OPERATION AND MAINTENANCE MANUAL FOR FLOATING BALL VALVES

Edition :1 Rev. 0

CONTENTS 1. 2. 3. 4. 5. 6. 7. PRECAUTIONS INSTALLATION MAINTENANCE DISASSEMBLY INSPECTION ASSEMBLY SPARE PARTS KIT HANDLING

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OPERATION AND MAINTENANCE MANUAL FOR FLOATING BALL VALVES

Edition :1 Rev. 0

1. PRECAUTIONS Protective clothing and equipment normally required when working with the fluid involved is recommended. Depressurise the line and cycle the valve as follows: place the valve in the open position and drain the line, cycle the valve to relieve residual pressure in the body cavity before removal from the line. After removal and before any disassembly, cycle the valve again several times. It is important to refer to the tag fastened on each valve for maximum pressure ratings and material description. General notes: This instruction manual is prepared to be used for installation maintenance and repair of valves only. Any other equipment fitted to the valve will not be covered by this manual. It is highly recommended to read carefully the instructions related to other equipment fitted to the valve before starting any of the following operations. 2. INSTALLATION 2.1 Handling Receipt and storage Check that the valve was not damaged during installation. Store the valve properly before installation. Keep it at covered and dry ambient before need on the erection site. Do not remove the protection plates before installing the valve into the pipeline. The valve is always delivered in the open position. Depreservation Depreserve the valve in accordance to depreservation procedures. Please note that certain valves may not be preserved but only clean-built. These are clearly marked by means of special tags. 2.2 Installation Flush or blow the pipes clean before installing the valve. Impurities, sand or welding rags might damage the ball surface and the seats. Place the lifting ropes around the valve body. Never lift the valve placing the ropes around the actuator. The valve can be installed in the most convenient position. Anyhow, we would recommend not to install it with the stem downwards , as in case of leakage through the gland packing, the flow media would run over the actuator. When installing the valve, please consider carefully the following points: disassemble the actuator without removing the cables any further instruction mentioned in the instruction manual for the actuator when tightening the flange bolts, please follow the recommendation practice of the gasket manufacturer ensure that the gaskets are suitable for the operating conditions do not attempt to correct pipe misalignments by means of flange bolts.

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OPERATION AND MAINTENANCE MANUAL FOR FLOATING BALL VALVES

Edition :1 Rev. 0

2.3 Supports Whenever possible, try to support properly the valve. This would minimise pipeline induced stress and vibrations into the valve body. It is recommended to support the valve by means of connected pipes and not by the valve body itself. Do not use, in any case, the flange or body bolts or parts of the actuator. 3. MAINTENANCE Good operation procedure requires periodic control to ensure the correct functioning of the valve. The frequency of these controls has to be established in relation to the type of service. Two main points must be observed: STEM LEAKAGE SEAT LEAKAGE STEM LEAKAGE Stem leakage could occur if O rings have been damaged. On this type of valve, external stem packing may be replaced while the valve is under pressure. Stem thrust washer is capable of generating a reasonable tight seal while the valve is under pressure for the period of time required to change stem packing. Should a under pressure repair be chosen, every precaution and procedures required to operate with the used fluid shall be adopted. SEAT LEAKAGE In order to check the proper sealing action of the seats, put the valve in closed position and bleed it through an appropriate connection downstream. No leakage should occur after the body cavity pressure and temperature are stabilised. In case of leakage of one of the seats, this type of valve will not seal properly in both directions. Whenever you discover that a seal fails, ensure you have available in stock the suitable spare parts to prevent any further damages. 4. DISASSEMBLY Before disassembling the valve, ensure you have the relevant spare parts available. Observe carefully always the instructions given in the PRECAUTIONS section. Remove the valve with its actuator from the pipeline then operate the valve to remove all flow media trapped in the body cavity. If the media is TOXIC or CORROSIVE, flush the valve TO AVOID ANY ACCIDENTS. In case that the valve should be returned to the manufacturer for repair works, please DO NOT disassemble it. When disassembling the valve, please use a clean surface such as cardboard, plastic or wood disassemble the actuator from the coupling flange following the instructions given by the actuator manufacturer in the relevant manual place the valve in the vertical position keeping the ball in the OPEN position disassemble the top plate and the stem Proceed to remove the fastening bolts between the two body sections. Lift the male body being sure that the seat doesnt pop out. Place the male body standing on its flange. Turn the ball into the closed position, clamp it by means of a nylon or rubber strip, lift it carefully and place it with the vertical bore on a soft surface

