Dear User,

Thank you for purchasing the Piston valve.

To maximize
your benefits from this product, we request you to read
these instructions thoroughly before installing the valve. If
you experience any difficulty with the installation or operation of this
valve please contact our customer service representative.

Piston Valves
This user manual corresponds to Piston Valves
Part Code No. F3A2017810 ,Revision 3,printed
on Feb 2010. If you experience any difficulty with
the installation or operation of this equipment,
please contact our Customer Service
representative.

Forbes Marshall Pvt. Limited

Whats Inside

1.1 Description :
Piston valves provide perfect tightness and durable stability on different mediums
such as steam,superheated steam,heat transfer fluid,water and compressed air.

1.1 Description
1.2 Size & pipe connection
1.3 Limiting conditions
1.4 Installing the valve
1.5 Operation

1.2 Size and Pipe Connections :

15 NB / 20 NB / 25 NB /32NB/ 40 NB
Screwed BSPT/NPT ends.
Socket weld ends.
50NB/65NB/80NB/100NB/125NB/150NB/200NB
Flange type : ANSI 150
Flange type : ANSI 300

1.6 Safety information

1.7 Maintenance
1.8 How to use extractor
1.9 How to use insertor
2.0 How to order spares

Limiting Conditions as per IBR norms :

For (15,20,25 & 40NB) socket weld ends.
Maximum operating pressure
: 78 bar g
Maximum operating temperature : 4250 C
Maximum hydraulic test pressure :156 bar g
For 15,20,& 25NB screwed ends.
Maximum operating pressure
: 78 bar g
Maximum operating temperature : 4250 C
Maximum hydraulic test pressure : 156 bar g
For (32 - 40 NB) screwed ends.
Maximum operating pressure
: 41.5 bar g
Maximum operating temperature : 4250 C
Maximum hydraulic test pressure : 83 bar g

1.3 Limiting Conditions :

For 50NB/65NB/80NB/100NB/125NB/150NB/200NB
Body design conditions : ANSI 300 Flanged ends
Maximum allowable pressure
: 51 bar g @ 380C
Maximum operating Pressure
: 41.5 bar g @ 2530C
Maximum operating temperature : 4250 C @ 28.8 bar g
Maximum hydraulic test Pressure: 83 bar g
Body design conditions : ANSI 150 Flanged ends
Maximum allowable pressure
: 19.6 bar g @ 380C
Maximum operating Pressure
: 14 bar g @ 1970C
Maximum operating temperature : 4250 C @ 5.5 bar g
Maximum hydraulic test Pressure : 28 bar g
Operating Range :
425

50-200 NB
50 NB

300
200

Steam
saturation
curve

100

0
0

10 14*

20

30

40 41.5*

51

Pressure bar g

The product must not be used in this region.

A - B Flanged ANSI 150
A - F Flanged ANSI 300
* PMO- Maximum operating Pressure

15/20/25 NB
5

32/40 NB

65-200 NB

1.4 Installing the Valve :

Please ensure before installing the
valve that the line is clear from all
foreign particles such as welding
fluxes, metals burrs and dirt.
It is preferred to keep in the valve
in open position to allow
maximum heat dissipation during
welding operation.
The valve should be fitted either in
Vertical or Horizontal line with inlet as
per the arrow direction on the valve
body.
1.5 Operation :
To open the valve turn the hand
wheel till it stops at the top and to
close the valve turn hand wheel till it
touches the bonnet. If any leakage is
observed through the gland, tighten
gland nut till leakage stops, if any
leakage is observed between the
body, bonnet face & outlet tighten
opposite Nuts equally half or one turn
until leakage stops. Never tighten
nuts when valve is in open
condition. Do not use Valve for
throttling. It should be either fully
open or fully close.
1.6 Safety Information :
Hazard analysis
Warning
The graphite
sealing rings
contain thin stainless steel
support rings which may cause
physical injury if not handled and
disposed of carefully.
Welding
a) Keep your head out of the
fumes.
b) Use enough ventilation,
exhaust at the arc or both, to keep
fumes and gases away from your
breathing
zone and the general
7
area.

c) Wear correct eye, ear and body

protection
d) Do not touch live electrical
parts
Safe operation of this product can
only be guaranteed if it is properly
installed, commissioned, used and
maintained by qualified personnel in
compliance with the User Manual.
General installation and safety
instructions for pipeline and plant
construction, as well as the proper
use of tools and safety equipment
must also be complied with.
1.6.1 Intended use
Referring to the User Manual, Nameplate & Technical Instruction Sheet,
check that the product is suitable for
the intended use/application.
i)The products have been specifically
designed for use on steam, air or
water / condensate.Use on other
fluids may be possible but, if this is
contemplated,Forbes Marshall
should be contacted to confirm the
suitability of the product for the
application being considered.
ii)

Check material suitability,

pressure and temperature and
their maximum and minimum
values. If the maximum
operating limits of the product
are lower than those of the
system in which it is being fitted,
or if malfunction of the product
could result in a dangerous overpressure or over-temperature
occurrence, ensure a safety
device is included in the system
to prevent such over-limit
situations.

