Service Manual
Contents
1. ACTUATOR TYPE POSITIONER TYPE LIMIT SWITCH TYPE SAAS MAINTENANCE SAAS MAINTENANCE SERVICE MAINTENANCE 6 SERVICE MAINTENANCE l SERVICE MAINTENANCE SERVICE MAINTENANCE SERVICE MAINTENANCE i SERVICE MAINTENANCE Oy FR Valve Products Ab L tv gen 2 FI 68570 Larsmo Finland www frvalve fi info frvalve fi TEL 358 0 6 78155 OO FAX 358 0 6 78155 49 MOBILE 358 0 50 512 37232. FRP BALL VALVES TABLE OF CONTENTS GENERAL HANDLING Receiving and Storing Installation in the Pipeline Supporting the Valve Start up MAINTENANCE OF THE INSTALLED VALVE Gland Packing Body Joint Ball and Seats Jammed or Stuck Valve RE ASSEMBLING Cleaning and Inspection of the Parts Installation of the Ball and Seats valve MAINTENANCE AND INSTALLATION INSTRUCTIONS Body Joint between the Body Halves Fitting the Body Joint Gasket Tightening the Body Joint Bolts Gland 1 1 411 8 iner 10 Fitting the Braided Gland 0 10 TEST PRESSURE INSTALLATION OF THE ACTUATOR Actuator Hand Lever Valve Parts Ordering Spare Parts Assembly Drawings Grinding Compounds and Belts Valve Stamping APPENDIX 1 Dimension Drawing of Tools for Pulling Out Actuators DWG No 8546 APPENDIX 2 Installation of Valve Types A and B Valve Details INSTRUCTIONS Z O lt lt lt O Z lt O lt 2 H lt lt GENERAL The ball valve is flanged or has a collar and a loose flange or butt and strap end It has two symmetrical body halves a one piece ball and a stem with the ball supported by its seats Standard valves are tight in both flow directions because the ball is against the downstream seat The valve can serve as a tight
3. 150 For unlubricated bolts the torque valves must be multiplied by 1 5 The flange bolt tightening sequence should be as indicated in the example below Start opposite the stem initially by hand then using 10 of the torque values given in Table 2 After that tighten to 50 and finally 100 of the torque values given Fig 11 A typical flange bolt tightening sequence 5 4 Gland packing 5 4 1 Fitting the braided gland packing The braided PTFE strip is generally used as gland packing If no pre cut rings are available cut the braided strip as shown in Fig 12 on the valve shaft Cut vertically with a sharp thin knife If a support ring is required place it at the bottom of the packing box Tap each packing ring in position one by one with a bushing or with the packing gland Locate the packing joints at a 90 angle to each other and a 45 angle to the flow opening No clearance must be visible between the ends of the packing rings and finally before installation in the pipeline TABLE 4 Dimensions of the packing box Shaft d Packing width b Strip Packing box depth h mm mm mm DN 100 DN 125 DN 150 DN 200 DN 250 DN 300 DN 350 400 DN 500 DN 600 DN 700 DN 800 45 Tighten the non pressurised gland packing three times initially when W h the valve is assembled then after it has been pressure tested 1 Table 5 below gives the tightening torques and minimum allowable ti
4. opening of the ball Fit the stop plate with the bearing bushing if required onto the stem Tighten the stop plate fastening nuts preliminarily Determine the open and closed positions of the ball by twisting the lever against the open and closed position pins Check the open position with the flow opening and the closed position with the position of the lever relative to the keyway and the body joint Finally tighten the stop plate A knob is fitted in the hand lever to facilitate locking of the valve in intermediate positions of the hand lever Stop plate Hexagon nut Washer Bushing Key shortened VALVE PARTS 8 1 Ordering spare parts Please give the following details in your order sheet Valve type given on the identification plate and in all related documents Part code number If the spare parts list is used the name and quantity of the part or the number of the parts list the item number the quantity and the name of the part 8 2 Assembly drawings Parts list 10 1 12 13 14 15 16 17 Part description Body Ball Seat Gland packing Body gasket Gland Bracket Loose flange Hex nut Hex nut Hex nut Stud Hex bolt Stud Washer Washer Washer Material FRP FRP PTFE C25 PTFE 109 Coretex AISI 6 Fe 37B Fe 380 Zn ISO 3506 A4 ISO 3506 A4 ISO 3506 A4 AISI 316 ISO 3506 A4 AISI 316 AISI
