��������

�����������

��������� ������������

����� �������

������ ��

1 P 70

������P

Table of Contents1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Reception and storing . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.2 Installation into pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . 32.3 Supporting the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 MAINTENANCE OF INSTALLED VALVE . . . . . . . . . . . . . . . . . . 63.1 Gland packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.2 Body joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.3 Ball and seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.4 Jammed or stuck valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 REPAIR OF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1 Removing the valve from the pipeline . . . . . . . . . . . . . . . . . . . 84.2 Disassembling the valve . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3 Inspection and maintenance of valve parts . . . . . . . . . . . . . . . . . 9

4.3.1 Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.3.2 Stellite seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.3.3 Locked-up stellite seats . . . . . . . . . . . . . . . . . . . . . . . . . 104.3.4 PTFE seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.3.5 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.3.6 Other parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 RE-ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.1 Cleaning and inspection of parts . . . . . . . . . . . . . . . . . . . . . . 125.2 Installation of ball and seats . . . . . . . . . . . . . . . . . . . . . . . . 12

5.2.1 Stellite seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.2.2 Locked-up stellite seats . . . . . . . . . . . . . . . . . . . . . . . . . 155.2.3 PTFE seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.3 Body joint between the body halves . . . . . . . . . . . . . . . . . . . . 185.3.1 Fitting the body joint gasket . . . . . . . . . . . . . . . . . . . . . . 185.3.2 Tightening the body joint bolts . . . . . . . . . . . . . . . . . . . . . 20

5.4 Gland packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225.4.1 Fitting the braided gland packing . . . . . . . . . . . . . . . . . . . . 225.4.2 Fitting the gland packing strip . . . . . . . . . . . . . . . . . . . . . 24

6 SUPPLEMENTARY VALVE CONSTRUCTIONS, INSTALLATION . . . . 256.1 Body with stellite bushing . . . . . . . . . . . . . . . . . . . . . . . . . 256.2 Ball with cylindrical pipe lining . . . . . . . . . . . . . . . . . . . . . . 26

7 INSTALLATION OF THE ACTUATOR . . . . . . . . . . . . . . . . . . . . 267.1 Hand lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8 VALVE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318.1 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318.2 Assembly drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8.2.1 Metal seated valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.2.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.2.3 Soft seated valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338.2.4 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.3 Valve stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359.2 Measuring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359.3 Grinding compounds and belts . . . . . . . . . . . . . . . . . . . . . . . 359.4 Actuator removing tool . . . . . . . . . . . . . . . . . . . . . . . . . . 35

- 2 -

1 GENERAL

The series P ball valve has flanges or welded ends, two symmetrical body halves, one-pieceball and stem with the ball supported by its seat rings.

Standard valves are tight in both flow directions, because the differential pressure acrossthe valve presses the ball against the down-stream seat.The same valve can serve as a throttling control valve and a tight shut-off valve.

2 HANDLING

2.1 Reception and storing

Check that the valve has not been damaged during transportation. Store the valve properlybefore installation. Do not take it to the erection site until installation is due to commence.Do not remove the protection plates before installing the valve into the pipeline.The valve is always delivered in the open position.

2.2 Installation into pipeline

Flush or blow the pipes clean before installing the valve. Impurities, sand and parts ofwelding electrodes might damage the ball surface and seats.

There are three marks to indicate the open-closed position of the valve:- an arrow on the drive center of the actuator- a groove at the end of the ball stem- the keyway of the ball stem

All are in the same direction with the flow opening. If you feel uncertain about the arrow,check by the groove and the keyway.

Place the lifting ropes 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 withthe stem downwards, because in case of leakage through the gland packing, medium wouldrun over the actuator.

- 3 -

If possible, install the valve in such a position that the actuator can, if necessary, be detachedwithout removing 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 not touch the pipeline, as pipeline vibrations might damage it or causeincorrect operation.

RIGHT

WRONG

Fig. 1 How to lift a ball valve

- 4 -

2.3 Supporting the valve

A well supported pipeline minimizes strain in the valve, caused by the vibrations in thepipeline.

