KIRLOSKAR BROTHERS LIMITED,

VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

INDEX

1. Introduction
2. Inspections on Receipt, Handling, Storage & Preservation
2.1 Inspection on Receipt & Handling
2.2 Storage & prevention
3. Instructions for Installation
3.1 Checks on Valve Assembly before Installation
3.2 Checks for the Pipeline before Installation
4. Commissioning
4.1 Pre- commissioning Checks
4.2 Commissioning
5. Operations
6. Maintenance Instructions
7. Troubleshooting of Kirloskar Foot Valves
8. Recommended Spares for Foot Valves
9. Safety Instructions
10. Ordering Information
11. Warranty Clause
12. Environmental Aspect
13. Product Recycle Program
14. Intimating Product / Performance Complaint

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DOC. VBU/IOM/Foot Valve-01
Issue No. 00, Rev. 01, Date 18.10.2022
KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

KIRLOSKAR SWING TYPE FOOT VALVE

1. INTRODUCTION

Flanged End Foot Valve

Typical View
Figure 1.

A foot valve is generally placed at the lower end of the suction pipe of a
centrifugal pump to prevent the suction pipe from emptying while the pump is
at rest; consequently, when the pump is first started it does not have to
exhaust the air from the suction pipe with the result that prompt starting of
the pump is secured. Foot valve is particularly useful when the suction lift or
vertical height of the pipe is considerable.
Kirloskar Foot Valves generally conform to IS:4038 standards for
dimensions, materials of construction and constructional features. These
Foot Valves are Rubber- Metal Seated.

2. INSPECTION ON RECEIPT, HANDLING, STORAGE & PRESERVATION

2.1 INSPECTION ON RECEIPT AND HANDLING

a. At receipt of the product, ensure that there is no transit damages to the

product received, especially on valve flanges, door faces etc.
b. Also ensure that Parts and Accessories are received as per ordered
scope of supply.
c. Ensure that adequate numbers of fasteners for mounting accessories
are received.

d. While unloading the product, please use the provision of lifting made
on the valve.
e. Use the safe lifting devices (e.g. slings, hoists, hooks etc.) of adequate
capacity.
f. Do not pass the slings through the weak parts of the product /
accessory
(e.g. strainer – when it is assembled on the valve).
g. The valve should be transported so that the rests on the horizontal floor
properly.
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KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

h. Support the valve properly during transportation to avoid toppling.

i. Handle the product carefully – do not push, drag, drop from height.

If damages, short supply or wrong supply are observed, report the same
immediately to the contact person mentioned in this manual.

2.2 STORAGE & PRESERVATION

If the valve has to be stored at site before installation,

a. Store it on horizontal level surface in dry and clean atmosphere.

b. Store the products in well-covered sheds, protected from sun, rain and
dust.
c. In the instance if the valve is required to be stored for long duration,
ensure that rust preventive should be applied on the machined
corrodible surfaces.
d. It is advisable to give a coat of grease on seat rings during the storage
period. Keep the seat rings away dusty atmosphere.

3. INSTRUCTIONS FOR INSTALLATION

CHECKS ON THE VALVE ASSEMBLY BEFORE INSTALLATION

a. Before taking the Foot Valve for pipe installation, make sure that it is
cleaned from inside and outside and there are no foreign or metallic
objects sticking on to its sealing elements. Also clean the valve interior
passages to remove any foreign matter & rust preventive on machined
surfaces.
b. Ensure that the entire rust preventive on the machined surface in the flow
area is removed, before the valve is put in pipe-line.
c. Note the marking details on valve body and valve pressure rating
adequacy with respect to operating pressure. Also check direction of flow
in the pipe-line and place the Foot Valve accordingly.
d. Valves should be installed in the pipeline, only after verifying the sealing
ability of valve. This can be done by examination of the seat surfaces for
freedom from surface damages, scratch marks / dent marks as well as
uniform mating of seating surfaces. If abnormalities of this type are
observed, contact KBL.
e. Foot Valve s are designed to generally operate in suction pipe lines or in
suction side. Operate the Door of Foot Valve manually from Full Close to
Full Open and Full Open to Full Close. Ensure that there is no undue
resistance / friction in the operation.
f. Before connecting valve & pipeline flanges, ensure that they do not have
parallel, angular and radial gaps. While fitting the valve in pipeline, ensure
that diagonally opposite bolts are simultaneously & uniformly tightened.
g. Orientation of Hinge Pin of the valve, while fitting in the pipe-line must be
horizontal. This can be ensured by checking verticality of edges of top &
bottom drilled flange holes with a plumb line.

