This document provides instructions for removing, rebuilding, and reapplying a bottom outlet valve on a general-purpose tank car. It outlines the certifications and personal protective equipment required. It then lists 15 detailed steps for removing the old valve, rebuilding and testing it according to manufacturer standards, cleaning the saddle, and securely reapplying the valve using a torque wrench to ensure proper fastening.

1. Removal, rebuild, and Application of Bottom Outlet
Valves on a General-Purpose Tank Car
Overview
This job aid is designed to assist by giving step by step instruction on how to safely remove a
bottom outlet valve, rebuild, and reapply.
Certifications Required for this Job
Valve Specialist 1
Valve Specialist 2
Leak test
Task
Removing, rebuilding, and applying a UTC bottom outlet valve (BOV).
Step Actions Example
1. a) Always wear proper PPE.
b) Hard Hat
c) Hearing Protection
d) Safety Glasses
e) Safety Steel Toe Shoes
f) Gloves
g) Face Shield
h) Knee Pads
i) Facemask
This Photo
by Unknown

2. Step Actions
2. a. Confirm that the tank is clean, empty
and tagged appropriately .
b. Compare the car number on the car
with the number on the work
order/write-up. Making sure they are
the same.
c. Identify why the car was shopped.
3. a) Review Certificate Of Construction
(COC)and fittings drawings
b) Compare the valves on the COC and
fittings drawing with the valves and
valve fasteners on the car making sure
they are the same.
c) To identify the kind of valve being
removed reference the valve’s
information plate
4. a) Make sure the parts for the car are
available by checking the parts bin
area
b) Compare the work order and parts
boxes for accuracy
c) Compare the part number on the work
order with the parts in the kit
d) Take the valve kit to the work
bench and store
C

3. Step Actions Example
5.
a) Cycle valve to drain any residual water
trapped in the valve left from the
cleaning prosses.
b) Remove the bottom outlet valve (BOV)
by using the BOV cart and the proper
tools.
c) 5/8"HEX--
d) Extension-----------
e) Crows Foot/Sockets-----
f) Impact gun (Only Use for Removal)
6. Position the BOV cart under the BOV.
Jack the Platform of the BOV cart up to
the nozzle of the BOV.
7. Loosen the bolts that hold the BOV to
the tank car saddle. A pneumatic
impact gun can be used to loosen the
bolts.

4. Step Actions Example
8. Use the BOV cart to safely lower the BOV.
9. Make sure the valve is in the open
position for transporting and storage to
help protect the ball from damage.
10. Tag the BOV with the car number
written on the tag.
11. Inspect, rebuild, and test valve per valve
manufactures standards. All information
can be found on the iPad.
Reference Documents
1. RES-205
2. RES-170
3. Mckenzievalve.com

5. Step Actions
12. Clean the tongue on the saddle
of the car.
13. a) Place valve on the BOV cart for
application.
b) Verify that the sealing surface
is free of any debris.
c) Position cart and BOV under
saddle.
d) Place the proper BOV to saddle
gasket in the grooved sealing
surface on the BOV
14. a) Use the BOV cart to lift the BOV
up to the BOV saddle.
b) Make sure the tongue and groove
on the BOV and saddle are
properly seated.
c) Apply proper anti-size to the
fasteners per customer or
standard requirements.
15. a) Apply the fastener to the BOV and
saddle finger tight.
b) Use calibrated torque wrench to
apply the proper torque to the
fastener per standard or gasket
manufactures requirements.
D
B