For maintenance it would be preferable not to support the valve. However, if necessary,support it by the body with pipe clamps and supports. Do not fasten supporting structuresto flange bolts or to the actuator. See Fig. 2.

2.4 Commissioning

Check that the pipeline is clean.Should the valve leak when the pipeline is pressure tested, possible reasons could be aninsufficient quantity of testing liquid, or a very low pipeline pressure due to which the balldoes not press tight against the seat. Therefore increase the differential pressure or assistthe movement of the ball, for example by slackening the actuator installation brackets andgland nuts, then lightly knock the stem or body. If it is necessary to slacken the brackets,check that the open position does not change.

The gland packing may leak after long storage. Tighten it uniformly by both nuts, see item5.4.1.

Fig. 2 How to support a ball valve

- 5 -

3 MAINTENANCE OF INSTALLED VALVE

No regular maintenance is necessary. However, check the gland packing tightness atregular intervals.

3.1 Gland packing

If the gland packing leaks after the nuts have been tightened to the values given in item5.4.1, change the packing. The valve must not be under oressure during this operation.

The change can be carried out without removing the actuator if cut packing rings have beenused.

Remove the old packing for instance with flexible removing tool, see Fig. 3. Install thenew packing as instructed in item 5.4.

3.2 Body joint

Should the body joint leak, tighten the nuts as per the torques given in item 5.3.2. If theleaking continues, open the body and check the body joint gasket. Also check that the bodyjoint sealing surfaces are level and undamaged, see item 5.3.1.

Fig. 3 Removal of the gland packing with a removing tool

- 6 -

3.3 Ball and seats

A valve leakage exceeding the acceptable values can be due to the ball incorrectly locatedbetween the seats or damaged sealing surfaces caused by dirt, grit, etc.Stellite seated valves have a clearance between the ball and seats to prevent jamming ofthe ball due to thermal expansion.

At low differential pressures or due to the weight of the actuator the force pressing the ballagainst the down-stream seat can be inadequate and the valve may leak. Therefore it willbe necessary to swing the ball externally against the down-stream seat by means of distancewashers located between the actuator and one of the brackets.

If damage to the down-stream sealing surface of the ball is suspected, try to stop the leakageby turn ing the ball through 180 degrees. If the leakage continues, then the down-streamseat or possibly both sealing surfaces of the ball are damaged. Turn the ball back to itsoriginal position and then turn the entire valve 180 degrees in the pipeline. Should theleakage still persist then it will be necessary to disassemble the valve and carefully checkthe sealing surfaces.

pressure

Fig. 4 Swinging the ball by means of the actuator installation brackets

- 7 -

3.4 Jammed or stuck valve

Jamming or sticking can be caused by accumulated medium between the ball and body.Turn the ball and throughly flush the valve inside.

Another reason could be too small a ball clearance for the operating temperature. In sucha case insulate the valve bodv properly. If the valve continues to stick then it will benecessary to dismantle the valve and check the ball clearance as stated in item 5.2.1.

4 REPAIR OF VALVE

It may be necessary to remove and disassemble the valve if the above steps (item 3) do notresolve the problems.

4.1 Removing the valve from the pipeline

Remove the valve with its actuator from the pipeline, then turn the valve to remove all flowmedium. If the medium 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 thevalve standing on its flange. Support the actuator so that it cannot overturn when theinstallation bolts are removed.

Fig. 5 Valve placed on a level surface for disassembly

- 8 -

Remove the actuator installation bolts. Pull the actuator away from the stem either with aoutpulling tool or by hand. The outpulling tool is shown in item 10.4.

Remove the installation brackets from the valve. Tap loose the key at the end of the ballstem. Remove any burrs from the keyway edges. Loosen the gland packing nuts. Removethe bolts that fasten the body halves. Lift the upper body half and place it standing on itsflange.

4.3 Inspection and maintenance of valve parts

Check each part separately and determine steps to be taken.

