USER MANUAL - Axel Larsson Maskinaffär AB
Contents
1. OPERATION The opening and closing of the valve is done by turning the handle a quarter turn 90 a valve is in open position when the handle is in line with the valve and pipe line b valve is in closed position when the handle is across the pipe line 5 2 AUTOMATED OPERATION Valve can be automatically operated by A pneumatic actuators DA or SR B hydraulic actuators C electrical actuators D gear box ma nually operated In this case no stop is fitted on the valve since it is normally a part of the actuators 1 9008 UK I Ref 1 900B UK 04 2012 www axel larsson se USER MANUAL Ball valve AL 37 AL 38 6 0 MAINTENANCE CAUTION Before starting the maintenance be sure that all pressure on the pipe is relieved open and close the ball valve at least once to release the pressure completely also from the valve body the ball valves if correctly used normally do not need any internal lubrification and maintenance However when necessary ball or seats can be replaced only by relatively qualified personnel following the instruction of the manual without needs to use any machinery for further information about the recommended SPARE PARTS LIST please check drawing catalogue or contact the factory 6 1 STEAM LEAKAGE If leakage is evident on stem packing area it can be eliminated by increasing the tightness of the lock nut 2B In case leakage is still per sisting the replacement of the stem packing 3 is reco2. cover on the ends of the valves shall not be removed 3 4 ATMOSFERIC PROTECTION a it is advisable to store the valve in waterproof conditions in a buil ding with an adeguate roof Ball valves shall be protected to safeguard against all the environments humidity moisture rain dust dirt sand mud salt air salt spray and seawater b all valves complete with actuators are to be stored in closed and dry conditions 3 5 LONG STORAGE PERIOD Valves to be stored for a long time shall be checked by the quality control personnel every 6 months every 3 months when valves are actuated 3 6 MAINTENANCE DURING STORAGE PERIOD a internal surface must be inspected to check complete dust or other foreign parts absence b old rust or any dust must be removed by wiping with proper solvent c after cleanig ball valves must be lubrificated by using an adeguate lubrificant d ball valves must be operated for a least 2 complete cycles 4 0 INSTALLATION 4 1 THE BALL VALVES MAY BE INSTALLED IN ANY POSI TION USING A STANDARD PIPE FITTING PRACTICES AXEL LARSSON Z1 Manufacturer Starline Italy 4 2 INFORMATION AND CAUTION BEFORE INSTALLA TION OF THE VALVE a pipe must be free of tension b pipe must be flushed to clean the dirt burrs calamines welding residues etc which would damage ball and seats c the valve must be kept in OPEN POSITION during installation and protective plastic cover must be removed only at the moment of
3. AXEL LARSSON Z1 TABLE WITH TIGHTNESS VALUES FOR HANDLE NUT 2A 2B AND BODY BOLTS l6 Valve Handle nut 2A Body bolts part no 16 DN Lock nut 2B Full bore Reduced Dimensions Nm Inch Dimensions Nm Inch bore LBS LBS 8 MIOxI 8 70 M8x17 35 310 10 15 MIOxI 8 70 M8x17 35 310 15 20 MIOxI 8 70 M8x17 35 310 20 25 MI2x1 25 15 130 M10x22 50 440 25 32 MI2x1 25 15 130 M10x22 50 440 32 40 MI5xI 5 25 220 MI2x30 70 620 40 50 MI5xI 5 25 220 MI2x30 70 620 50 65 MI5xI 5 25 220 MI2x30 70 620 65 80 M22x1 5 40 355 MI2x35 70 620 80 100 M24x2 50 440 MI2x35 70 620 ITEM PART NAME NO 6 1 Gland packing 8 1 jJOmRingstem 79 1 Bal 1 18 e Start up 5 of ordered quantity e Suggested materials after 2 years service ee Suggested materials after 5 years service AXEL LARSSON Xi www axel larsson se Head Office Axel Larsson Maskinaffar AB Truckvagen 12 P O Box 805 SE 194 28 Upplands Vasby Stockholm Sweden Telephone 46 8 555 247 00 Fax 46 8 555 247 90 E mail info axel larsson se Design and specifications subject to change without prior notice
4. Ref 1 900B UK 04 2012 www axel larsson se USER MANUAL Ball valve AL 37 AL 38 1 0 SCOPE This manual is intended as a guide to assist custumers or end users for storage installation and maintenance of Starline ball valves in the standard arrangements For this reason subsequent additions and special instruction to the present manual will be provided in case of special ball valve critical services or customer requirements 2 0 APPLICABILITY This manual is applicable to Starline ball valves 3 0 STORAGE 3 1 INFORMATION ON SURFACE PROTECTION EXTERNAL INTERNAL AND PACKING DETAILS a before shipment from Starline factory all c s valves A105 LF2 are protected against corrosion by phosphated treatment b all S S valves 304 316 F51 F44 F321 etc are pickled and passivated c a pure vaseline oil is used as lubrificant on all internal surfaces this may be removed with a solvent if found objectionable All valves are adeguately packed into a strong cardboard case in such a way to avoid any possible damage during transport and storage period before use 3 2 CAUTION AND MAINTENANCE PERIOD 3 3 IF BALL VALVES ARE NOT DESTINATED FOR IMME DIATE USE FOLLOWING CAUTIONS MUST BE TAKEN a if possible it would de advisable to leave the ball valves in their own packing cases during the entire period of storage b ball valve must remain in open position during all this time c in order to prevent any damage the protective plastic
