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Valve Service
Aug 24, 2018

Installation, Operation and Maintenance Instructions

for Conbraco’s

IBV-125 Series

Cast Iron Ball Valves

1 IOMM-IBV125-299

Valve IBV-125 IBV-E-125

Size (Standard) (Epoxy Coated) Repair Kit

2” 6P-208-01 6Q-208-01 6P-028-01

2-1/2” 6P-209-01 6Q-209-01 6P-029-01

3” 6P-200-01 6Q-200-01 6P-020-01

4” 6P-20A-01 6Q-20A-01 6P-02A-01

6” 6P-20C-01 6Q-20C-01 6P-02C-01

8” 6P-20E-01 6Q-20E-01 6P-02E-01

10” 6P-20G-01 6Q-20G-01 6P-02G-01

Introduction

This manual presents guidelines for the Installation,

Operation and Maintenance of Conbraco’s Full Port Cast

Iron Ball Valve, the IBV-125 Series. Review the entire

manual before beginning any work.

Installation

Proper valve selection is the first step in any successful

installation. Refer to the "Conbraco’s Cast Iron Ball

Valve" catalog for application guidance or contact your

distributor or the factory for more detailed assistance.

>Pre-Installation Inspection<

A leading cause of premature valve failure is poor

house-keeping. Inspect the piping system prior to valve

installation, whenever possible, to insure that it has been

properly flushed and cleared of construction and

fabrication debris. The seating surfaces in soft seated

valves are particularly susceptible to weld slag and sand

blasting grit. Pipe scale, metal chips and other foreign

materials should be removed.

Prior to installation, remove the valve from its packing

and remove any end covers. Examine the flow bore for

debris. All of Conbraco’s ball valves are shipped in the

open position to prevent damage to the ball surface.

Any foreign matter must be removed. Do not install a

damaged valve.

>Flanged End Valve Installation<

After determining that the valve is in good condition,

attention should be given to the flange face. Dents and

heavy scratches should be repaired. Do not install

damaged valves.

Conbraco’s Cast Iron Ball valves may be installed in any

position using standard pipe fitting practices. Special

considerations are required when bolting cast iron

valves to steel flanges. When Class 125 CI valves are

to be bolted to Class 150 steel flanges, the steel flanges

shall be flat faced. Due to the brittle nature of cast iron,

consideration should also be given to proper piping

alignment.

Operation

The IBV-125 series features quarter turn operation; full

open to full closed. Standard operation is clockwise to

close. Valves 2” through 6” are furnished standard with

a lever operator. The 8” and 10” valves have gear

operators and handwheels as standard. Gear Operators

are available for all sizes.

Maintenance

Due to its simplicity, the only preventive maintenance is

to periodically inspect the valve for leaks and ease of

operation. Do not disassemble or remove any part

from a valve under pressure. Before removing a

valve from the line, place it in the half-open position to

remove any line pressure or pressure trapped in the

body cavity.

>Valve Adjustments<

The stem packing was adjusted at the factory to provide

a leak-tight seal when the valve was new but,

compaction can occur within these seals that makes readjustment

necessary. Stem leakage should be stopped

as soon as it is detected. Adjust the packing gland bolts

per the following table:

Valve Gland Bolt Torque

Size Size (max.)

2” 3/8”-16UNC 20 ft-lbs

2-1/2” 3/8”-16UNC 20 ft-lbs

3” 3/8”-16UNC 20 ft-lbs

4” 3/8”-16UNC 20 ft-lbs

6” 1/2”-13UNC 45 ft-lbs

8” 1/2”-13UNC 45 ft-lbs

10” 5/8”-11UNC 93 ft-lbs

Do not over tighten. Over-tightening will result in

excessive operating torque. If stem leakage continues,

or operating torque becomes excessive, de-pressurize

the valve and replace the stem seals. Obtain repair kits

from the factory.

Valves with high operating torque not resulting from

stem seal over-tightening or valves which have leakage

past the seats may have damaged seats or ball

surfaces. These valves should be de-pressurized,

removed from the piping system, disassembled and

inspected for damage.