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KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

CHECKS FOR THE PIPE-LINE BEFORE INSTALLATION

a. Clean the pipeline thoroughly so that it does not contain any solid matters
which may damage the valve internals.
b. Avoid parallel, radial and angular mismatch between connecting flanges of
valve and the pipeline.
c. Piping should be adequately supported and anchored (if required) in such
a way that the piping system does not impose any forces & moments on
the valve body and the hydraulic thrust arising due to valve closure is
carried & sustained by valve supports. Valve flanges are not designed to
carry any external loads and moments arising due to pipe expansions /
contractions. It is advisable to use Flange Adapter Assembly, after the
valve to facilitate valve dismantling and to prevent any undue loads being
transmitted to valve flange.
d. Ensure that pipeline flanges are parallel and are mating the valve flange
without leaving any parallel, angular or radial gap between the flanges. Do
not over-tighten the flange bolts / nuts to make the flanges parallel
forcefully. That may develop undue stresses in the valve flanges & body
leading their deformation & malfunctioning.
e. Maximum flow velocity in the pipe-line should not exceed 4 m/s.
f. The valves are mainly designed for handling clear water h maximum
impurities of 5000 PPM.

4. COMMISSIONING

4.1 PRE-COMMISSIONING CHECKS

a. Ensure manually that the valve operates smoothly.
b. The entire pipe flange bolting is properly tightened.
c. Surge protection devices (if any) are operative.

4.2 COMMISSIONING

a. Charge the pipe-line with water.

b. Ensure that there is no leakage through flange gaskets.

Now the valve is commissioned for its Operation.

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KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

5. OPERATION

As shown in Figure, the valve consists of a body, a disc, and a seat with a
resilient seal. The valves are designed to prevent reverse flow and maintain a
flooded suction when installed at the foot or end of the suction piping. The
resilient seal provides drop tight shutoff and the strainer prevents debris from
entering the valve and piping system. The seat and seal are rigidly held in the
bottom of the valve. As the flow enters the valve from the bottom, the disc is
lifted by the flow. Upon pump shut down, the return flow and weight of the disc
close the valve rapidly and maintain the pump prime.

6. MAINTENANCE INSTRUCTIONS

Maintenance Check Points:

Sr. Parameter to Check Method of Weekly During

Checking Overhaul
01 Leakage through valve seat Visual / Feel •
02 Noise / Vibrations while Opening or Feel •
Closing the Valve
03 Condition of Door Face /slant faces – Visual & feeler •
scratches, dent marks, intactness gauge
04 Condition of Hinge Pin Visual •

Kirloskar Foot Valves require very little maintenance if maintenance check

point are attended to during periodic inspection & during overhaul. However,
valves could malfunction in unusual conditions of usage, water contamination
and may require maintenance as below:

7. TROUBLE SHOOTING OF KIRLOSKAR FOOT VALVE S

Sr. Problem Probable Reason Action Required

01 Leakage through the a. External object caught a. Try to flush away the
valve seat between door face & body external object by
ring. creating flow to flush it
away. If it does not work,
open flanged joint to
reach the object and
remove it manually (**).

b. Replace the Door face /

b. Worn out / Deformed or Body ring
damaged seat ring / door face

02 Leakage through a. Inadequate tightening of a. Re-tighten the flanged

side flanges flanged joint joint
b. Damaged gasket
c. Parallel / angular gap between b. Replace gasket (**)
valve and pipe flanges c. Remove parallel / angular
gap between valve and
pipe flanges (**)

IMPORTANT (**): All these procedures require emptying piping and

removal of the valve from the pipeline.

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KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

(%%) : As the Body Rings / Door Faces require very

precise machining for surface for mating surface finish, interference fit in their
respective recesses and accurate mating, confirmation of blue match for leak-
tight performance; we strongly recommend that this operation of Body Ring /
Door Face Ring should be replaced at KBL factory only

8. RECOMMENDED SPARES FOR FOOT VALVES

Product Cross Sectional and General Assembly Drawing attached with this
manual indicates the components of the respective valves, along with the
recommended spares.
We strongly recommend to keep the spares handy all the time to be able to
eliminate delays in attending the operation troubles and scheduled
replacements / overhauls.