4.3.1 Ball

Lift the ball from the body onto a soft surface and clean it. Check the sealing surfaces ofthe ball and stem. Remove smaller scratches and impurities with emery cloth. File off anyburrs 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.

Fig. 6 Removal of actuator with the outpulling tool

- 9 -

4.3.2 Stellite seats

To check the backseal remove the stellite seats. Rotate the seat in its groove tapping witha chisel, until it moves freely. Turn the body upside down and hammer the end of the seatthrough the flow opening.

If the seat is badly damaged and will not come out, weld a suitable flat iron bar onto it,which can then be hit through the flow opening.

Change PTFE seals only if they are in a bad condition. Graphite backseals should alwaysbe changed.

4.3.3 Locked-up stellite seats

If the seats are in good condition it is not necessary to remove them unless the back sealneeds to be checked.

Carefully grind off most of the metal from the locking points. Then chisel off the lockingpoints by using a sharp single edged chisel. See Fig. 7. Remove the seats as instructed initem 4.3.2. If the seats are locked-up with stellite bushing as described in item 5.2.2 grindoff the welding joint of the bushing, remove the bushing by pressing it into the body sothat the seat will come out. See Fig. 8.

Chiselling off the locking pointsFig. 7 Grinding off the locking points

- 10 -

4.3.4 PTFE seats

PTFE seats need not be removed if they are still in a good condition unless it can be seenthat medium has accumulated behind them.

If the original seats are to be refitted remove them very carefully by means of a thin knifeor screwdriver. Insert the blade between the metal clamp and seat, and from several pointslift the seat from the groove.

4.3.5 Body

Body gasket must always be replaced during maintenance. Clean all sealing surfacescarefully. Do not round the sharp edges at the convergence point of the body joint as thiscould cause leakage. See Fig. 9.

Fig. 8 Grinding off the welded joint in a stellite bushing

sharp edges

Fig. 9 Sharp edges of sealing surfaces

- 11 -

4.3.6 Other parts

Clean all other parts, i.e. packing gland, nuts and bolts, etc.

After cleaning and inspection keep all parts well protected until re-assembling, especiallythe ball, seats and body joint surfaces.

If the damage is so severe that the valvc cannot be repaired by changing the parts, returnit assembled to the manufacturer for repairs.

5 RE-ASSEMBLING

Re-assemble the Series P-valve so that the body half with a tongue in its flange liesunderneath. Place this male part in an upright position, the body joint upwards, on a levelsurface. Then install the parts in the following order:

(5.1) seats(5.2) ball(5.3) body joint between the body halves(5.4) gland packings

In each of the above phases assemble a group of parts, the construction of which will varyslightly depending on the valve application. Detailed instructions and description of theconstruction of the groups of parts are given later. The last phase is to hammer the ballstem key into place.

5.1 Cleaning and inspection of parts

Begin by checking the parts. Remove any burrs and scratches and clean again the internalparts.

In PTFE-seated valves check that the sealing outer periphery of the seats is undamaged.

5.2 Installation of ball and seats

In each size the bodies, balls and seats are interchangeable. Valves with stellite seats havehard chrome platcd or stellited balls; those with PTFE seats have polished balls of the basicmaterial.

- 12 -

5.2.1 Stellite seats

With PTFE strip as back seal.

5.2.1.1 Checking the ball clearance

When installing new seats or a ball check the ball clearance as follows:Locate the ball seat into its groove without the backseal.Lift the ball into the male body half.Do not fit the body joint gasket.Lift the female body half into position.In order to keep the ball seat in position during this operation, place it slant ways in thegroove or centralize it on the ball so that it slips into the groove when the upper body halfis lowered into place.Tighten several of the flange bolts by hand.Move the ball to the closed position.Move the ball up and down by lifting and pushing the stem, the maximum distance possible,see Fig. 10.Then measure the ball clearance with a dial indicator, a T-gauge or two feeler gauges.

feeler gauge

Measure C taken with a dialindicator or T-gaugeMeasure

C√2

measuredsimultaneously with two feelergauges where "C" equals ballclearance or movement.