2 IOMM-IBV125-299

>Valve Overhaul<

The first step is to contact your distributor to acquire an

appropriate rebuild kit. These kits contain a complete

set of seats, seals and gaskets.

Disassembly Process

1. Assure appropriately sized wrenches and lifting

devices are available.

2. Place the valve in the half-open position, assuring

no pressure is trapped in the valve body.

3. Remove the handle or valve operator.

4. Remove the packing gland fasteners, gland plate

and gland ring.

5. Remove the body bolts and remove the tail piece

from the valve body.

6. Using an appropropriate lifting device, remove the

ball from the body cavity.

7. Remove the stem from the valve body. Due to

presence of corrosion products it may be necessary

to drive the stem from the valve body using a soft

face hammer, being careful not to damage the

stem.

Inspection

Note: If replacement of the body or ball is required, we

recommend replacement of the entire valve.

1. Thoroughly clean all the components in preparation

for inspection.

2. Examine the sealing surfaces within the body. If

these surfaces are pitted or deeply scratched the

valve must be replaced. A scratch is anything you

can feel with your fingernail. Machining marks may

be present and will not interfere with sealing.

Scratches that can be seen but not felt may be

polished out using #120 grit emery cloth or finer.

3. Examine the stuffing box. Polish these surfaces

with #120 (or finer) grit emery cloth and inspect for

pits and scratches. Deep scratches running down

the side of the stuffing box will necessitate the

replacement of the valve.

4. Examine the stem. Machine marks may be present

extending around the part. These will not interfere

with effective sealing. If longitudinal scratches or

pitting is present, the stem must be replaced.

5. If the ball has pits or scratches as described above,

it should be replaced.

6. Inspect the spare parts provided to assure they are

correct, in good condition and have not suffered

damage in storage or shipment.

Re-assembly

1. Use a lubricant which is recommended for the

intended service. Only small amounts of assembly

lubricants are necessary.

2. Lubricate the new seats and install them in the body

and tail piece.

3. Lubricate the stem. Install the thrust washer on the

stem and install the stem in the body.

4. Lubricate the new stem packings and place them

one at a time over the stem and push them to the

bottom of the stuffing box.

5. Lubricate the gland ring and install with the original

gland bolts provided they are in good condition.

Tighten only finger tight at this time. Rotate the

stem to the closed position.

6. Place the body with the cavity facing upward. Lower

the ball into the body cavity making sure the stem

slot in the ball aligns with the tang on the stem. The

ball should come to rest on the body seat.

7. Set the new body gasket in place.

8. Set the tail piece onto the body. On larger tail

pieces use appropriate lifting equipment to set the

tailpiece. Lift the tail piece by opposite pipeline

flange bolt holes and lower it onto the body. It may

be necessary to use a heavier grease on the tail

piece seat to hold it in its place during this step.

9. Align the pipeline flange bolt patterns (two-hole).

10. Install the body fasteners hand tight. Torque to the

value indicated in the table below in three equal

steps using a criss-cross pattern.

11. Torque the packing gland fasteners to the level

indicated in the section >Valve Adjustments<.

12. Install the operating mechanism, lever or gear, in its

original orientation. Cycle the valve three to five

times to assure smooth operation.

13. Complete the re-assembly with a check of the body

bolt torque by going around the bolt pattern

clockwise at the specified level. Check the packing

gland fasteners torque again at this time.

14. The valve is now ready for testing and use.

Valve Body Bolt Torque

Size Size (max.)

2” 1/2”-13UNC 45 ft-lbs

2-1/2” 1/2”-13UNC 45 ft-lbs

3” 1/2”-13UNC 45 ft-lbs

4” 1/2”-13UNC 45 ft-lbs

6” 9/16”-12UNC 57 ft-lbs

8” 5/8”-11UNC 93 ft-lbs

10” 5/8”-11UNC 93 ft-lbs

Final Adjustments

Occasionally after testing or initial start-up, a minor stem

or packing leak may occur. Adjust the packing plate

bolts in accordance with the section entitled "Valve

Adjustments".


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