5. packing leaks after the nuts have been tightened to the values indicated in item 5 4 1 change the packing The valve must not be under pressure when this is done The change can be carried out without removal of the actuator because cut packing rings have been used Remove the old packing with a flexible removal tool see Fig 3 Fig 3 Removal of gland packing Install the new packing as instructed in item 5 4 with a removing tool 3 2 Body joint Should the body joint leak tighten the nuts to the torque values given in item 5 3 2 If leaking continues open the body and check the body joint gasket Also check that the body joint sealing surfaces are level and undamaged see item 5 3 1 3 3 Ball and seats Pressure A leak rate exceeding the acceptable values can be caused by the ball being incorrectly located between the seats or damaged sealing surfaces resulting from dirt grit etc At low differential pressures or due to the weight of the actuator the force pressing the ball against the downstream seat can be inadeguate and the valve may leak Therefore it will be necessary to swing the ball externally against the downstream seat by means of spacer washers located between the actuator and one of the brackets Fig 4 Swinging the ball by means of the actuator installation brackets If damage to the downstream sealing surface of the ball is suspected try to stop the leak by turning the ball 180 deg
6. shutoff valve HANDLING 2 1 Receiving and Storing Check that the valve has not been damaged during transportation Store the valve properly before installation Do not take it to the erection site until ready for installation Do not remove the protection plates before installing the valve in the pipeline The valve is always shipped in the open position 2 2 Installation in the pipeline Flush or blow the pipelines clean before installing the valve Impurities sand and parts of welding electrodes could damage the ball surface and seats There are three marks to indicate the open or closed position of the valve a an arrow on the drive centre of the actuator b a groove at the end of the ball stem c the keyway of the ball stem All of the marks are in the same direction as the flow opening If you feel uncertain about any arrow check the groove and the keyway Place the lifting belt around the valve body Never lift the valve by the actuator see Fig 1 The valve can be installed in any convenient position however avoid installing it with the stem downwards because any gland packing leakage could pass over the actuator If possible install the valve in such a position that the actuator can if necessary be removed without removal of the valve from the pipeline Be sure to use flange gaskets that are suitable for the operating conditions Do not attempt to correct pipe misalignments by means of the flange bolts The actuator must no
7. 316 AISI 316 AISI 316 16 EQUIPMENT No special tools are needed to repair ball valves However a special removal tool is recommended for the actuator removal for dimensions refer to Appendix 1 9 1 Tools For body and neck bolts it is recommended to use socked tools 9 2 Grinding compounds and belts For the ball and seats Grinding cloth with a coarseness of for pre grinding 160 to 320 for finishing 600 For sealing surfaces of the stem Grinding cloth with a coarseness of about 400 9 3 Valve stamping Identification plate pressure class nominal size valve number maximum temperature ma valve 18 Electrode esim 6 9 ESAB OK 75 65 Lubricating a Molykote BR2 R Supporting ring Du Ds x 2 20 21 VALVE DETAILS SERIAL NUMBER valve CUSTOMER LOCATION INSTALLATION DATE SERVICE CONTRACT YES 0 PRESSURE RATING VALVE SIZE DESIGN AND APPLICATION MATERIAL MOUNTING PARTS
8. ghtening margins If the margin is too small add another packing Fig 12 Cutting a braided packing strip ring Tighten with a torque wrench 1 Tightening margin XJ xD Fig 13 Tightening margin for new gland packing STEM DIA NUT SIZES TIGHTENING TORQUE TABLE 5 Tightening torques for gland packing MIN ALLOWED TIGHTENING MARGIN ft lb mm in 37 10 3 8 66 13 1 27 110 13 1 2 TEST PRESSURE The valve test is performed according to the pipeline standards see Table 6 The test duration of shell test and seat test in minutes with water as medium Pressure rates according LOO1 TABLE 6 Press rating Material of flange drilling valve body Shell test bar PSI Test Pressure of ball seats in bar Nominal size DN 100 4 DN 500 20 ANSI 150 ANSI 300 PN 10 PN 16 PN 25 15 220 45 675 15 220 24 350 38 550 Nominal size DN 600 24 DN 1000 40 DN lt 100 4 max 15 220 DN 100 max 15 DN 150 500 6 14 max 6 90 max 6 bar 90 max 4 bar 60 max 2 5 bar 37 TABLE 7 Nominal size DN Shell test in MIN Seat test in MIN Fig 14 Leak test of the valve 80 lt DN lt 15 200 lt DN lt 250 300 lt DN lt 450 500 lt DN lt 1000 Should the differential pressure across the PTFE seated valve be lower than the test pressure for the seats test the seats at working pressure Choose the
