NEWCO VALVES

Newmans Inc., Newmans Valve Ltd.

Newco/OIC Forged Valve

Operation & Maintenance
Manual
 Newco Valves Newco Forged Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

1. Introduction and Safety Information 1

1.1. Introduction................................................................................................................................. 1
1.2. Safety Information ...................................................................................................................... 1
2. Storage, preparation and Installation 2
2.1. Storage. ....................................................................................................................................... 2
2.1.1. Temporary Storage.............................................................................................................. 2
2.1.2. Long Term Storage. ............................................................................................................ 2
2.2. Preparation. ................................................................................................................................. 2
2.3. Installation................................................................................................................................... 3
2.3.1. Flanged Valves.................................................................................................................... 3
2.3.2. Socket and Threaded Valves............................................................................................... 3
2.3.3. Valve Installation by Welding. ........................................................................................... 3
3. Maintenance and Repair 4
3.1. Inspection and Maintenance ....................................................................................................... 4
3.1.1. Periodic Inspection.............................................................................................................. 4
3.1.3. Maintenance........................................................................................................................ 4
3.2. Trouble-shooting......................................................................................................................... 5
3.3. Stem Packing Replacement......................................................................................................... 6
4. Newco Forged Steel Valves 8
4.1. Bolted/Welded Bonnet Gate and Globe Valves.......................................................................... 8
4.1.1. Operation............................................................................................................................. 8
4.1.2. Disassembly ........................................................................................................................ 8
4.1.3. Reassembly ......................................................................................................................... 8
4.2. Bolted/Welded Cap Swing-Type Check Valves....................................................................... 10
4.2.1. Operation........................................................................................................................... 10
4.2.2. Disassembly ...................................................................................................................... 10
4.2.3. Reassembly ....................................................................................................................... 10
4.3. Bolted/Welded Cap Lift Check Valves..................................................................................... 11
4.3.1. Operation........................................................................................................................... 11
4.3.2. Disassembly ...................................................................................................................... 11
4.3.3. Reassembly ....................................................................................................................... 11
5. About Newco Valves 12
5.1. Identifying Newco Figure Numbers ......................................................................................... 12
5.2. Ordering Parts ........................................................................................................................... 13
Appendix A 14
Table A -- Torque Values for Bonnet Bolting ...................................................................................... 14

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 Newco Valves Newco Forged Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

1. INTRODUCTION AND SAFETY INFORMATION

1.1. Introduction

This manual has been prepared to serve as a guide to insure continuous satisfactory service and assist in restoring of a valve
to proper working condition.

It covers 'NEWCO' Forged Class 150 through 2500, bolted/welded bonnet, outside screw and yoke, flanged /threaded /socket
welded, carbon steel, stainless steel and alloy steel valves. The installation, storage, operation, disassembly / reassembly
inspection and repair, service problems, maintenance and preventive maintenance covering these valves are also included in
this manual.

Prior to performing any work on these valves, it would be useful to have a general understanding of their construction.
Chapter 4 shows the valve's basic construction.

1.2. Safety Information

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual.
They are recommended precautions that must be understood and applied during operation and maintenance of the equipment
covered herein.

a. To avoid injury, never attempt disassembly while there are pressures either upstream or
downstream. Even when replacing packing rings caution is necessary to avoid possible
injury.

b. Do not attempt to disassemble a valve while there is pressure in the line. Make sure both
upstream and downstream pressures are removed before disassembly. Disassemble with
caution in the event that all pressures have not been relieved.

c. Prior to replacing packing rings, remove all pressure from the valve. The packing can also be
replaced while there is pressure BUT the valve must be tightly backseated. This will not
insure complete safety and it is not recommended. If the backseat faces have been damaged
by foreign material the backseat may leak into the packing chamber.

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 Newco Valves Newco Forged Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

2. STORAGE, PREPARATION AND INSTALLATION

2.1. Storage.

2.1.1. Temporary Storage.

If valves are to be stored before installation, the following should be observed:

a. Keep the valves wrapped and protected as shipped from the manufacturer.
b. Do not remove the protective end covering until the valve is ready for installation. This will reduce the possibility of
foreign material damaging internal valve components.
c. Valves stored outdoors should be positioned such that water does not accumulate in the valve body.

