaptor ring.
8. Push the packing set into the packing box using
the gland until the packing set is fully seated.
9. Install and tighten the gland bolts (12) until they
just touch the gland (11) and then one more full
turn.
10. Reintroduce pressure and check for leaks. If a
leak is noticed, evenly tighten the gland bolts (12)
just until the leak stops. Excess compression will
increase operating torque and shorten the packing
life.
DISASSEMBLY
To disassemble/re-assemble the valve the plug shaft must
be vertical. It may be necessary to remove the valve from
the pipeline and rotate so it is sitting on a solid surface.
Before removing the valve, ensure operating equipment is
tagged and locked out and there is no pressure within the
valve. Pressure can be relieved by removing the pipe plug
(13) in the valve cover. Drain or remove the liquid from the
valve.
WARNING
The cover may blow off the top of the valve if
the cover bolts are removed with pressure
inside the valve. Remove ALL pressure before
disassembly
Refer to page 4 for parts identification and location.
A skilled technician should perform all work. No special
tools are required.
1. If disassembling in-line, ensure there is no
pressure within the valve and operating equipment
is locked out. If possible, drain the liquid from the
valve.
2. Close the valve.
3. Scribe or mark the actuator and cover for proper
alignment upon reassembly.
4. Remove the fasteners used to mount the actuator
and lift off the actuator, making sure not to lose the
keys, couplings, etc. for reassembly.
5. Remove the gland bolts (12) and gland (11).
Using a pick, remove the packing set (8)
6. Scribe or mark the cover (5) and body (1) for
proper alignment upon reassembly.
7. Remove the cover bolts (3).
8. Install two eyebolts in opposite holes in the cover’s
actuator mounting flange. Lift the cover straight
up and off the plug shaft. Remove the cover O-
ring (4).
9. Remove the plug (2) by turning and lifting out of
the body.
10. Inspect the upper and lower bearings (7) and
bushings (10) and the upper and lower thrust
bearings/grit excluders (6) for wear. Replace if
needed. It may be necessary to remove the end
plate (15) to extract the lower bearing and
bushing.
11. Inspect the plug’s rubber coating for wear, tears,
and other damage. Replace if necessary.
12. Inspect the welded nickel seating surface in the
body. Minor smooth edged dents and nicks can
be accommodated by the plug’s rubber coating,
but significant sharp edged gouges, dents and
nicks may necessitate replacing the entire valve.
ASSEMBLY
The valve is reassembled by reversing the disassembly
sequence with consideration of the following:
1. Clean and polish all machined bearing and sealing
surfaces. Apply a light coat of lubricant to assist in
the assembly.
2. Install lower bushing (10) in bottom of body and
lower plug bearing (7) on the bottom of the plug.
Place and center the thrust bearing (6) on the
lower bushing (10).
3. Carefully lower plug (2) into body until it enters the
thrust bearing (6) and lower bushing (10). Rotate
the plug until it is nearly closed.
4. Install upper thrust bearing (6) and plug bearing
(7) on the plug shaft and upper bushing (10) in the
cover (5).
5. Lubricate and install the cover O-ring (4) and
carefully lower the cover (5) over the plug shaft so
the marks are aligned.
6. Install cover bolts (3) and tighten in an alternating
manner.
7. Lubricate and install shaft packing (8).
8. Place packing gland (11) over plug shaft and push
packing (8) into the packing box until it is firmly
seated.
9. Install gland bolts (12), tighten until they just touch
the gland (11) and then one more full turn.
10. Align and install actuator.
11. Close valve and (reinstall in line) and introduce
pressure. Check for leaks. If a leak from the shaft
packing is noticed, evenly tighten the gland bolts
(12) just until the leak stops. Excess compression
will increase operating torque and shorten the
packing life.
REPLACEMENT PARTS
Genuine replacement parts are available from your local
VAG/GA Industries representative or from the factory:
VAG USA, LLC
234 Clay Avenue
Mars, PA 16046 USA
Telephone: [phone]
Fax: [phone]
E-mail: [e-mail]
Please have the nameplate data available when ordering
parts. Identify needed part(s) by Shop Order (SO) Number,
Figure Number, valve size and individual part number.
All parts ordered individually.
WARRANTY:
The Warranty for GA Industries valves is included in our
Terms and Conditions which can be found here:
https://gaindustries.com/terms

4
STANDARD PARTS LIST –EXPOSED VALVES
Part No. Part Name Std. Material
1 Body Cast Iron w/Ni Seat
2 Plug Ductile Iron/Buna-N
3 Cover Bolts Zinc Plated Steel
4 Cover O-Ring Buna-N
5. Cover Cast Iron
6. Thrust Bearing (2) PTFE
7. Bearing (2) PTFE Coated 316SS
8. Packing Buna-N
9. Key Steel
10. Bushing (2) 316 Stainless Steel
11. Packing Gland Cast Iron
12. Gland Bolts Zinc Plated Steel
13. Pipe Plug Steel
14. End Plate O-Ring Buna-N
15. End Plate Cast Iron
16. End Plate Screws Zinc Plated Steel
STANDARD PARTS LIST –BURIED VALVES
Part No. Part Name Std. Material
1. Body Cast Iron w/Ni Seat
2. Plug Ductile Iron/Buna-N
3. Cover Bolts Stainless Steel
4. Cover O-Ring Buna-N
5. Cover Cast Iron
6. Thrust Bearing (2) PTFE
7. Bearing (2) PTFE Coated 316SS
8. Packing Buna-N
9. Key Steel
10. Bushing (2) 316 Stainless Steel
11. Packing Gland Cast Iron
12. Gland Bolts Stainless Steel
13. Pipe Plug Steel
14. End Plate O-Ring Buna-N
15. End Plate Cast Iron
16. End Plate Screws Stainless Steel
GA Industries Figure 517R Rectangular Port Eccentric Plug Valve
Flanged Exposed Valve Shown
(Buried service valves have same parts but without packing access windows in cover)