Iii) Determine the correct installation

situation and direction of fluid flow.
iv) Forbes Marshall products are
not intended to withstand
external stresses that may be
induced by any system to which
they are fitted. It is the
responsibility of the installer to
consider these stresses and take
adequate precautions to
minimize them.
1.6.2 Access
Ensure safe access and if necessary
a safe working platform (suitably
guarded) before attempting to work
on the product. Arrange suitable
lifting gear if required.
1.6.3 Lighting
Ensure adequate lighting,
particularly where detailed or
intricate work is required.
1.6.4 Hazardous liquids or gases
in the pipeline
Consider what is in the pipeline or
what may have been in the pipeline at
some previous time. Consider:
flammable materials, substances
hazardous to health, extremes of
temperature.
1.6.5 Hazardous environment
around the product

1.6.6 The system

Consider the effect on the complete
system of the work proposed. Will any
proposed action (e.g. closing isolation
valves, electrical isolation) put any
other part of the system or any
personnel at risk? Dangers might
include isolation of vents or protective
devices or the rendering ineffective of
controls or alarms. Ensure isolation
valves are turned on and off in a gradual
way to avoid system shocks.
1.6.7 Pressure systems
Ensure that any pressure is isolated
and safely vented to atmospheric
pressure. Consider double isolation
(double block and bleed) and the
locking or labelling of closed valves. Do
not assume that the system has
depressurised even when the
pressure gauge indicates zero.
1.6.8 Temperature
Allow time for temperature to normalise
after isolation to avoid danger of burns.
Consider whether protective clothing
(including safety glasses) is required.
1.6.9 Tools and consumables
Before starting work ensure that you
have suitable tools and /or
consumables available. Use only
genuine Forbes Marshall replacement
parts.

Consider: explosion risk areas, lack

of oxygen (e.g. tanks, pits),
dangerous gases, extremes of
temperature, hot surfaces, fire
hazard (e.g. during welding),
excessive noise, moving machinery.
8

1.6.10 Protective clothing

Consider whether you and /or others
in the vicinity require any protective
clothing to protect against the
hazards of, for example, chemicals,
high /low temperature, radiation,
noise, falling objects, and dangers to
eyes and face.
1.6.11 Permits to work
All work must be carried out or be
supervised by a suitably competent
person. Installation and operating
personnel should be trained in the
correct use of the product according
to the User Manual. Where a formal
'permit to work' system is in force it
must be complied with. Where there
is no such system, it is recommended
that a responsible person should
know what work is going on and,
where necessary, arrange to have
an assistant whose primary
responsibility is safety.
Display 'warning notices' if
necessary.
1.6.12 Handling
Manual handling of large and /or
heavy products may present a risk of
injury. Lifting, pushing, pulling,
carrying or supporting a load by
bodily force can cause injury
particularly to the back. You are
advised to assess the risks taking
into account the task, the individual,
the load and the working
environment and use the appropriate
handling method depending on the
circumstances of the work being
done.

1.6.13 Residual hazards

1.7 Maintenance :
For 15-50NB

In normal use, the external surface of

the product may be very hot. If used
at the maximum permitted operating
conditions, the surface temperature
may reach temperatures in excess of
425C (797F). Many products are
not self-draining. Take due care
when dismantling or removing the
product from an installation.

Unless otherwise stated in the User

Manual, this product is recyclable
and no ecological hazard is
anticipated with its disposal providing
due care is taken.

Maintenance of Piston valve is very

easy and can be done when valve is
in position and not in service. If any
leakage is observed through the
Bonnet hole tighten all nuts equally
(refer 1.5). If leakage still does not
stop then follow the procedure
mentioned below.
Keep Valve fully open remove nuts
(7) & Belliville Washer (8) turn
handwheel in clockwise direction till it
touches the bonnet. Pull hand wheel
carefully along with Bonnet to
remove piston from Body. Avoid any
damage to piston. Clean Piston with
Soft Cloth. Remove top Sealing
Rings (9) with the help of extractor,
Remove Spacer (10) (which is free in
the body) Remove Bottom sealing
rings (9) with the help of Extractor.
Replace new set of Bottom sealing
rings Spacer and Top sealing rings
stack with the inserter. Align piston
with the Top sealing ring and push
gently. Ensure that the belleville
washers are placed properly in cup
form and tighten all nuts with equal
pressure when the Piston is at the
end of bottom sealing rings.Please
refer Page No. 12-15 for Extractor
& inserter sealing ring stack &
page 21 for component details.
Maintain body and bonnet gap as
per table 1

1.6.17 Returning products

For 65-200NB

Customers and stockiest are

reminded that while returning
products to Forbes Marshall they
must provide information on any
hazards and the precautions to be
taken due to contamination residues
or mechanical damage.