2.1.2. Long Term Storage.

If the valves are to be stored in excess of one year, they should be prepared in the following manner:

a. Remove the packing and apply a preservative to the packing chamber.

b. Do not remove the protective end covering.
c. Valve which will remain in storage for an excessive period of time should have a preservative applied to the external
surface.
d. Do not store the valves outdoors.

2.2. Preparation.

a. Remove the valve end protection.

b. Prior to shipment from the manufacturer, a preservative may have been applied to the inner body of the valve. This
preservative may be removed with a solvent.
c. The inside of the valve should be inspected and blown out with compressed air. Adjacent piping must be clean and free
from debris to prevent damage to the valve.
d. Make sure the valve is positioned such that there is sufficient space so that the handwheel is easily and safely reached
and there is enough clearance for the stem when the valve is open.
e. Install the valve according to the flow indicator on the valve body. Note gate valves can be installed in any position
without regard for the direction of the flow, unless marked with the flow direction.
f. Gate valves and globe valves are not designed for throttling and should be kept in the fully open or closed
position. Should the valve be used in a partially open or closed position, the bottom of the wedge and the seat may
become eroded in a very short time. This may also cause a chatter noise in the line.

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 Newco Valves Newco Forged Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

2.3. Installation

2.3.1. Flanged Valves.

Bolting and gasket material should be compatible with the valve's body material and pressure class. Care should be taken
that flanges are straight and parallel. Bolts should be evenly tightened in a star pattern. This will ensure a uniform gasket
loading.

2.3.2. Socket and Threaded Valves.

Ensure that the socket/threaded connection is clean and free from any foreign debris or burrs. For any welding required,
check that body material (as specified on nameplate), and pipe materials are compatible for weld procedure.

2.3.3. Valve Installation by Welding.

Unless the valve contains PTFE packing and/or gasket, leave valves assembled and in the lightly closed position during
installation, welding and post-weld heat treatment. This will prevent the valve seat from floating or warping during the
process. After welding completion, open the valve and flush the line to clean out any foreign matter.

Valves containing PTFE packing and/or gasket must be disassembled for installation as the welding temperature can
adversely affect the PTFE components. Match mark each component during disassembly for proper reassembly.

The responsibility for welding of the valves into piping systems is that of those performing the welding. Refer to ASME
B31.1, B31.3, etc. Written welding procedures covering all attributes of the process and materials to be welded shall be in
accordance with Section IX of the ASME Boiler and Pressure Vessel Code and any additional requirements from the
applicable piping code including any possible necessary localized PWHT depending on material specifications.

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 Newco Valves Newco Forged Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

3. MAINTENANCE AND REPAIR

3.1. Inspection and Maintenance
A periodic inspection and maintenance schedule should be established for each valve. The time frame given for the
implementation of these schedules are to be used as a guide only in establishing routine inspection and maintenance
schedules. Exact time periods for performing these procedures cannot be provided due to the unknown nature of the service
conditions each valve is in.

3.1.1. Periodic Inspection.

A periodic inspection should be performed on each unit. As mentioned previously, this time frame should be adjusted
depending on usage and service conditions. An infrequently used unit may have a longer time period between the
performance of a periodic inspection. If, on the other hand, a valve is in constant service a shorter time period between
inspections would be appropriate.

The inspection is used as a means to identify a problem before it can cause a shutdown of the system. A periodic inspection
should include the following:

a. Examine the valve stem for cleanliness and lubrication. The stem threads should be coated with a clean grease lubricant.
b. Some valves have a grease fitting in the bonnet or yoke. If it is dry, lubricate with a hand grease gun.
c. Open and close the valve. The actions should be smooth without any binding of the stem through full travel.
d. If valve is in service and under pressure:
i) Examine the body to bonnet connection for leakage through the gasket. If leakage is found, tighten the
bonnet nuts evenly in a star pattern until the leakage stops. Do not exceed the maximum torque values in
Table A. If the leakage persists, see section 3.2. (NOTE: this does not apply to welded bonnets)
ii) Check the stem packing for any leakage during the opening and closing action. If a leak is found, tighten the
gland nuts alternately with no more than a quarter turn on each nut until the leak stops. If the leakage
persists, see section 3.2.
iii) Inspect the exterior of the valves for cleanliness. Remove any dirt, grime or oil from the valve body and
bonnet.