9. SAFETY INSTRUCTIONS FOR “KIRLOSKAR” MAKE

VALVES TO BE FOLLOWED BY USER, AT SITE
[These Safety Instructions are the integral part of “Instruction
Manual for Installation, Operation and Maintenance of Kirloskar
Make Valves”]
PART – A: GENERAL INFORMATION & SAFETY
REQUIREMENTS

1. The Products supplied by KBL have been designed with safety in mind.
Where hazards can not be eliminated, the risk has been minimized by the
use of guards and other design features. Some hazards can not be
guarded against and the instructions below MUST BE COMPLIED WITH
for safe operations. These instructions can not cover all circumstances;
USER of the product is responsible for using safe-working practices at all
times.
2. KBL product are designed for installation in designated area, which are to
be kept clean and free of obstructions that may restrict safe access to the
controls and maintenance access points.
3. Access to the equipment should be kept restricted to the personnel
responsible for installation, operation and maintenance and they must be
trained, adequately qualified and supplied with adequate tools for their
respective tasks.
4. KBL requires that, all personnel that are responsible for installation,
operation or maintenance of the equipment, have access to study the
product instruction manual BEFORE any work is done and they will
comply with all local and industry based safety instructions and
regulations.
5. Personnel protection safety equipment must be worn where local rules
apply.
6. Read the instruction manual before installation, operation and
maintenance of the equipment.
7. Note that the limit of product application and permissible use of the
product is according to the respective product design & testing standard

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KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

and product pressure rating. Operation of the equipment beyond these

limits will increase risk from hazards and may lead to premature and
hazardous failure of the valve / accessories.
8. Clear and easy access to all controls etc. must be maintained at all times.
Hazardous or flammable materials must not be stored near valves unless
safe areas or racking and suitable containers have been provided.
9. IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF THE
KBL PRODUCT COULD RESULT IN INJURY OR DEATH.

PART – B: SAFETY INSTRUCTIONS WHLIE HANDLING, STORAGE AND

USAGE

1. For handling / lifting the valves, use devices of adequate capacities

certified by competent authorities.
2. Before fitting the valve in pipeline, ensure that Pressure Rating of the valve
is suitable for maximum working pressure / surge pressure that may arise
in the pipeline.
3. During using the valve, ensure that approved technical rules & regulations
e.g. trading regulations, regulations for prevention of accidents, steam
boiler regulations, regulations of gas mains under high pressure,
regulations for combustible fluids, local safety regulations etc. are
followed.
4. During repairs / maintenance of the valve at site, the user shall take
minimum following precautions:

a. Provide adequate working platform near the valve.

b. Make pipelines pressure less and harmless i.e. switch off the pumps,
empty the pipelines, remove and switch-off all electric connections (in
case of electric operated valves).
c. If work is carried-out in vicinity of the valve, which leads to dusty
atmosphere (e.g. concrete work, masonry, painting, sandblasting etc.) the
valve / valve components must be covered effectively.
d. Valve operator/Workmen/Supervisors have to ensure that, no any Body
Part should be near Seat Ring or on seat ring when doors are in open
position. It may cause serious injury due to quick / Sudden closing of
valve Doors

10. ORDERING INFORMATION

(To be sent to the Contact Person mentioned in this manual)

Details required to be furnished while ordering Spares

a. KBL Order Acceptance Number (O/A No. or Sale Order No.)

b. Product Description – Type, Size, Pressure Rating etc.
c. Product Serial No. (This is hard punch marked on Valve Flange)
d. KBL SAP Product Code – This code is mentioned in the Invoice though
which the product has been dispatched.
e. KBL Cross Sectional Assembly Drawing No. for the product (if provided)

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KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

f. Required Part Name & Part No. as shown in the Cross Sectional
Assembly drawing.
g. Material of construction of the required part, as that appears in the Cross
Sectional Assembly drawing.

11. WARRANTY CLAUSE

Kirloskar Brothers Limited (KBL) warrants that the valve manufactured

and supplied by KBL to be free from defects in material, workmanship
and construction, when used in accordance with installation and
technical instructions provided, for a period of twelve months from the
date of commissioning of the equipment or 18 months from the date
of dispatch of valve from its factory, whichever is earlier.

THIS WARRANTY DOES NOT APPLY TO VALVES WHICH ARE

MISUSED, OR ABUSED, OR DAMAGED FROM INSTALLATION, OR NOT
USED IN ACCORDANCE WITH KBL’S INSTRUCTIONS. NORMAL WEAR
OF VALVES IS NOT INCLUDED IN THIS WARRANTY.

Any parts or other accessories not manufactured by Kirloskar Brothers

Limited but supplied through KBL shall carry the warranty of the
original manufacturer.

