6. SERVICE / SPARE PARTS ........................................... 8
7. EXPLODED VIEW & PARTS LIST ............................. 10
8. HOW TO ORDER ...................................................... 11
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about safe handling and operation of the valve.
If you require additional assistance, please contact the manufacturer or manufacturer’s representative.
Addresses and phone numbers are printed on the back cover.
See also www.metso.com/products/valves/tank-car-valves/ for the latest documentation.
SAVE THESE INSTRUCTIONS!
Subject to change without notice.
All trademarks are property of their respective owners.
IMO 4/19
IMO-R20 EN 3
1. GENERAL
1.1 Scope of the Manual
This instruction manual contains important information
regarding the installation, operation and maintenance of
the Jamesbury® 4” (DN 100) Series 9RET & 9REL Fire-Tite Tank
Car Bottom Unloading Valves. Please read these instructions
carefully and save them for future reference.
WARNING
AS THE USE OF THE VALVE IS APPLICATION SPECIFIC, A NUMBER
OF FACTORS SHOULD BE TAKEN INTO ACCOUNT WHEN SELECTING
A VALVE FOR A GIVEN APPLICATION. THEREFORE, SOME OF THE
SITUATIONS IN WHICH THE VALVES ARE USED ARE OUTSIDE THE
SCOPE OF THIS MANUAL.
IF YOU HAVE ANY QUESTIONS CONCERNING THE USE, APPLICATION
OR COMPATIBILITY OF THE VALVE WITH THE INTENDED SERVICE,
CONTACT METSO FOR MORE INFORMATION.
1.2 Valve Markings
The valve has an identication plate attached to the pipeline
ange (see Figure 1).
1.3 Safety Precautions
WARNING
DO NOT EXCEED THE VALVE PERFORMANCE LIMITATIONS!
EXCEEDING THE PRESSURE OR TEMPERATURE LIMITATIONS MARKED
ON THE VALVE IDENTIFICATION PLATE MAY CAUSE DAMAGE AND
LEAD TO UNCONTROLLED PRESSURE RELEASE. DAMAGE OR
PERSONAL INJURY MAY RESULT.
WARNING
SEAT AND BODY RATINGS!
THE PRACTICAL AND SAFE USE OF THIS PRODUCT IS DETERMINED
BY BOTH THE SEAT AND BODY RATINGS. READ THE IDENTIFICATION
PLATE AND CHECK BOTH RATINGS. THIS PRODUCT IS AVAILABLE
WITH A VARIETY OF SEAT MATERIALS. SOME OF THE SEAT MATERIALS
HAVE PRESSURE RATINGS THAT ARE LESS THAN THE BODY RATINGS.
ALL OF THE BODY AND SEAT RATINGS ARE DEPENDENT ON VALVE
TYPE AND SIZE, SEAT MATERIAL, AND TEMPERATURE.
DO NOT EXCEED THESE RATINGS!
WARNING
BEWARE OF BALL MOVEMENT!
KEEP HANDS, OTHER PARTS OF THE BODY, TOOLS AND OTHER
OBJECTS OUT OF THE OPEN FLOW PORT. LEAVE NO FOREIGN
OBJECTS INSIDE THE TANK CAR. WHEN THE VALVE IS ACTUATED, THE
BALL FUNCTIONS AS A CUTTING DEVISE. FAILURE TO DO THIS MAY
RESULT IN DAMAGE OR PERSONAL INJURY!
Figure 1. Identification Plate
Identication plate markings:
1. Ball/Stem material
2. Valve catalog code
3. Seat Material
4. Body Material
5. Maximum operating pressure
6. Maximum/minimum shut-o pressure/temperature
7. Approvals/Special Service marking
8. Model
9. Assembly date
2. TRANSPORTATION AND STORAGE
Check the valve and the accompanying devices for any
damage that may have occurred during transport.
Store the valve carefully. Storage indoors in a dry place is
recommended.
Do not remove the ow port protectors until installing the
valve.
Move the valve to its intended location just before installation.
The valve is usually delivered in the open position.
If the valve(s) will be stored for a long period, follow the
recommendations in IMO-S1 to maintain the valve’s integrity.
IMO 4/19
4 IMO-R20 EN
3. INSTALLATION
3.1 General
Remove the ow port protectors and check that the valve
is clean inside. Clean valve if necessary. The machined line
of the top of the stem (5), is a visual indicator of the ball (3)
port position and ow direction. Figure 2 shows the valve
installed on the tankcar. Line horizontal indicates the closed
position. Line vertical indicates the open position. This
applied to both Standard and FO operation.