3.1.2. Post Inspection.

After completion of this periodic inspection, valves that are providing satisfactory service require no further disassembly or
inspection. Should a valve be found which is not performing satisfactorily, see section 3.2 "Troubleshooting".

3.1.3. Maintenance.
Other than periodic inspection, no routine maintenance is required. Routine replacement of parts, such as gasket and packing
is not usually performed until these parts fail. Once in service, it may become apparent that these and other parts require
repair or replacement due to usage and service conditions. A maintenance schedule should be developed taking these
conditions into consideration to replace parts which have a tendency to wear within a given time frame. These can then be
replaced during a routine overhaul prior to any failure.

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 Newco Valves Newco Forged Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

3.2. Trouble-shooting

The following chart will cover the various problems that are common to most valves. It will provide information that will aid
in isolating and correcting these problems.

Table 3-2 Valve Troubleshooting

PROBLEM PROBABLE CAUSE SOLUTION

Leakage through a. Gland nuts are loose a. Tighten gland bolting.
the stem packing b. Gland is binding against the stem b. Check to insure gland is centered
or packing chamberwall and evenly tightened
c. Inadequate amount of packing c. Install additional packing rings see
rings section 3.3
d. Packing is hard and dry d. Replace with new packing see
section 3.3
e. Packing was not properly cut and e. Replace with new packing see
staggered section 3.3
f. Stem is damaged f. Repair or replace as required
Problems in g. Stem binding during travel g. Remove dirt and lubricate stem with
operating valve grease
h. Stem packing is exerting excessive h. Check torque on gland nuts.
force on the stem
i. Stem is damaged i. Examine stem through full open
and close action. Repair or replace
as required
j. Internal components may be j. Disassemble the valve. Inspect and
damaged repair as needed.
Bonnet Leakage k. Bonnet nuts are loose k. Tighten to values listed in Table A.
l. Gasket is damaged l. Disassemble and install a new
gasket.
m. Flange faces are damaged m. Repair and install a new gasket
Seat Leakage n. Valve not properly seated n. Check to see if valve is tightly
closed
o. Internal components are damaged o. Inspect internal components and
or worn repair as required (for detailed
repair consult Newmans
representative).

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 Newco Valves Newco Forged Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

3.3. Stem Packing Replacement

WARNING

To prevent injury ensure that all pressure is removed from the valve both upstream and downstream before
disassembly.

a. Check original tightness of valve operation. Remove gland nuts. Lift the gland up the stem clear of the packing chamber.
b. Remove the existing or defective packing rings with a sharp tool or packing remover. Do not scratch or score the
machined surfaces of the stem or packing chamber.
c. Examine the machined surface of the stem in the packing chamber. Remove any scratches, scoring or burrs with emery
cloth or hand filing. Clean the stem with a solvent soaked cloth.
d. Count original number of rings and measure x-section thickness. If original packing cannot be counted or measured,
follow the steps below:
1.) Measure the stem diameter (OD), stuffing box diameter (ID) and stuffing box depth (d).
2.) Packing x-section (R) = (ID - OD)/2
3.) #rings = (1.25 x d)/R
e. Install new packing. Cut each ring at a 45-degree angle and stagger the joints at 120 degrees, every fourth joint will be in
the same position as the first. Install rings individually using a split ring spacer, compressing each ring by hand
tightening = 1/4 turns on each gland nut.
f. When packing chamber becomes filled with packing, reassemble gland and gland flange. Alternate tightening gland
flange nuts 1/4 turn at a time until eye bolts begin to get tight. (If gland travels more than the height of one packing ring
into the packing chamber, insert one more ring and repeat step F until chamber is filled.
g. Compare valve operation to original tightness. If valve operation is considerably tighter than original operating tightness,
back off 1/4 turn on each gland nut and recheck tightness.
h. Several hours after a repacked valve has been returned to service, inspect the area to ensure full compression, tight
bolting and no leakage. Should leakage occur, tighten gland nuts at 1/4-turn increments until leakage stops.