Fig. 10 Measuring the ball clearance.

- 13 -

5.2.1.2 Assembly of the stellite seats

Locate the back seal in the seat groove as shown in Fig. 12. If necessary, fasten the PTFEstrip with 3-4 small PTFE keys.

Locate the ball seats into the groove and lift the ball onto the male body half.Fit the body joint gasket as instructed in item 5.3.

Fig. 11 Stellite seats

PTFE key

Fig. 12 Cutting and fastening the back seal strip

- 14 -

5.2.2 Locked-up stellite seats

Locking the seat

a) with a metal clamp which is peened over the seat shoulder by punching it at 4-8 pointswith a punch. Be careful not to deform the seat by excessive punching,

b) with a stellite bushing pressed against the seat shoulder and welded at the flange-end ofthe valve as instructed in item 6.1.

There are three different ways to lock the seat, depending on the back seal material. Theseare described later.

The thickness "t" of the filling cone, made of gasket sheet and required for pressing of theback seals, is calculated as follows:

t ≤ ballclearanceC

√2

Fig. 13 Locking with a metalclamp

Stellite seat

Stellite bushing

Weld

Fig. 14 Locking with a stellitebushing

Fig. 15 Filling cone

- 15 -

5.2.2.1 Assembly by pressing

Tighten the body halves together in a press or by tightening at least half of the flange boltsthus compressing seals into the grooves. At this stage it is sufficient to tighten the bolts toapprox. 50 % of the final torque required, see Table 3.

Disassemble the valve. Lock up the seats as instructed in item 5.2.2. Lift the ball into themale body half. Fit the body joint gasket as instructed in item 5.3.

Filling cone

Fig. 16 Assembly by pressing

- 16 -

5.2.2.2 High temperature seats with graphite sheet as back seal

High temperature seats are always locked up.

Locate the ball seat with a graphite back seal into the body groove. Fit the ball and thefemale body half onto the male half. Check the clearance as instructed in item 5.2.1.1 withthe graphite seals fitted.

Remove the upper body half, turn the ball to the open position and place the filling conebetween the ball and seat. Replace the upper body half.

Tighten, in a press or by the flange bolts, the body halves together as instructed in 5.2.2.1.

Disassemble the valve. Lock up the seats as per 5.2.2. Fit the ball into the male body half.Fit the body joint gasket as instructed in item 5.3.

Ball

Seat

Graphite seal

Fig. 17 Locked-up high temperature seats

- 17 -

5.2.3 PTFE seats

Assembly of PTFE seats

The ball and seats are pre-pressed to ensure a good tighteness even at low differentialpressures. The shape of the pre-pressed seats guarantees good valve sealing and tightshut-off ability.

The pre-pressed edge must be unbroken. The clearance need not be checked as the innerparts, ball and seat will not be changed.

Fit the ball into position on the male body half and fit the body joint gasket as instructedin 5.3.

5.3 Body joint between the body halves

5.3.1 Fitting the body joint gasket

The gasket is either a strip or a sheet depending on valve application.

Ball

PTFE seat

Fig. 18 PTFE seats

- 18 -

5.3.1.1 Soft PTFE strip

Fit the sealing strip following the shoulder of the male body half against the bushing onball stem, see Fig. 19.

Press the strip against the mounting bushing so that a part of it will extrude into the packingcavity when the body halves are mounted together. Cut the strip leaving about 5 mm extrato both ends.