Flush the tank car carefully before installing the valve. Foreign
objects, such as sand or pieces of welding electrodes, will
damage the ball and seats.
3.2 Handles
If the valve handle (31) has to be removed for any reason,
the handle must be remounted in the same orientation.
WARNING
FAILURE TO PROPERLY MOUNT THE HANDLE MAY RESULT IN
IMPROPER VALVE OPERATION, DAMAGE OR PERSONAL INJURY.
Refer to the Section 4, MAINTENANCE for stem seal
adjustment. If there is weepage past the stem seals upon
installation, it means the valve may have been subject
to wide temperature variations in shipment. Leak-tight
performance will be restored by a simple stem seal
adjustment described in the MAINTENANCE section.
3.4 Commissioning
Ensure that there is no dirt or foreign objects left inside the
valve or tank car. Flush the tank car carefully. Make sure that
the valve is fully open when ushing.
Ensure that all nuts, ttings, and cables are properly
fastened.
3.5 Steam jacket connections
The steam-jacketed valve should be rmly attached to
the tank car prior to tting and welding of steam jacket
connections. See Section 3.2.
The valve does not need to be disassembled prior to tting
or welding of steam jacket connections; however the valve
must be in either the fully open or fully closed position.
3.3 Installing on the Tank Car
WARNING
THE VALVE SHOULD BE TIGHTENED ON FLANGES USING
APPROPRIATE GASKETS AND FASTENERS COMPATIBLE WITH THE
APPLICATION, AND IN COMPLIANCE WITH APPLICABLE PIPING
CODES AND STANDARDS. CENTER THE FLANGE GASKETS CAREFULLY
WHEN FITTING THE VALVE ON FLANGES. DO NOT ATTEMPT TO
CORRECT MISALIGNMENT BY MEANS OF FLANGE BOLTING!
Open the valve
The valve may be installed in any position and oers
tightness in both directions. It is recommended; however,
that the valve be installed with the tongue and groove
connection is installed against the tank car.
TANK CAR SIDE
Carefully t the steam lines to the valve’s steam jacket
connections. There should be no side loads on the valve’s
steam jacket connections due to misalignment of the steam
line piping.
Welded connections should only be made by ASME, Section
IX qualied welders. Additional AAR welder qualications
may apply.
An AAR certied welding inspector should inspect the
steam jacket connection welds prior to pressure testing.
Following approval of the welds, pneumatically test the
pressure tightness of the steam jacket connections to the
maximum system steam pressure plus 10%. DO NOT EXCEED
250 psig (17.2 barg). Cover the welds with a leak detection
uid and observe for three (3) minutes. Any indication of
leakage is cause for rejection.
IMO 4/19
Indicates valve in closed position
Indicates valve in open position
Figure 2.
IMO-R20 EN 5
4. MAINTENANCE
4.1 General
Good operating procedure requires periodic observation
to ensure that the valve is functioning well. The frequency
of observation will depend on the application. Routine
maintenance consists of tightening the hex nuts (item 18
in Figure 8) periodically to compensate for stem seal wear.
Stem nut torque should be about 350 in.-lb.
Overhaul maintenance consists of replacing seats and
seals. A standard repair kit consisting of these parts may be
obtained through your authorized Metso Distributor.
NOTE: Repair kits include thrust bearings (70), secondary
stem seal (71), seats (7), body seal (65) and stem seals (69).
Refer to the Repair Kit chart (see Table 1).
WARNING
FOR YOUR SAFETY IT IS IMPORTANT THE FOLLOWING PRECAUTIONS
BE TAKEN PRIOR TO REMOVAL OF THE VALVE FROM THE TANK CAR
OR BEFORE ANY DISASSEMBLY:
1. WEAR ANY PROTECTIVE CLOTHING OR EQUIPMENT NORMALLY
REQUIRED WHEN WORKING WITH THE FLUID INVOLVED.
2. DEPRESSURIZE THE TANK CAR AND CYCLE THE VALVE AS
FOLLOWS:
A. PLACE THE VALVE IN THE OPEN POSITION AND DRAIN THE
TANK CAR.
B. CYCLE THE VALVE TO RELIEVE RESIDUAL PRESSURE IN THE
BODY CAVITY BEFORE REMOVAL FROM THE TANK CAR.
C. AFTER REMOVAL AND BEFORE ANY DISASSEMBLY, CYCLE
THE VALVE AGAIN SEVERAL TIMES.