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OPERATION AND MAINTENANCE MANUAL FOR FLOATING BALL VALVES

Edition :1 Rev. 0

take the bottom seat out of the female body. 5. INSPECTION Regardless to the reason of taking the valve apart we highly recommend all steps mentioned hereinafter to be followed. Clean ball surface with a soft cloth and a solvent, if required check ball surface for major scratches, pitting or erosion particularly in the seat sealing area if scratches in ball bearing are found, immediately refer to the manufacturer since, unless especially requested, bearings are not included in the spare parts kits if scratches or other damages are found on the ball it must be changed, NO REPAIR IN ANY WAY IS ALLOWED, refer immediately to the manufacturer since the ball is not included in the spare parts kit check the stem packing and sealing area; there must be no evident scratches or wear on the surface in case of minor scratches it is recommended to polish or grind that surface check the seal of seat for any damage or deformation no scratches or deformations are allowed on the seal of seat. In case you find a damaged seat change the complete seat. After having inspected all items and replaced the fault ones, clean down all parts for assembly. All O rings and sealing rings must be replaced at any time a valve becomes disassembled. 6. ASSEMBLY A good lubricant compatible with the flow media should be applied seats, seals, ball and stem to facilitate assembly and for ease of initial operation. Clean seats and seals areas and all other parts before assembly. Assembling requires a certain skill from the operator. Before starting any assembly, please become familiar with the procedure lay down afterwards. Firesafe valves have grafoil seal rings throughout. Handling and installation of these seals requires a great amount of precautions since they are very fragile and can not be repaired. Place both female and male bodies standing on their flanges install the seat in the female body insert, by gently hammering, the stem in the adequate position. Ensure that antistatic device, if present, has not pop out install thrust washer on the stem install body O rings install the stem in the valve body lift the ball and carefully place it in the female body over the bottom seat assembly. Turn it to the closed position in order to insert the stem in the ball slot install the seat in the male body turn the male body upside down, lift it by the flange. Install it on the female body avoiding shocks that can make the seat assembly slipping out install the packing gasket around the protruding part of the stem fix the top flange aligned and tighten the screws thigten completely the body, top flange bolts and screws. Use table 1 for bolt torque

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OPERATION AND MAINTENANCE MANUAL FOR FLOATING BALL VALVES

Edition :1 Rev. 0

operate several times the valve to be sure that there are no sticks or interference. Install all accessories in accordance to their own instruction manual, test the valve in accordance to the approved procedures. 7) SPARE PARTS KIT HANDLING Spare parts kits require particular attention during storage, handling and installation. It is essential that these are not removed from their package until re-assembly of the valve can start. Many items included in the spare parts kit are very fragile and are delivered in packages suitable for their protection. Store always spare parts kits in dry covered places, dont allow them to be staked. Maintain the spares always identified by means of their originally attached labels

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OPERATION AND MAINTENANCE MANUAL FOR FLOATING BALL VALVES

Edition :1 Rev. 0

TABLE 1 BOLT SIZE diam. mm 10 12 14 16 18 20 22 24 27 30 33 36 39 42 45 48 52 56 60 64 68 72 76 80 85 90 95 100 105 110 115 120 125 TORQUE Nxm B7/L7 56.00 95.30 151.86 231.38 320.65 451.92 609.10 780.92 1146.24 1560.41 2111.51 2867.76 3697.45 4673.41 5807.51 7111.62 9076.05 11010.71 13610.65 16589.92 19974.32 23789.62 28061.60 32816.05 39355.35 47256.04 55535.61 65409.82 75634.78 86871.16 100077.81 113563.55 129289.63 TORQUE Nxm B8M/B8 30.22 51.46 82.00 124.95 173.15 244.04 328.91 421.70 618.97 842.62 1140.22 1548.59 1996.62 2523.64 3136.05 3840.28 4901.07 5945.78 7349.75 8958.56 10786.13 12846.39 15153.26 17720.67 21251.89 25518.26 29989.23 35321.30 40842.78 46910.43 54042.02 61324.32 69816.40

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Date 08.04.2002