Valve size Strip ø Strip lenghtmm (in) mm (in) mm (in)405065

(1 1/2")( 2")

(2 1/2")

222

(5/64")(5/64")(5/64")

300350420

( 12")( 14")(16,5")

80100125150

(3")( 4")( 5")( 6")

2223

( 5/64")(5/64")(5/64")(1/8")

480630730900

(19") ( 25")( 29")(36")

200250300350

(8")( 10")( 12")( 14")

3333

(1/8")(1/8")(1/8")(1/8")

1120139016101830

(44")( 55")( 64")(72")

Table 1 Dimensions of soft PTFE strip

Fig. 19 Fitting the soft PTFE strip

- 19 -

5.3.1.2 Graphite sheet gasket

When fitting the gasket which comes supplied in a ring-shape, trim the ends as shown inthe above figure. For large valves, 12" and larger, a straight strip can be cut from a sheetand bent following the shoulder of the male body half against the bushing on the ball stem.The thickness of the sheet is 0.4 mm (0.016").

5.3.2 Tightening the body joint bolts

After fitting the body joint gasket lift the female body half, complete with pre-installedseat, see item 5.2, onto the ball. Turn the body halves and align them so that the sealingsurfaces do not form noticable steps between the body halves.

Fig. 20 Cutting the graphite sheet gasket

Steps in the joint can cause leakage

Fig. 21 Guiding with mounting bushing

- 20 -

Lubricate the flange and neck bolts, screw into place and tighten to the torques given inTable 2. If hexagon bolts are used as flange bolts the tightening is simpler if the bolts areinserted from below so that the nuts are screwed on from above the body joint flange.Neck bolts in valve sizes 100 mm (4") and smaller must be placed before installing thebody halves. Center them so that the distance from the outer side of the nut to the shoulderof the bolt is equal at both ends.For unlubricated bolts the torque values must be multiplied by factor (~1,5).

Flange bolt tightening sequence to be as per the example below. Start opposite to the stem,initially to 10 % of the torque values given in Table 2. Then tighten in the same sequenceto the final torques.

UNC 5/16 3/8 1/2 5/8 3/4 7/8 1 1 1/4 1 1/2Nm

ft-lb

25

18

45

35

100

75

200

150

350

250

500

350

700

500

1300

950

1600

1200

Table 2. Torques for bolts - lubricated

Neck bolts

Fig. 22 Flange bolt tightening sequence - a typical example

- 21 -

5.4 Gland packing

Depending on application the gland packing is either braided PTFE or Grafoil strip.

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. 23 on the valve shaft.Cut vertically with a sharp thin knife.If a support ring is recuired, place it at the bottom of the packing box. Tap each packingring in position, only by one, with a bush or with the packing gland. Locate eacho packingjoint at 90° angle to each other and 45° to the flow opening.

Shaft diameter Packing width, b Packing box depth, hmm (in) mm (in) mm (in)2535

(1")(1 3/8")

6,356,35

(1/4")(1/4")

2525

(1")(1")

405570

(1 1/2")(2 5/32")(2 3/4")

6,3588

(1/4")(5/16")(5/16")

253232

(1")(1 1/4")(1 1/4")

8595105

(3 11/32")(3 3/4")

(4")

81111

(5/16")(7/16")(7/16")

405555

(1 1/4")(2 5/32")(2 5/32")

Table 3. Dimensions of thc packing box

- 22 -

No clearance must be shown between the ends of the packing ring.Tighten the non-pressurized gland packing three times: initially when the valve isassembled, then after it has been pressure tested, and finally before installing into thepipeline.Table 4 below gives the tightening torques and minimum allowed tightening margins. Ifthe margin is too small add another packing ring. Tighten with a torque wrench.

Fig. 23 Cutting a braidedpacking strip

Tightening margin

Fig. 24 Tightening margin of newgland packing

Stem diameter Size of nut Torque Min. tightening marginallowed

mm (in) Nm ft-lb mm (in)25--4045-5570-8595-130

(1"-1 1/4")(1 1/2"-2 1/4")(2 3/4"-3 1/2")(3 3/4"-5 1/4")

3/8 UNC1/2 UNC5/8 UNC3/4 UNC

205090150

143766110

9101313

(3/8")(3/8")(1/2")(1/2")

Table 4 Tightening torques for gland packing

- 23 -

5.4.2 Fitting the gland packing strip

The material is usually graphite. It is also mentioncd in the valve parts list.