7. Remove the six socket head cap screws (73). Slowly
relieve the load on the insert (2). Remove insert (2) from
the body (1) by tightening the set screws (72) evenly
and alternately until the insert (2) can be removed.
Should the insert (2) remain jammed in the valve, place
the ball in the partially open position. Using a wooden
or plastic rod and mallet, tap the insert from inside the
valve. Do not use a metal rod or hammer on any valve
component. BE CAREFUL NOT TO SCRATCH THE BALL.
NOTE: In the event that a socket head cap screw (73) breaks;
break the shape edges. Beware of handling the valve as
sheared components may have sharp edges. Reduce the
remnant of the cap screw to a level ush with the surface.
Be careful not to damage any sealing surfaces.
WARNING
THE SOCKET HEAD CAP SCREWS 73 ARE USED FOR ASSEMBLY
PURPOSES ONLY. THE SCREWS ARE NOT CONSIDERED PRESSURE
RETAINING. A MINIMUM OF TWO SOCKET HEAD CAP SCREWS
73 OPPOSITE EACH OTHER ARE REQUIRED TO ASSURE PROPER
ALIGNMENT AND SECURE THE INSERT 2.
8. Remove the body seal (65) and the seat (7), if the seat
did not come out with the insert from the insert (2).
9. If the ball (3) does not swing free from the body, with
the ball in the fully closed position, use a piece of wood
or some other soft material to gently tap the ball (from
the end opposite the body cap). This should loosen the
ball so that it can be pivoted free of the stem (5).
10. Carefully remove the bottom seat (7) out of the body,
BEING CAREFUL NOT TO SCRATCH THE BODY
SEALING SURFACE BEHIND THE SEAT.
4.2 Disassembly
NOTE: lf complete disassembly becomes necessary; it is
recommended to replace all seats and seals. Refer to the
Repair Kit chart (see Table 1).
NOTE: Always use original OEM parts to make sure that the
valve functions properly.
1. Follow the steps in all the WARNING sections above
before performing any work on the valve.
2. Open and close the valve and leave in the closed
position. Valve needs to be raised above the working
surface slightly because the ball protrudes slightly from
either end of the valve when in the closed position.
3. Remove handle pin (35), handle (31) from top of stem;
if present.
4. Remove the retaining ring (34) and hex nuts (18).
5. Remove the disc springs (76), at washers (77), indicator
stop (32), stop bushings (39), compression plate (10)
and compression ring (9).
6. Compress the insert (2), using a maximum load of
18,600 lbs., to relieve tension from the socket head cap
screws (73). The load must be evenly distributed around
the ange of the insert. Ensure that the socket head cap
screws (73) are not obscured.
NOTE: If the valve has Barrier seats, (see Section 4.6.1) for
Barrier seat disassembly.
11. Press the stem (5) from the top into the valve body and
remove it through the insert end of the body.
12. Remove and discard the lower stem seals (70), and
secondary stem seal (71), BEING CAREFUL NOT TO
SCRATCH ANY SEALING SURFACES INTHE BODY.
13. Remove the packing (69), BEING CAREFUL NOT TO
SCRATCH ANY SEALING SURFACE INSIDE THE STEM
BORE.
4.3 Checking Parts
NOTE: For detailed instructions on visual inspection of
critical components, refer to IMO-R26.
1. Clean all disassembled parts.
2. Check the stem (5) and ball (3) for damage. Pay particular
attention to the sealing areas.
3. Check all sealing and gasket surfaces of the body (1)
and insert (2).
4. Replace any damaged parts.
IMO 4/19
6 IMO-R20 EN
4.4 Assembly
It is advisable to replace seats and seals if complete
disassembly and reassembly become necessary. Refer to the
Repair Kit chart (see Table 1). Although it is not required,
a lubricant, compatible with the tank car commodity, may
be applied to the seats, seals, ball and stem to facilitate
assembly and for ease of initial operation.
1. Clean all valve components if not done previously.
2. Re-inspect all components for damage before
reassembling the valve. Look for damage to the sealing
areas of the stem, body and insert; and look for wear in
the bearing areas. Replace any damaged parts.
3. Carefully clean and polish the ball (3) sealing surface: It
should be free of all scratches and grooves.
4. If the ball is slightly damaged, it may be possible
to smooth the sealing surface with crocus cloth or
equivalent. If deep scratches are present, replace the ball.
