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TITLE: 

NO.:   

KEROTEST MODEL-1 

REV.:  10 

GATE VALVE 

DATE:  7/12/07 

OPERATIONS MANUAL 

PAGE:  20 OF 35 

 

This report is the property of Kerotest Manufacturing Corp. 5500 Second Avenue, Pittsburgh, PA  15207 and may not be 
copied by any means without the expressed written consent of Kerotest. It is intended for the sole purpose of helping 
Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any 
manner injurious to the interests of Kerotest

PRIMARY REPACKING PROCEDURE – LATEST DESIGN 

WITH STEM WEATHER SEAL (AFTER 1987) 

 

CONDITION 1 – VALVE UNDER PRESSURE 

 

Note:

  A slight leak in the backseat seal can cause difficulty in replacing the v-rings; a 

straightened paper clip or smooth wire can be used on the side of the v-rings to allow 
pressure to vent until the adapter can be quickly inserted and the gland bolted down. 

 
10. 

Place upper thrust washer (7) on stem (11) if removed.  Install weather seal o-ring (5) in 
stem groove.  Position gasket (6) and gland, with weather seal lead-in chamfer side 
down, on cover, being careful not to cut o-ring.  Insert cap screws (3) fully and tighten to 
torque shown in Table I.  Place operating square (2) on stem and then secure with nut 
(1). 

 
Valve is ready for service. 

Summary of Contents for MODEL-1

Page 1: ...intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest...

Page 2: ...any manner injurious to the interests of Kerotest REVISION SHEET REVISION DATE DESCRIPTION OF REVISION 1 11 28 90 2 09 04 91 3 07 16 93 4 03 28 96 5 05 30 97 Added Bonnet Leak Repair Attachment 2 6 1...

Page 3: ...d in any manner injurious to the interests of Kerotest INTRODUCTION The Kerotest Model 1 design employs the following features These include Maintenance Free No Gland Tightening No Lubrication during...

Page 4: ...5500 Second Avenue Pittsburgh PA 15207 and may not be copied by any means without the expressed written consent of Kerotest It is intended for the sole purpose of helping Kerotest customers evaluate K...

Page 5: ...ng Corp 5500 Second Avenue Pittsburgh PA 15207 and may not be copied by any means without the expressed written consent of Kerotest It is intended for the sole purpose of helping Kerotest customers ev...

Page 6: ...5 5 1125 10 5 450 NA NA 5 1125 12 AND 16 15 450 NA NA 15 1125 HYDROSTATIC SEAT TEST SIZE 285 MOP 500 WOG 740 MOP TIME MINUTES PRESSURE PSIG TIME MINUTES PRESSURE PSIG TIME MINUTES PRESSURE PSIG 2 THRU...

Page 7: ...ng compound to the threads on the pipe The threading compound should be applied sparingly The wrench used for installing these valves should be applied to the end of the valve next to the pipe to whic...

Page 8: ...80 opposite the previous one see sketch below Two passes should be made Once pass for half tightness and final pass for full tightness Butt Weld End Valves Valve ends are machined per ANSI B16 25 Note...

Page 9: ...e closed completely but throttled for a short time in order that the turbulence created will flush away any sediment or dirt that might have settled in the valve In the event of an emergency the above...

Page 10: ...over as the nuts are turned If gland rises as the nuts are loosened backseat seal has not been obtained Retighten nuts replace and retighten missing bolts and then reattempt backseat seal Continue to...

Page 11: ...ose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest PRIMARY REPACKING PROCEDU...

Page 12: ...st It is intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of...

Page 13: ...ove two of the cap screws 3 Replace with two all thread studs size and length recommended in table above Thread all thread studs into cover until they bottom Install a nut on each stud and tighten Rem...

Page 14: ...essful seat shut off has not been obtained Rotate stem in the direction for opening valve until it contacts lower thrust washer Caution Be careful not to break gate seal or packing will be subject of...

Page 15: ...Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest SECONDARY REPACKING PROCEDURE EARLY DESI...

Page 16: ...r the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest SECONDARY...

Page 17: ...cap screws 3 and gland 4 Upper thrust washer 6 may remain in gland 4 or on stem 10 4 Rotate stem 10 in same direction as closing the valve until it is free from the wedge Withdraw stem from valve Lowe...

Page 18: ...nd may not be copied by any means without the expressed written consent of Kerotest It is intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released...

Page 19: ...g cap screws 3 4 Slowly and evenly loosen the two nuts on the all thread studs watching that the studs do not unthread from cover as the nuts are turned If gland rises as the nuts are loosened backsea...