Maintenance of Piston valve is very

easy and can be done when valve is
in position and not in service. If any
leakage is observed through the
gland tighten gland nut to stop the
leakage through gland and to stop
the leakage at outlet or between the
body and the bonnet face tighten all
nuts equally as explained earlier. If

1.6.14 Freezing
Provision must be made to protect
products which are not self-draining
against frost damage in
environments where they may be
exposed to temperatures below
freezing point.
1.6.15 Safety information
The graphite stem sealing rings
contain thin stainless steel support
rings which may cause physical
injury if not handled and disposed of
carefully.
1.6.16 Disposal

Leakage yet does not stop then

follow the procedure mentioned
below.
Keep Valve fully open remove nuts &
Belleville Washer turn handwheel in
clockwise direction till it touches the
bonnet. Pull hand wheel carefully
along with Bonnet to remove piston
from Body. In case the bonnet
assembly does not come out of the
body use tapped hole for
removing bonnet assembly as
shown in Fig 1. Avoid any damage to
piston.Clean Piston with Soft Cloth.
Remove top sealing stack with the
help of extractor, Remove Spacer
(which is free in the body). Remove
Bottom sealing stack with the help of
extractor. Replace Bottom sealing
stack, place spacer and replace top
sealing stack with the inserter. Insert
Bonnet sealing ring (Graphite)
carefully. Place Bonnet pistonspindle sub assembly on clean table.
.To replace gland sealing rings
remove nyloc nut and handwheel.
Hold bonnet by hand and remove
spindle-piston sub assembly by
rotating spindle in clock wise
direction with the help of screw driver.
Remove gland nut and extract gland
sealing stack with extractor. Insert
new gland sealing stack with the
inserter. Screw gland nut in the
bonnet.Place bonnet on spindle
piston sub assembly and rotate
spindle in anticlockwise direction till it
stops.
Align Bonnet piston sub assembly in
the Top sealing stack and push it
gently. Place the handwheel on the
square of spindle, Place name plate
and nyloc nut. Place Beleville washer
in the cup form as shown in the
diagram and hand tighten all the
nuts. Now rotate handwheel in
clockwise direction till it touches the
bonnet. (Close position of the valve).
10

Tighten all the nuts with equal

pressure.Open isolation valve, if any
leakage is observed through the
gland tighten gland nut. In case
leakage is observed at the outlet or
between body face and bonnet
tighten opposite nut equally half or
one turn as explained earlier.
Please refer Page No. 16-19 for
Extractor & inserter sealing ring
stack & page 21 component
details.
For Lubrication use Molykote M30
lubricating oil.Lubricate
frequently through
spindle
threads ,split nut and stem.
Operate once or twice after
lubrication.

Gap between Body & bonnet face

TABLE 1
SIZE
15/20/25NB
32/40/50NB
65NB
80NB
100/125NB
150NB
200NB

PUSH GENTLY
BY HAND

Two tapped holes

provided for
removing the
bonnet assly. from
body by tightening
the bolts

1.8 How to use Extractor:

Insert Sealing Ring Stack on the

inserter as shown in Page No. 13, 15,
18 & place the inserter inside the
body perpendicular to the face.
Ensure that sealing ring Stack is
properly guided in the body bore.
Now use a Mallet to push the inserter
inside the body to place the bottom
sealing stack. After placing bottom
sealing stack ,remove inserter from
the body ,place spacer inside the
body (which is free in the body).Now
Repeat the same process to insert
top sealing ring stack with the help of
inserter.
11

FOR 15-40NB

EXTRACTOR TOOL

BONNET

Insert extractor in the body dig

extractor in the sealing rings & lever
up to remove Top Sealing Stack as
shown in Page No. 12, 14, 16.
Remove spacer (which is free) from
the body. Repeat the same process
to remove bottom sealing Stack, as
explained above.
1.9 How to use Inserter :

GAP(mm)
6
9.5
17
18
20
26
30

GAP
BODY

(Ref. Above Table)

EXTRACT TOP SEALING RING STACK FIRST

PUSH GENTLY
BY HAND

EXTRACTOR TOOL
Fig 1

SIZE
65/80/100/125NB
150/200NB

TAPPING
M12
M16

REMOVE SPACER WHICH IS FREE IN THE BODY

EXTRACT BOTTOM SEALING RING STACK

12

MALLET

FOR 50NB

INSERTOR TOOL
PUSH GENTLY
BY HAND

EXTRACTOR TOOL

INSERT BOTTOM SEALING RING STACK FIRST

MALLET

EXTRACT TOP SEALING RING STACK FIRST

INSERTER TOOL

SEALING RING STACK

PLACE SEALING STACK IN

THIS WAY ON INSERTOR

PLACE SPACER WHICH IS FREE IN THE BODY.