9. nd body joint surfaces If the damage is so severe that the valve cannot be repaired by changing the parts return it assembled to the manufacturer for repairs Fig 7 Sharp edges of sealing RE ASSEMBLING Re assemble the valve such that the body half with a tongue in its flange lies underneath Place this male part in an upright orientation body joint up on a level surface Then install the parts in the following order seats 5 2 e ball 5 2 body joint between the body halves 5 3 gland packing 5 4 In each of the above phases assemble a group of parts the construction of which will vary slightly with the valve application Detailed instructions and description of the construction of the groups of parts are given later The last phase is to hammer the ball stem key into place 5 1 Cleaning and inspection of parts Begin by checking the parts Remove any burrs and scratches and again clean the internal parts For PTFE seated valves check that the outer periphery of the seats is undamaged 5 2 Installation of the ball and seats In each size the bodies ball and seats are interchangeable Assembly of PTFE seats The seats are pre pressed to ensure a good tightness even at low differential pressures The shape of the pre pressed seats guarantees good valve sealing and tight shutoff ability The pre pressed edge must be unbroken N The clearance need not be checked as the inner parts ball and seat
10. rees If the leakage continues then the downstream seat or possibly both sealing surfaces of the ball are damaged Turn the ball back to its original position and then turn the entire valve 180 degrees in the pipeline Should the leakage still persist it will be necessary to disassemble the valve and carefully check the sealing surfaces 3 4 Jammed or stuck valve Jamming or sticking can be caused by process accumulation between the ball and the body Turn the ball and thoroughly flush the valve inside 4 REPAIR OF THE VALVE It may be necessary to remove and disassemble the valve if the above steps in item 3 do not resolve the problems 4 1 Removing the valve from the pipeline First remove the valve with its actuator from the pipeline Then turn the valve to remove all process material If the process is toxic or corrosive flush the valve to avoid accidents If the valve is going to be returned to the manufacturer for repairs do not disassemble it 4 2 Disassembling the valve Disassemble the valve on a clean level surface of wood cardboard or plastic Place the valve standing on its flange Support the actuator so that it cannot fall over when the installation bolts are removed Remove the actuator installation bolts Pull the actuator away from the stem either with a removal tool or by hand The removal tool is shown in Appendix 1 Remove the brackets from the valve Tap Loose the key at the end of the ball s
11. t touch the pipeline as pipeline vibrations might damage it or cause incorrect operation Do not install a flanged valve Type A for collars A flanged valve must be fixed to the flange and sealed with a full face seal Fig 1 How to lift a ball valve Fig 2 How to support ball valve 2 3 Supporting the valve A well supported pipeline minimises strain to the valve caused by vibrations in the pipeline For maintenance it would be preferable to support the pipeline not the valve However if necessary support it by the body with pipe clamps and supports Do not fasten supporting structures to flange bolts or to the actuator See Fig 2 2 4 Start up Check that the pipeline is clean Should the valve leak when the pipeline is pressure tested the cause might be an insufficient quantity of testing liquid or a very low pipeline pressure from the ball not being pressed tightly against the seat In this case increase the differential pressure or assist the movement of the ball by loosening the actuator brackets then lightly knocking the steam or body If it is necessary to loosen the brackets make sure that the open position does not change The packing may leak after long storage Tighten it uniformly with both nuts see item 54 MAINTENANCE OF THE INSTALLED VALVE No regular maintenance is necessary However check the gland packing tightness at regular intervals 3 1 Gland packing If the gland