5. With the body insert side facing up, slide one valve
seat (7) sideways into the body (1) to below the stem
bore, and tilt it into place so that the proper surface (see
Figure 3) will be adjacent to the ball (3), being careful
not to cut or scratch the seat.
NOTE: For Barrier seat assembly, (see Section 4.6.2).
9. Place the compression ring (9) on the stem (5) and t
10. Place indicator stop (32) over the stem (5). A tamper-
NOTE: For valves with the “FO” option, (see Identication
Plate), the indicator stop (32) is marked “FO”. When placing
the indicator stop over the stem, “FO” marking must be facing
up. At this point, the stem with the indicator stop mounted
and located between stop bushings (39) is positioned so
that a clockwise rotation of the stem will open the valve.
Figure 4 Proper V-ring Orientation
the compression plate (10) over stem (5) and bonnet
studs (14). Place one stop bushings (50) over each
bonnet stud (see Figure 5 for proper orientation).
proof pin in the stem will allow the indicator stop onto
the stem only one way. At this point, the stem with
the indicator stop mounted and located between stop
bushings (39) is positioned so that a counterclockwise
rotation of the stem will open the valve.
Figure 3 Proper Seat and Ball Orientation
6. From inside the body (1), insert the one lower stem seal
(70), the secondary stem seal (71), and the second lower
stem seal (70) into the stem bore (see Figure 8).
7. Insert the stem (5) through the body cap end of the
body (1), being careful not to scratch the stem sealing
surface; and press it gently up into the stem bore until
resistance is felt from the thrust bearing.
8. Hold the stem in place from the bottom and insert the
packing (69) (see Figure 4 for proper v-ring orientation),
over the stem (5).
11. Place retaining ring (34) over the stem and into the
groove on the stem.
12. Place two disc springs (76) over each bonnet stud (14),
(see Figure 5 for proper disc spring orientation). Place a
at washer (77) over each bonnet stud (14).
18
14
77
76
Uncompressed
Compressed
Figure 5 Proper Disc Spring Orientations
IMO 4/19
IMO-R20 EN 7
13. Holding the stem (5) rmly against the lower stem seal,
place a bonnet stud nut (18) on each bonnet stud (14)
and tighten nuts alternately until the disc springs (76)
are fully compressed and at. Then tighten an additional
¼ turn. Verify that the compression plate (10) remains
parallel with the body bonnet. If necessary, retighten
the bonnet stud nuts (18) until the bonnet plate is level.
WARNING
IF THE BONNET PLATE IS NOT LEVEL AND PARALLEL TO THE BODY,
AN UNEVEN LOAD IS APPLIED TO THE PACKING AND MAY RESULT IN
LEAKAGE AND PREMATURE WEAR.
14. Insert the ball (3) rotating it onto the stem (5) in the
closed position. If necessary, turn the stem blade to
align with the ball slot. Make certain that the stem
blade is in the middle of the ball slot; i.e. equal distance
from the ends of the slot. Rotate the ball if necessary
(see Figure 3).
15. Gently place the body gasket (65) into the machined
recess of the body (1).
16. Place the second seat (7) into the insert (2) so that the
proper surface adjacent to the ball, (see Figure 3).
NOTE: For Barrier seat assembly, (see Section 4.6.2).
17. Liberally apply Dow Corning 111 Lubricant & Sealant,
or equivalent, to the threads of the socket head cap
screws (73) and the set screws (72).
22. Cycle the valve slowly with a gentle back and forth
motion building gradually to the full quarter turn. By
cycling slowly, the seat lips will seat against the ball.
Take care to avoid scratching the ball O.D.
4.5 Pressure Testing the Valve
WARNING
WHEN PRESSURE TESTING, EXERCISE CAUTION AND MAKE SURE
ALL EQUIPMENT USED IS IN GOOD WORKING CONDITION AND
APPROPRIATE FOR THE INTENDED PRESSURE.
If the valve is to be tested prior to returning to service make
sure the test pressures are in accordance with an applicable
standard.
When testing the valve for external tightness, keep the ball
in the half open position.
If testing the valve seat tightness, please contact Metso for
advice.
WARNING
WHEN PERFORMING ANY TESTS, NEVER EXCEED THE MAXIMUM
OPERATING PRESSURE OR MAXIMUM SHUTOFF PRESSURE LISTED
ON THE IDENTIFICATION PLATE!
4.6 Barrier Seat Assembly
18. Install the set screws in manner that they do not
protrude through the insert (2) or above the insert face.
Wipe all excess lubricant from the insert surface.