4

13

INSERT TOP SEALING RING STACK

REMOVE SPACER WHICH IS FREE IN THE BODY

EXTRACT BOTTOM SEALING RING STACK

14

FOR 65-200NB

MALLET

PULL
INSERTOR TOOL

EXTRACTOR

15

INSERT BOTTOM SEALING RING STACK FIRST

PLACE SPACER WHICH IS FREE IN THE BODY.

INSERT TOP SEALING RING STACK

EXTRACT TOP SEALING STACK FIRST

REMOVE SPACER (WHICH IS FREE)

FROM THE BODY

16

PULL

INLET

INSERT SPACER (WHICH IS FREE)

IN THE BODY KEEPING BLIND WALL OF
SPACER AT THE INLET SIDE OF THE VALVE

EXTRACT BOTTOM SEALING STACK

MALLET

INSERTER

17

INSERT BOTTOM SEALING STACK

INSERT TOP SEALING STACK

18

INSERTER TOOL

COMPONENT LIST AND LUBRICATION

DETAILS
5

11

12
OIL

SEALING RING STACK

LUBRICATION POINT
REFER 1.7 MAINTENANCE

PLACE SEALING STACK IN

THIS WAY ON INSERTOR

3
10

1
9

INLET

15-25 NB Piston Valve

Always open & close Valve fully
Do not use Valve Key

EXTRACT GLAND SEALING STACK

Description of Component
No.
1
2
3
4
5
6
7
8
9
10
11
12

19

Part
Body
Bonnet
Piston
Spindle
Nyloc Nut
Stud
Nut
B. Washer
Sealing Rings
Spacer
Handwheel
Name Plate

Recommended tightening
torques for bonnet nuts
SIZE
15NB
20NB
25NB

TORQUE
3-5 Nm
5-7 Nm

INSERT GLAND SEALING STACK

20

14

OIL
5

11

LUBRICATION POINT
REFER 1.7 MAINTAINANCE

OIL
12

LUBRICATION POINT
REFER 1.7 MAINTENANCE

4
7

13

INLET

10

40-50 NB Piston Valve

Always open & close Valve fully
Do not use Valve Key

INLET

Description of Component 32-50NB

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Part
Body
Bonnet
Piston
Spindle
Nut
Stud
Nut
B. Washer
Sealing Rings
Spacer
Handwheel
Split Nut
Thrust Plate
Name plate

OPEN POSITION
(Always open valve fully)

Recommended tightening
torques for bonnet nuts

65-200 NB Piston Valve

Always open & close Valve fully
Do not use Valve Key

SIZE
65NB
80NB
100NB
125NB
150NB
200NB

TORQUE
50-60 Nm
70-80 Nm
80-90 Nm

21
22

NYLOC NUT
NAME PLATE
HANDWHEEL

How to order spares

Always order spares by using the description & P.C. No. given below & stating size
15-50NB
65-200NB

GLAND NUT
GLAND SEALING STACK
BONNET

SPINDLE
SPLIT NUT

Spare kit contains : Sealing ring stack

spare kit contains : Body sealing ring stack
Bonnet sealing ring
Gland sealing ring stack

Part codes for spares

Sl.

Description

Part Code No.

15/20 NB Spare Kit

F3A2017591

2.

25 NB Spare Kit

F3A2017592

3.

32/40NB Spare Kit

F3A2017678

4.

50 NB Spare Kit

F3A2017679

THRUST PLATE

65 NB Spare Kit

F3A2019470

STEM

6.

80 NB Spare Kit

F3A2017740

100 NB Spare Kit

F3A2017741

125 NB Spare Kit

F3A2019421

150 NB Spare Kit

F3A2017742

10

200 NB Spare Kit

F3A2017743

BACK SEAT
PISTON
SS WASHER
LH NUT
BONNET SEALING RING
TOP SEALING STACK
SPACER
STUD
NUT
BELEVILLE WASHER
BOTTOM SEALING STACK

BODY

65-200NB
EXPLODED VIEW
23

24

Notes

25

Notes

26