5. e values given in the table 9 2 BALL SEATS AND SEALS RE ASSEMBLY a insert the fourth seat into the body and then insert the ball b insert the seat retainer 23 together with the seat 10 and retainer seal 18 and then repeat the operations on the opposite way ONLY NOW you can assemble the no 2 end caps and tighten c repeat the operations on the third way third and fourth in case of 4 ways 10 0 TESTING a after having completed the re assembly check for the maneuvrabi lity of the valve and make sure that ball rotates freely b if facilities are available test the ball valve to the appropriate speci fication 11 0 AUTOMATED BALL VALVES a if the valve is automated reinstall the actuators and please note that the handle is not used If necessary reset the stops First set the valve in open position and check that ball is fully open Second set the valve in closed position and check adjusting if necessary for the best closure b CAUTION Valves with electrical actuators should be tested star ting from valve in HALF OPEN HALF CLOSED POSITION This is to ensure that electrical connection is all right and rotation is correct In case of wrong position switch off electrical actuators immediately and change the direction Limit and torque switches are ineffective if rotation is wrong 1 9008 UK 2 Ref 1 900B UK 04 2012 www axel larsson se USER MANUAL Bal l valve AL 3 7 AL 3 8 Manufacturer Starline Italy
6. ful not to damage the ball c remove handle nut A2 name plate handle stop washer 17 lock nut 2B spring washer 4 gland packing 6 d push the stem 5 into the body 12 Remove packing rings 7 from body and O ring 8 plus thrustwasher 7 from stem 8 0 INSPECTION AND REPLACEMENT With the valve completely disassembled clean and examine all the following components a surface of the ball any surface defect particulary in the seating area will be extremely detrimental to the performance of the valve and therefore the ball should be replaced if found defective b seats replacement of seats is recommended c stem seals and body seals also to be discarted and replaced by a AXEL LARSSON Z1 Manufacturer Starline Italy new one d remaining components of the valve after cleaning it is required a careful examination for wear corrosion and mechanical damages par ticulary on threaded components If components are found defective they should be replaced 9 0 RE ASSEMBLY Clean inside of body and stem housing A light oil grease compatible with line fluid can be used on ball seats and stem surfaces 9 1 STEM RE ASSEMBLY a replace thrust washer and O ring 7 8 and then insert the stem from inside body b install the packing ring 3 gland packing 6 spring washer 4 and lock nut 2B and tighten To avoid rotation of stem apply temporarily the handle c install stop washer 17 handle name palte handle nut 2A and tighten se
7. installation d at the moment of the shipment the ball is lubrificated with a pure vaseline oil which can be easily removed with a solvent if required e ball valves normally have a space between ball and inside cavity of the body which could trap the product care should be taken to drain the cavity f care should always be taken to install the automated ball valves Check for a correct actuator rotation and well done alectrical con nection 4 3 INSTALLATION OF THREADED ENDS Use conventional sealant such as hemp core ptfe etc 4 4 INSTALLATION OF WELDED ENDS BALL VALVES SW BW with short ends instructions for welding the valve on the line l tack weld in four points on both end cap 2 lift out the center piece and complete the welding 3 insert the center piece and control for easy operation WELDED NIPPLES or integral nipple B instructions for welding the valves on the line with valve in open position tack weld in four points on both ends and then complete the welding without desmantling the valve and control for easy operation 4 6 INSTALLATION OF FLANGED ENDS Easy fitting on the adeguate bolts nuts and gaskets 5 0 OPERATION CAUTION During the operation the ball valves must be in either complete OPEN or CLOSED position in order to ensure their smooth and efficient working and long duration of seats Leaving the ball in half open position could eventualy cause damage to the soft seats 5 1 MANUAL
8. mmended For handle nut and lock nut 2A 2B tightness see table 6 2 BODY SEALS LEAKAGE Check for the tightness of the body bolts 16 according to table in case it is still leaking it is necessary to replace the body seals 11 18 6 3 IN LINE OR SEATS LEAKAGE Check that valve is in fully closed position if so and the leakage is persisting the valve must be disassembled to replace damaged parts 6 4 SAFETY PRECAUTION BEFORE REMOVING THE BALL VALVE FROM THE LINE FOR DISASSEMBLE a check that all pressure is exhausted from the line upstream and downstream and half open the ball to ensure that no pressure is trapped in the body cavity In other words it must be drained of all fluid gas and pressure b remove the valve from the line and cycle valve at minimum full cycle to ensure that any pressure trapped is released c CAUTION If the fluid in the line and into the valve is toxic infam mable corrosive or damaging for any other reason it is advisable to take following precaution during the valve repairing use protective eye mask or glasses use gloves overalls and suitable footwear ensure that running water and fire extinguisher is easily avilable at any moment 7 0 VALVE DISASSEMBLY TO INSPECT AND OR REPLACE BODY SEALS SEATS PACKING AND BALL a set the valve in open position and take out all body bolts 16 and complete body from end connections b close the ball and remove seats 10 ball 9 and body seals 11 18 be care
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