Figure 3.1.3-1 (a) Valve Stuffing Box Assembly (b) Packing Detail

GLAND
FLANGE
BRAIDED
END RING

GLAND
DIE-FORMED
RINGS
(3 min.)
PACKING
BRAIDED
END RING

120 STAGGER OF JOINTS 45 END CUT

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Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

THIS PAGE
INTENTIONALLY
LEFT BLANK

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 Newco Valves Newco Forged Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

4. NEWCO FORGED STEEL VALVES

4.1. Bolted/Welded Bonnet Gate and Globe Valves

4.1.1. Operation
By turning the handwheel counter-clockwise, the stem, to which the wedge (or disc) is attached at the base, is drawn up
through the yokesleeve. By turning the handwheel clockwise, the action is reversed and the wedge (or disc) is lowered into
the closed position.

4.1.2. Disassembly a. Thoroughly clean the valve interior, body and bonnet
flange surfaces and all components. Remove all scale,
WARNING oil, grease or other foreign material. Wipe the seating
surface of the wedge (or disc) and valve seat with a
To prevent injury ensure that all pressure is removed solvent soaked cloth.
from the valve both upstream and downstream before b. Install the stem carefully, sliding it through the packing
disassembly. and gland until the threads are engaged with the
yokesleeve. Slowly rotate the stem clockwise until it
NOTE: Welded bonnet valves can be disassembled but is extends beyond the bonnet.
not justifiable due to the amount of time required to do c. Place handwheel in position atop the valve, stem nut for
this. gate valves and stem for globe valves. Secure with
handwheel nut.
a. Close the valve and then open, two full handwheel d. Position a new gasket on the body flange aligned with
turns. Match or mark flange with metal tool or paint to the bolt holes. The gasket should not extend over the
clearly show the original position for reassembly. open body cavity. The gasket may be coated with a
b. Caution should be taken when loosening body-bonnet light oil.
bolting, as pressure may still be present in bonnet. e. For gate valves, install the wedge to the "T" head of the
c. Once assured there is no more pressure in the line, stem connection. For globe valves, install the disc and
remove the bonnet bolting. Lift the bonnet-stem-wedge secure it with the bushing or disc nut to the stem and
(or disc) assembly out of the body, taking care not to tackweld.
scratch the seating surface. For gate valves, as the f. Lift the bonnet-stem-wedge assembly up and over the
assembly is drawn out of the body, match or mark the body. Check the location marks on the body, bonnet
wedge so that it can be replaced in the same position. flange and wedge. Carefully lower the assembly until
d. Remove the bonnet gasket from the valve body flange. the body and bonnet flanges and the location marks
e. For gate valves, remove the wedge from the stem "T" meet. Again, caution must be used to prevent scoring or
head, carefully protecting the seating surface. . For scratching of the seating surfaces. Keeping the bonnet
globe valves, remove the disc from the stem by cutting stationary, open the valve a few turns to ensure the
tackwelds and unthreading the disc nut or bushing. wedge (or disc) is not touching the seat.
f. Unfasten the handwheel nut. Remove the handwheel g. Line up the body and bonnet holes. Make sure the
from the valve. gasket does not extend into any of the bolt holes. Install
g. To remove the valve stem, loosen the gland bolting and the bonnet bolting and tighten in a star pattern to evenly
gland. Disengage the stem from the yokesleeve by load the gasket to the torque values listed in Table A.
rotating it counterclockwise and pulling from below h. Install new packing as per section 3.3.
until the stem is free of the packing chamber. Be i. Align and center the gland in the packing chamber.
careful not to score or scratch the stem machined Evenly tighten the gland nuts until snug, then alternate
surface or the threads. tightening with no more than a quarter turn on each.
j. Open and close the valve using the handwheel. The
4.1.3. Reassembly action should be smooth and regular through full stem
travel.