Page 20: ...E LATEST DESIGN WITH STEM WEATHER SEAL AFTER 1987 CONDITION 1 VALVE UNDER PRESSURE Note A slight leak in the backseat seal can cause difficulty in replacing the v rings a straightened paper clip or sm...

Page 21: ...tended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest P...

Page 22: ...cap screws 3 Replace with two all thread studs size and length recommended in table above Thread all thread studs into cover until they bottom Install a nut on each stud and tighten Remove all remain...

Page 23: ...the bleeding pressure does not diminish successful seat shut off has not been obtained Rotate stem in the direction for opening valve until it contact lower thrust washer Caution Be careful not to bre...

Page 24: ...any third party or otherwise used in any manner injurious to the interests of Kerotest SECONDARY REPACKING PROCEDURE LATEST DESIGN WITH STEM WEATHER SEAL AFTER 1987 CONDITION 2 VALVE UNDER PRESSURE A...

Page 25: ...urpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest SECONDARY REPACKING PR...

Page 26: ...er 7 may remain in gland 4 or on stem 11 4 Rotate stem 11 in same direction as closing the valve until it is free from the wedge Withdraw stem from valve Lower thrust washer 13 may remain in the cover...

Page 27: ...be copied by any means without the expressed written consent of Kerotest It is intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any thi...

Page 28: ...shear at minimum cross sectional area at the top of stem This should enable you to utilize a pipe wrench on the remainder of stem protruding above the gland The Secondary Repacking Procedure may now b...

Page 29: ...means without the expressed written consent of Kerotest It is intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or othe...

Page 30: ...valuate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest PRESSURE DROP Valve pressure drop equivalent length in feet...

Page 31: ...ed for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest VALVE...

Page 32: ...leased to any third party or otherwise used in any manner injurious to the interests of Kerotest CRITICAL TORQUE Excessive or unlimited torque will ultimately cause a structural failure of the valve T...

Page 33: ...e sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest ACCESSORIES Ha...

Page 34: ...he o rings from the I D of the packing adapter 2 Install part 1 thrust pad and dowel pin 6 until it seats on the ledge below the packing 3 Install part 2 threaded bushing on top of part 1 4 Install sp...

Page 35: ...7 and may not be copied by any means without the expressed written consent of Kerotest It is intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be relea...

Page 36: ...written consent of Kerotest It is intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner inj...

Page 37: ...ucts and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest REVISION SHEET REV DATE WRITTEN BY APPROVED BY Q A APPROVAL DESCRIPTION OF REVISI...

Page 38: ...ted below These parts are available from Kerotest at no charge to the customer Valve Size Bolt Part Numbers Description Gasket Part Numbers 1 1 4 and Smaller 88370085 A574 Socket HD 3 8 16 x 1 1 4 Lon...

Page 39: ...Part Number 72544802 for 4 and 6 valve sizes Support clamps are not required on 8 and larger valve sizes Aside from this follow the instructions in this procedure for valve sizes 8 and larger If using...

Page 40: ...rests of Kerotest A Mainseat wedge up to double the amount of operating toque shown in Enclosure 4 CAUTION Only proceed if a tight enough seat seal is achieved to allow subsequent work to be safely pe...

Page 41: ...e gasket and mating sealing surfaces can be cleaned and polished Re coat the gasket and sealing surfaces with Slic Tite TFE Paste Reverse the procedure above and install new bonnet bolts and tighten t...

Page 42: ...a small chisel or punch could be used to try and extract the bolt When bolt is broken down below the flange an easy out must be used to extract it If available a left handed drill bit will sometimes r...

Page 43: ...REMOVAL GUIDE 1 Secure cover to body with clamps on sizes 6 and smaller 2 Spray penetrating oil on bolt surface 3 Tap bolt 3 to 4 times to loosen rust around threads 4 Position punch at the center of...

Page 44: ...without the expressed written consent of Kerotest It is intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise...

Page 45: ...of torque 2 Carefully remove operating square A gear puller device allows for easy removal Caution Before proceeding with operating square removal insure gland plate is securely fastened to valve 3 S...

Page 46: ...tsburgh PA 15207 and may not be copied by any means without the expressed written consent of Kerotest It is intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and m...

Page 47: ...nded for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the interests of Kerotest ENC...

Page 48: ...of Kerotest It is intended for the sole purpose of helping Kerotest customers evaluate Kerotest products and may not be released to any third party or otherwise used in any manner injurious to the in...

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