KBL’S SOLE LIABILITY UNDER THIS WARRANTY SHALL BE LIMITED

TO EITHER REPLACING OR REPAIRING WITHOUT CHARGE, AT ITS
FACTORY OR ELSEWHERE AT ITS DISCRETION, ANY VALVE NOT
MEETING THIS WARRANTY, OR AT KBL’S OPTION, REFUNDING THE
PURCHASE PRICE. KIRLOSKAR BROTHERS LIMITED SHALL IN NO
EVENT BE LIABLE FOR ANY OTHER DIRECT OR ANY SPECIAL
INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND UNDER THIS
CONTRACT OR OTHERWISE.

Kirloskar Brothers Limited warranty does not cover and KBL makes no
warranty with respect to any defects, failures, deficiencies, or errors
which include but are not limited to: (a) Not timely reported to KBL; or
(b) Due to misapplication, modification, disassembly or abnormal
conditions or corrosive matters; or (c) Due to operation, either
intentional or otherwise, in an improper manner; (d) damage during
transit.

In case of delay of delivery due to lack of instructions from a customer

or delay in accepting delivery by a customer, the period of 18 months
shall be considered from the date of notification from Kirloskar
Brothers Limited to customer that the valves are ready for dispatch.

The foregoing warranty constitutes KBL's sole liability.

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KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED,

INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE.

For Installation , Operation & Maintenance Manuals pl. refer

following link :
www.kirloskarpumps.com  DOWNLOAD CENTRE  Product IOM
Manual  Product Category  Valve

12. ENVIRONMENTAL ASPECT

Our products are designed and manufactured considering all environmental

aspects to minimize impact on the environment. We ensure that the product
supplied by us utilizes less energy during their life cycle and it does not emit
any hazardous gas or cause any harm to any living being or to the
environment.
User of this product is recommended to follow the operating instructions and
maintain the product in periodic manner, in order to ensure that it always
functions with optimum energy efficiency.

13. PRODUCT RECYCLE PROGRAM

As a commitment towards a greener future, conservation of natural resources

and reduction of carbon foot print, Kirloskar Brothers Limited offers to take
back/replace its used products once it has reached the end-of-life and ensure
that it is recycled/ disposed in an environment friendly manner with the
following objective.
 To facilitate our customers for recycling / safe disposal of ‘end-of-life’
product in environment friendly through a recycle program.
 To minimize the impact caused by product disposal on society /
environment.
 To reuse the recyclable components as secondary source of raw
material.
 To ensure implementation of control mechanism over third part for
recycle/safe disposal of the waste generated.
 To offer or replace customer’s existing product with more efficient and
environment friendly product.
End of life of Kirloskar Brothers Limited product shall be considered, when a
customer has declared that the product has become redundant (the product
has become obsolete/unfit for use/non-functional and cannot be refurbished in
consultation with Kirloskar Brothers Limited personnel) Or the customer
wishes to replace the existing product for a shift in technology/for replacement
of product by latest/advanced technology of more energy efficient friendly
product.
As the product reaches its End-of-Life, the customer shall communicate the
same through the Kirloskar Brothers Limited mail ID,
cusotmercare.recycle@kbl.co.inor approach the nearest Customer Support
Service/Regional Offices/ Authorized Dealer/Authorized Service Dealers who
in turn shall communicate the same to Zonal Customer Support Service
representative.
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KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

14. INTIMATING PRODUCT / PERFORMANCE COMPLAINT

(Information to be sent to the Contact Person mentioned in this manual)

While communicating product complaint, furnish following information to help

us to resolve the problem promptly.

a. KBL Order Acceptance Number (O/A No. or Sale Order No.)

b. Product Description Type, Size, Pressure Rating etc.
c. Product Serial No. (This is hard punch marked on Valve Flange)
d. KBL SAP Product Code This code is mentioned in the Invoice though
which the product has been dispatched.
e. KBL Cross Sectional Assembly Drawing No. for the product (if provided)
f. Exact nature of complaint

If the complaint is related to Short Supply, Wrong Supply, Transit Damage, it

is necessary to communicate the Invoice Number which will help in tracking
the cause of the problem.

## AS A CONTINUOUS IMPROVEMENT PROCESS, THE CONSTRUCTION &

ARRANGEMENT SHOWN IN DRAWING MAY DIFFER WITH ACTUAL PRODUCT.

In case if you need additional information or help, please contact:

Customer Support Cell

Kirloskar Brothers Limited
“Yamuna”, Survey No.98/ 3 to 7,
Baner,
Pune- 411045
Toll free no: 1800-10-34443
e-mail: kirloskarvalves@kbl.co.in

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KIRLOSKAR BROTHERS LIMITED,
VALVE BUSINESS UNIT, KIRLOSKARVADI, INDIA

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