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 Newco Valves Newco Forged Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

Figure 4.1-1 Bolted Bonnet Gate Valve with Welded Bonnet

18 HAND WHEEL NUT
17 NAME PLATE
16 HAND WHEEL
15 SLEEVE
14 SLEEVE WASHER
13 EYE BOLT
12 EYE BOLT NUT
11 GLAND FLANGE
10 GLAND
09 PACKING
08 EYE BOLT PIN
07 BONNET BOLT
06 BONNET
05 GASKET
04 STEM
03 WEDGE
02 SEAT RING
01 BODY

WELDED BONNET DETAIL

Figure 4.1-2 Bolted Bonnet Globe Valve With Welded Bonnet Y-Pattern Globe
20* SEAT RING
19* DISC NUT
18 SEAT RING
17 NUT
16 WASHER
15 NAME PLATE
14 HANDWHEEL
13 STEM NUT
12* EYE BOLT/STUD
11 EYE BOLT NUT
10 GLAND FLANGE
09 GLAND
08 GLAND PACKING
07* EYE BOLT PIN
06* BONNET BOLT
05 BONNET
04* GASKET
03 STEM
02 DICK
01 BODY

* MAY VARY WITH DESIGN

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Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
®

4.2. Bolted/Welded Cap Swing-Type Check Valves

4.2.1. Operation
The Swing Check valve's operation is automatic and requires no assistance. When the flow exerts sufficient pressure against
the disc to overcome the disc's weight, the disc, which is set on a hinge, lifts allowing the flow to continue through the piping
system. As the pressure decreases, the disc lowers until its own weight forces it to seat. This prevents the possibility of a
reversal in the flow.

4.2.2. Disassembly 4.2.3. Reassembly

WARNING a. Thoroughly clean the valve interior and all
components. Remove all scale, oil, grease, or other
To prevent injury ensure that all pressure is removed foreign material. Wipe the seating surface of the
from the valve both upstream and downstream before disc and valve seat with a solvent soaked cloth.
disassembly. Clean the body and cover flange surfaces and all
bolting.
NOTE: Welded cap valves can be disassembled but is b. Install the disc and secure it to the arm with the disc
not justifiable due to the amount of time required to nut. Insert and secure a new pin (peen over if
do this. required). Do not use the old pin unless a new one
is unavailable.
a. Match or mark cover and body with metal tool or c. Place the disc-arm assembly in the valve and insert
paint to clearly show the original position for the hinge pin.
reassembly. d. Replace any tackwelds as required.
b. Caution should be taken when loosening body-cover e. Open the valve by lifting the arm. The action should
bolting, as pressure may still be present. be smooth and regular through full hinge pin
c. Once assured there is no more pressure in the line, rotation.
remove the cover bolting and lift the cover off the f. Position a new gasket on the body flange aligned
body. with the bolt holes. The gasket should not extend
d. Remove the gasket from the valve body flange. over the open body cavity. Do not reuse a gasket.
e. If so equipped remove any tackwelds. The gasket may be coated with a light oil.
f. Remove the hinge pin from support arms in cap. It g. Line up the body and cover holes. Make sure the
may be necessary to use a punch, as pin may have gasket does not extend into any of the bolt holes.
been penned over. Install the cover bolting and tighten in a star pattern
g. To remove the disc from swing arm, remove the to evenly load the gasket to the torque values listed
cotter pin and unfasten the disc nut. in Table A.

Figure 4.2-1 Bolted/Welded Cap Swing-Type Check Valve

11 COVER BOLT
10 NAME PLATE
9 COVER
8 GASKET
7 SUPPORTER
6 SUPPORTER PIN
5 HINGE
4 RETAINING NUT
3 DISC
2 SEAT RING
1 BODY

WELDED BONNET DETAIL

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Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
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4.3. Bolted/Welded Cap Lift Check Valves

4.3.1. Operation
The Lift Check valve's operation is automatic and requires no assistance. When the flow exerts sufficient pressure against the
plug/ball to overcome the plug/ball weight, the plug/ball, lifts allowing the flow to continue through the piping system. As
the pressure decreases, the plug/ball lowers until its own weight forces it to seat. This prevents the possibility of a reversal in
the flow.