12. tem Remove any burrs from the keyway edges Loosen the gland packing nuts Remove the bolts that fasten the body halves in place Lift the upper body half and place it flat on its flange Fig 6 Removal of the actuator with the removal tool 3 Inspection and maintenance of the valve parts Check each part separately and determine the steps to be taken 4 3 1 Ball Lift the ball from the body onto a soft surface and clean the stem Remove impurities with emery cloth File off any burrs from the stem keyway If there are any deeper scratches on the sealing surfaces or if the ball is not fully spherical it must be returned to the manufacturer for repair 4 3 2 PTFE seats PTFE seats do not need to be removed if they are still in good condition unless process material has accumulated behind them If the original seats are to be refitted remove them very carefully by means of a thin knife or screwdriver Insert the blade between the body lip and seat and lift the seat from the groove from several points 4 3 3 The body The body gasket must always be replaced during maintenance Clean all sealing surfaces carefully Do not round the sharp edges at the convergence point of the body joint as this could cause leakage See Fig 7 4 3 4 Other parts Clean all remaining parts the gland box nuts and bolts etc After cleaning and inspection keep all parts well protected until re assembly O O especially the ball seats a
13. test pressure according to the lower pressure rating i e that of the body or the flange drilling as appropriate During the shell test use blind flanges and keep the ball partly open No leakage is allowed through PTFE seated FRP valves with new ball and seats when DN 500 applies INSTALLATION OF THE ACTUATOR 71 Actuator The Neles drive centre is suitable for various types of control units Clean the stem bore File off any burrs Lubricate the stem bore and ball stem Fasten the actuator brackets to the valve loosely Insert the reducing bushing in the actuator stem bore if required In the actuator stem bore there are two keyways at a 90 angle from each other The ball stem has a keyway parallel to the flow port of the ball 13 When mounting a cylinder actuator choose the actuator keyway that establishes the piston in its upper position top end of the cylinder when the valve is closed When installing a screw operator choose the actuator keyway that establishes the closed valve position when the handwheel is turned clockwise Push the actuator onto the ball stem extremely carefully Any excess force may damage the sealing of the ball and seats When there is a threaded hole at the end of the stem the actuator can be pulled into position with a bolt Position the actuator to be as straight as possible with regard to the valve Lubricate the fastening bolts and tighten them along with the bracket nu
14. ts Adjust the open and closed positions of the ball by means of the adjustment screws in Stop screw for closed position Stop screw for open position Fig 15 Open and closed position of the actuator the actuator see Fig 15 The correct open position is obtained by means Bracket of the flow opening and the closed position by means of the arrow marked on the actuator Hexagon bolt No adjustments are necessary if the actuator was installed on the same Hexagon nut valve previously It is only necessary to drive the actuator to its open position and then twist the entire actuator Turn the ball to the fully open position and tighten the bolts and nuts Secure the stop screw at Washer Bushing the top of the cylinder with a non hardening sealant such as Loctite 76 Key For the installation parts required see figures 16 and 17 with part lists Washer 8 pcs in size 40 Actuator Ball valve Actuator 1 Ball Valve 7 2 Hand lever When a hand lever is installed on the valve the ball stem has a shortened key to avoid interference with the lower surface of the stop plate or the bearing bushing Push the hand lever onto the ball stem parallel to the flow
15. will not be changed Fit seats into both body halves Fit a ball into position on the male body half and fit the body joint gasket as instructed in step 5 3 N N 5 3 Body joint between the body halves 5 3 1 Fitting the body joint gasket The gasket is a soft PTFE strip Fig 9 Fitting the soft PTFE strip Fit the sealing strip to the body half as shown in Fig 9 TABLE 1 Dimensions of the soft PTFE strip Valve size Strip O Strip length in 3 16 3 16 3 16 3 16 5 16 5 16 5 16 5 16 5 16 5 16 3 8 5 16 Press the strip against the mounting bushing so that part of it will extrude into the packing cavity when the body halves are mounted together Cut the strip leaving about 5 mm extra at both ends 5 3 2 Tightening the body joint bolts After fitting the body joint gasket lift the female body half complete with pre installed seat see item 5 2 to the ball Turn and align the body halves so that the sealing surfaces do not form noticeable steps between the body halves Lubricate the flange and neck bolts screw into place and tighten to the torque values given in Table 2 If hexagon bolts are used as flange bolts the tightening is simpler if the bolts are inserted from below so that the nuts are screwed on above the body joint flange TABLE 2 Torgues for bolts lubricated Bolt size M16 Tightening torque Nm 200 Tightening torque ft lb
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