19. Fit the insert (2) into the valve body (1), aligning the
mounting holes in the insert with the threaded holes
in the body.
20. Compress the insert (2) into the body (1) to relieve
tension on the socket head cap screws (73). The load
must be evenly distributed around the ange of the
insert. Ensure that the socket head cap screw positions
are not obscured. Install the lubricated socket head
cap screws and tighten them in a crisscross pattern
to approximately 23 INLBS. Slowly relieve the load
compressing the insert.
WARNING
A MINIMUM OF TWO 2 SOCKET HEAD CAP SCREWS, OPPOSITE
EACH OTHER, ARE REQUIRED TO SECURE THE INSERT. IT IS NOT
RECOMMENDED TO PLACE A VALVE BACK IN SERVICE WITH LESS
THAN TWO 2 INSERT SCREWS 73!
21. If valve is equipped with a handle, aligning the slot in
the handle with drive on the stem, lower handle (31)
straight down in line with the valve stem until it is
completely engaged. Place handle pin (35) through
hole in handle.
This section covers the disassembly and assembly of Barrier
Seats only. Follow the instructions in the DISASSEMBLY
and ASSEMBLY sections of this IMO for all other parts.
4.6.1 Disassembly
1. Break the tack welds and remove the seat (7) and O-ring
(49) from the valve insert (2) and body (1), BEING
CAREFUL NOT TO SCRATCH ANY SEALING SURFACES
INTHE BODY OR THE INSERT.
2. Clean the areas that were previously tack welded in
both the body and the insert to bare metal.other parts.
4.6.2 Assembly
1. Place O-ring (49) in the groove on the back of the seat
(7). A small amount of lubricant, compatible with the
commodity in the tank car, applied to the O-ring will
help hold the O-ring in the groove during assembly.
2. Insure that all sealing surfaces are cleaned before
continuing.
3. Slide the rst seat (7) with O-ring (49) into the body (1)
below the stem opening and tilt it into place so that the
proper face will come in contact with the ball (3), (see
Figure 6).
IMO 4/19
8 IMO-R20 EN
4. Center and rmly clamp the seat (7) and O-ring (49)
into the body (1) using the xture in Figure 7. Ensure
threads of threaded rod and nut are clean and in good
condition. Apply a lubricant compatible with the media
to the threads. To compress each seat, apply a torque of
12 – 15 ft lbs to the nut. Tack weld the seat into position
per the instructions indicated in Figure 7.
5. Assemble seat (7) and O-ring (49) into the insert (2)
using steps 1 – 4 above and Figure 7.
7
49
5. REPAIR KITS
*Refer to Section 1.2, Valve Markings and check area “3” on
your Valve’s identification plate to determine the correct
seat material for your valve.
See Table 1 for Repair Kit part numbers.
TABLE 1.
REPAIR KITS
PTFE SeatsRKR-53TT
Xtreme® SeatsRKR-53XT
Barrier SeatsRKR-53MB
6. SERVICE / SPARE PARTS
For further information on spare parts and service
or assistance visit our web-site at www.metso.com/
products/valves/tank-car-valves/.
NOTE: When ordering spare parts, always include the
following information:
Figure 6 Proper Seat Placements
a. Valve catalog code from identication plate.
b. If the valve is serialized – the serial number (from
identication plate)
c. From Figure 8, the ballooned part number, part
name and quantity required.
d. Repair kits contain one pair of seats, a body seal,
stem seals and a secondary stem seal.
IMO 4/19
Plate or Bar
0.1875 Min. Typ.
3/8-16 Threaded Rod x 3" Long
ø5.375
(4) Cut-outs for Welding Purposes
1.Hold o-ring in place in back ofseat with compatible greaseduring assembly.
2.Clamp seat rmly in body orinsertseat cavity.
3.Tack weld 1/4"(6.35 mm) long in(4) places 90˚ apart using 308Lweld rod. Do not exceed 300˚F atweld. Clean weld areas to baremetal before welding.
IMO-R20 EN 9
0.1875 Min. Typ.
3/8-16 Threaded Rod x 3” Long
Plate or Bar
(4) Cut-outs for Welding Purposes
Figure 7 Barrier Seat Fixture & Instructions
ø5.375
1. Hold o-ring in place in back of
seat with compatible grease
during assembly.
2. Clamp seat firmly in body or
insert seat cavity.
3. Tack weld 1/4”(6.35 mm) long
in (4) places 90˚ apart using
308L weld rod. Do not exceed
300˚F at weld. Clean weld areas
to bare metal before welding.