If no pre-pressed rings are available, make the packing ring by winding the strip onto thestem, to fit exactly the packing box diameter.

With this type of packing a support ring is always necessary.

Tighten the packing rings one by one as instructed in item 5.4.1. Their thickness isnormally reduced by about 50 %.

Grafoil strip

Support ring

Fig. 25 Making a gland packing ring from a strip

- 24 -

6 SUPPLEMENTARY VALVE CONSTRUCTIONS, INSTALLATION

6.1 Body with stellite bushing

For applications where the standard body material would quickly wear out, the flowopening is stellite lined. Usually the ball is also stellited.

Press the bushing into position so that the end which protrudes inside the valve is at thegiven distance "h" from the seat groove bottom.Tack-weld the flange end, without build-up, 4 to 8 tacks of about 10 mm each, dependingon valve size.

Fig. 26 Installation of stellitebushing

Size hmm (in) mm (in)405065

(1 1/2)(2)(2 1/2)

44,54,5

(5/32)(11/64)(11/64)

80100125150

(3)(4)(5)(6)

4,54,54,55

(11/64)(11/64)(11/64)(13/64)

200250300350

(8)(10)(12)(14)

5,5666

(7/32)(1/4)(1/4)(1/4)

- 25 -

6.2 Ball with cylindrical pipe lining

This type of a ball is intended for applications where a straight flow opening is required.

The pipe is formed from thin plate and will not withstand pressure. The pressure is balancedby a small hole drilled through the bottom of the ball.The pipe lining is not fastened to the ball; the lining being joined by a longitudinal weldedseam.

7 INSTALLATION OF THE ACTUATOR

The Metso Automation drive center is suitable for various 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 bush in the actuatorstem bore, if required.

In the actuator stem bore there are two keyways at 90° angle from each other. The ballstem has a keyway parallel to the flow port of the ball.

When mounting a cylinder actuator choose the actuator keyway that establishes the pistonin its upper position (top end of the cylinder) when the valve is closed.

Welded seam

Center boring

Fig. 27 Pipe lining of ball

- 26 -

When installing a screw operator choose the actuator keyway that establishes the closedvalve position when the handwheel is turned clockwise.

Push the actuator onto the ball stem carefully. Any excess force may damage the sealingof the ball and seat, especially soft seats, e.g. PTFE.

When there is a threaded hole at the end of the stem, the actuator can be pulled into positionusing a bolt.

Locate the actuator as straight as possible with regard to the valve. Lubricate the fasteningbolts and tighten them together with the bracket nuts.

Adjust the open and closed positions of the ball by means of the adjustment screws in theactuator, see Fig. 28. The correct open position is obtained by means of the flow opening,and the closed position by means of the arrow marked on the actuator. No adjustments arenecessary if the actuator was installed on the same valve previously. It is only necessaryto drive the actuator to its open position and then twist the entire actuator. Turn the ball tothe fully open position and tighten the bolts and nuts.

Safeguard the stop screw at the top of the cylinder with a non-hardening sealant, e.g. Loctite76.For required installation parts, see Fig. Nos. 29, 30 and 31 with parts lists.

Stop screw ofclosed position

Stop screw ofopen position

Fig. 28 Open and closed position of actuator

- 27 -

Actuator

Ball valve

Fig. 29 No bushing between valve stem and actuator bore

One or two keys,depending on wallthickness of bushing (5)

Actuator

Ball valve

Fig. 30 Bushing between valve stem and actuator bore

- 28 -

Parts list for Figures 29, 30 and 31

Item Qty Part1 2 Bracket2 4 x) Hexagon bolt3 4 Hexagon nut4 4 Washer5 1 Bushing6 1 Key7 4 x) Washer

x) = 8 pcs in size 40.

7.1 Hand lever

When a hand lever is installed on the valve the ball stem has a shortened key, to avoidinterference with the lower surface of the stop plate or the bearing bushing.

Push the hand lever onto the ball stem, parallel to the flow opening of the ball.