4.3.2. Disassembly 4.3.3. Reassembly

WARNING a. Thoroughly clean the valve interior and all components.
Remove all scale, oil, grease, or other foreign material.
To prevent injury ensure that all pressure is removed Wipe the seating surface of the plug/ball and valve seat
from the valve both upstream and downstream before with a solvent soaked cloth. Clean the body and cover
disassembly. flange surfaces and all bolting.
d. Replace ball/plug by sliding it back into the body. If so
NOTE: Welded cap valves can be disassembled but is not equipped place spring in following ball.
justifiable due to the amount of time required to do this. e. Open the valve by sliding plug/ball up and down. The
action should be smooth and regular through full
a. Match or mark cover and body with metal tool or paint to plug/ball travel.
clearly show the original position for reassembly. f. Position a new gasket on the body flange aligned with
b. Caution should be taken when loosening body-cover the bolt holes. The gasket should not extend over the
bolting as pressure may still be present. open body cavity. Do not reuse a gasket. The gasket
c. Once assured there is no more pressure in the line, may be coated with a light oil.
remove the cover bolting and lift the cover off the body. g. Line up the body and cover holes. Make sure the gasket
d. Remove the gasket from the valve body flange. does not extend into any of the bolt holes. Install the
g. For ball type valves remove spring (if so equipped) cover bolting and tighten in a star pattern to evenly load
before sliding out the ball. For plug type, simply slide the gasket to the torque values listed in Table A.
out the plug.

Figure 4.3-1 Bolted/Welded Cap Lift Check Valve

8* GASKET

7* SUPPORTER

6 SUPPORTER PIN

5 HINGE

4 RETAINING NUT

3 DISC

2* SEAT RING
1 BODY

* VARIES WITH DESIGN

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Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
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5. ABOUT NEWCO VALVES

5.1. Identifying Newco Figure Numbers

Newco valves can be identified by a distinct figure number on the identification plate. This plate is located either on the
body/bonnet flange or on the bonnet yoke. The figure number gives all the necessary information for identifying valve type,
material, end connections, pressure rating, etc. Listed below is the basic set-up.

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Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
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5.2. Ordering Parts

Although valves have many parts common to one another, they are not interchangeable, other that with those of identical
material, size and pattern. All the valve's parts can be replaced, but with proper care and maintenance, they will provide
continuous satisfactory service. Should a part require replacement, please provide the following information:

Valve Size
Newco Figure
Two Digit Foundry Code (on body)
Part Description
Drawing No. (If known)
Item No. (If known)

It is recommended that a spare gasket and set of packing for the various valves be kept in stock.

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Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
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APPENDIX A

Table A -- Torque Values for Bonnet Bolting

Bolt Nominal Torque Bolt Nominal Torque

Diameter Diameter
(in.) (ft-lb) (N-M) (in.) (ft-lb) (N-M)
1/4 4 5 1 200 271
5/16 8 11 1-1/8 375 509
3/8 12 16 1-1/4 525 712
7/16 20 27 1-3/8 715 970
1/2 30 41 1-1/2 925 1254
9/16 45 61 1-5/8 1200 1627
5/8 60 81 1-3/4 1500 2034
3/4 110 149 1-7/8 1850 2509
7/8 170 231 2 2260 3064

Notes:
1. Values are for B7 bolting only. For other bolting material, please consult your local Newco representative.
2. Values above are based on 30,000 psi (206.85 Mpa) bolting stress and lubricated with a heavy graphite and oil
mixture. Non-lubricated bolts have and efficiency of 50% of the values stated.
3. Do not exceed by more than 25% of values stated when emergency torquing is required.
4. All bolts shall be torqued in a star pattern as shown below to ensure uniform gasket loading.
1 5

8 3

4 7

6 2
Bolt torquing sequence. 1-2-3-4-5-6-7-8

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