Fig. 31 Stem extension for high temperature

- 29 -

Fit the stop plate, with the bearing bushing if required, onto the stem.

Tighten preliminarily the stop plate fastening nuts.

Determine the open and closed positions of the ball by twisting the lever against the openand closed position pins. Check the open position with the flow opening, and the closedposition 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.

Parts list

Item Qty Part

1 1 Stop plate3 2 Hexagon nut4 2 Washer5 1 Bushing6 1 Key (shortened)

Fig. 32 Installation of hand lever

- 30 -

8 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- Manufacturing number of valve, stamped on pipe flange - in flangeless valves on

machined part of the welded end.- Parts code number. If valve’s spare parts list is used, the name and quantity of the part,or- number of parts lists item number, quantitvand the name of the part,or- number of this manual, item number, quantity and the name of the part.

- 31 -

8.2 Assembly drawings

8.2.1 Metal seated valve

8.2.2 Parts list

Item Quantity Part

1 1 Body half, male2 1 Body half , female3 1 Ball4 2 Seat5 1 Gland6 2 Stud7 Hexagon screw8 2 Stud bolt9 4 Hexagon nut10 Hexagon nut11 2 Hexagon nut12 1 Key13 2 Back seal x)

14 Gasket x)

16 Gland packing x)

19 1 ID plate

x = Recommended spare parts

Metal seat

Manufacturing number

- 32 -

8.2.3 Soft seated valve

8.2.4 Parts list

Item Quantity Part

1 1 Body half, male2 1 Body half , female3 1 Ball4 2 Seat5 1 Gland6 2 Stud7 Hexagon screw8 2 Stud bolt9 4 Hexagon nut10 Hexagon nut11 2 Hexagon nut12 1 Key13 2 Back seal x)

14 Gasket x)

16 Gland packing x)

19 1 ID plate

x = Recommended spare parts

PTFE seat

Manufacturing number

- 33 -

8.3 Valve stamping

Mfg. No

Seat material

Tester’s initials

Mark of pressure testing.Two marks on a stelliteseated valve=tightness acc.to MSS SP-72

Ball dia. belownominal one (

mm100

)

Batch No. of body material

Pressure ratingof body

Nominal size

Ball clearance ofstellite-seated valveStamped withletter-numbercombination, e.g. CL 0.55

Direction markof ball opening

Pair No. of body halves

Name ofmanufacturing

Material code

Casting code

Name plate

- 34 -

9 EQUIPMENT

No special equipment is needed to repair P-series ball valves. However, a special outpullingtool is recommended for the actuator removal, for dimensions refer to item 9.4.

9.1 Tools

Series P ball valves are threaded to ANSI B1.1-1974 standard, so American standard toolsare to be used.For body and neck bolts it is recommended to use socket tools.

9.2 Measuring devices

Measure the ball clearance either with a dial indicator, T-gauge or feeler gauges.In PTFE-seated valves the clearance for thermal expansion between the ball and seat ismeasured with feeler gauges.

9.3 Grinding compounds and belts

For the ball and seats:Diamond or boric carbide paste - for pre-grinding, coarseness 28/20 µm - for finishing, 7/5µm. Thin with thinner suitable for diamond grinding when necessary.

For sealing surface of the stem:Grinding cloth with a coarseness of about 400.

9.4 Actuator removing tool

Fig. 33. Actuator removing tool

- 35 -

Unit 7, 2-6 Apollo Court, Blackburn, Victoria 3130AUSTRALIATel. int. +61-53-9894 7922, Fax +61-53-9894 7933

AUSTRIA Russbergstrasse 58, A-1210 ViennaTel. int. +43-1-292 2604, Fax +43-1-290 1213

BELGIUM Bogemansstraat 155, B-1780 WemmelTel. int +32-2-461 0227, Fax +32-2-461 0386

BRAZIL Caixa Postal 691, 12 201-970 Sao José dos Campos, SPTel. int. +55-123-401 000, Fax +55-123-211 400

CANADA 2445 Sheffield Road, Ottawa, Ontario K1B 3V6Tel. int. +1-613-746 7239, Fax +1-613-746 0639

CHINA 1063 Si Ping Road, Shanghai 200092Tel. int. +86-21-502 1410, Fax +86-21-502 0368

DENMARK Vitus Berings Plads 1, P.O.Box 468, DK-8700 HorsensTel. int. +45-75-601 111, Fax +45-75-612 522

FINLAND Levytie 6, P.O.Box 6, FIN-00881 HelsinkiTel. int. +358-204-80 150, Fax +358-204-80 151

FRANCE 6-8 rue du Maine, F-68271 Wittenheim CedexTel. int. +33-389-506 400, Fax +33-389-506 440

GERMANY Zur Kaule 2-3, D-51491 OverathTel. int. +49-2206-60 040, Fax +49-2206-80 691

ITALY Via Santa Maria 90, I-20093 Cologno MonzeneTel. int. +39-2-254 5137, Fax +39-2-254 8445

JAPAN K-1 Building, 6 F, 5-8-7 Kamata, Ohta-ku, Tokyo 144Tel. int. +81-3-3737 3311, Fax +81-3-3737 3303

KOREA, SOUTH Room 1101, Manhattan Bldg. 36-2, Yoido-DongYungdeungpo-Ku, SeoulTel. int. +82-2-786 1507/1508, Fax +82-2-786 1509

MEXICO Neles-Jamesbury Fabmex S.A. de C.V.1430 Gail Borden Place, Unit B, El Paso, Texas 79935, USATel. int. +915-595-3772, Fax +011-521-422 0955

NETHERLANDS Pampuslaan 15, P.O.Box 417, NL-1380 AK WeespTel. int. +31-294-418 585, Fax +31-294-419 472

NORWAY Soknedalsveien 23, Postuttak, N-3500 HönefossTel. int. +47-32-125 111, Fax +47-32-126 008

PORTUGAL Av. 5 de Outubro, 12-4 Esq. 1000 LisbonTel. int. +351-1-315 2249, Fax +351-1-355 7468

SAUDI ARABIA c/o Al-Bustan Village, P.O.Box 88,Dhahran Airport 31932Tel. int. +966-3-857 1896, Fax +966-3-857 1094

SINGAPORE 501 Orchard Road #05-09, Wheelock Place,Singapore 238880Tel. int. +65-735 5200, Fax +65-735 4566SOUTH AFRICA 54 Suni Avenue, Corporate Park, Midrand,P.O.Box 6975, Halfway House 1685, JohannesburgTel. int. +27-11-314-1234, Fax +27-11-314-1826

NELES-JAMESBURY GROUPA MEMBER OF RAUMA CORPORATION

SPAIN Parc Tecnologic del Valles, C/.Argenters, 08290 CerdanyolaTel. int. +34-3-582 4454, Fax +34-3-582 4453

SWEDEN Gåsängsv. 1-3, P.O.Box 1068, S-14122 HuddingeTel. int. +46-8-774 0640, Fax +46-8-774 9789

U.A.E P.O.Box 17175, Jebel Ali Freezone, DubaiTel. int. +971-4-836 974, Fax +971-4-836 836

UNITED KINGDOM Rutherford Road,Basingstoke, Hampshire RG24 8PDTel. int. +44-1256-376 200, Fax +44-1256-811 668

USA 640 Lincoln Street, Worcester, Mass. 01605Tel. int. +1-508-852 0200, Fax +508-852 8172

VENEZUELA Torre Miranda, Nùcleo "A", Piso 6, Oficina A-64,Avenida Francisco de Miranda, Chacao, Caracas 1060Tel. int. +58-2-267 4364, Fax +58-2-267 0562

THAILAND 1000/58 Sukhumvit 71 Road15th Floor, PB Tower, Klongton, Klontoey, Bangkok 10110Tel. int. +66-2-713-3301/2, Fax +66-2-713-3303