M03 rev.9 Pag 1 / 11

Procedure : M03 rev.9

STORAGE, INSTALLATION

AND MAINTENANCE INSTRUCTIONS FOR TRUNNION MOUNTED 3 PIECES SPLIT BODY BALL VALVES

WITH SUPPORT PLATE

Attached dwg. SD0003/00-00

- STORAGE

The type of packing must be defined by the customers order and shall be appropriate to ensure safe transportation to the final destination and possible conservation before installation.

The valves have to be stored in a closed, cleaned and dry place, protected from bad weather and corrosive

atmosphere.

Make sure that the end sealing surfaces and/or B.W. ends have been coated with corrosion protection

painting and correctly closed by means of wooden or rubber discs.

Periodical checks have to be carried out in the dedicated storage area to verify that the integrity of packing

is maintained.

Note

Storage in an open area for a limited period can be considered only in case the valves have appropriate

packing [packed in cases for sea transportation and goods well protected with barrier sacks].

Do not place the packages directly on the ground.

Do not expose the packages to the weather or directly to the sun.

Verify the packaging every two months.

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M03 rev.9 Pag 2 / 11

- INSTALLATION

Remove the valve from crate or case by means of lifting lugs being careful not to damage the valve ends

and do not dent the paint.

Remove the protection discs and the corrosion protection coating from the ends.

Make sure that the relevant surfaces are not damaged and there are no loose parts.

Before installation, fix the gear or the actuator to the valve top (if shipped separately take care to not put

grease between valve mounting flange and gear or actuator mounting flange), tighten the bolting (100a 100b) as per section Bolting par. A and table B, set the open and close position or verify the operator set-up in case the actuator has been fixed on the top of the valve by us.

Remove any foreign object from the valve bore.

Make sure that the valve is correctly placed and aligned with the line.

For bolted end valves be careful to use adequate gaskets and bolting. Tighten the bolts gradually, in cross

position with the proper loads recommended by the gasket supplier or end user recommended practice.

Important

It is strongly recommended to perform piping flushing before installation of the valve; if this is not

possible, the valve must be set with the ball in full open position before starting the flushing.

For welded end valves use an adequate welding procedure which shall limit the temperature to maximum

100 C at 100 mm of distance from the seat ring rear face. The use of transition pup is mandatory when

this condition is not possible.

In case of welding to higher strength pipe the thickness of the component shall at least equal times to the

ratio of minimum specified yield strength of the pipe to minimum specified yield strength of the

component. The maximum thickness of the component shell not exceed 1.5 times the pipe thickness. The

use of transition pup is mandatory when the above condition can not be achievable.

To avoid bending stresses the valve and the line piping have to be correctly supported.

Unless specifically requested the valves are not designed for supporting external loads (e.g. seismic loads).

In order to check the integrity of valve components and avoid damages due to wear we suggest regular in service maintenance operations at least once per year (more than once a year in case of severe use e.g. dirty service) or whenever requested by local regulations.

The limits of temperature and pressure are clearly indicated on the name plate, Valbart Srl declines any

responsibility for any use outside the above limits.

Valbart Srl declines any responsibility should the valve not be used for the service indicated on the clients data sheets.

The user is not allowed, in no case, to modify the valve; this action causes immediate expiring of guarantee

period and API marking.

Valbart refuses any liability for any damage to personnel, property or plants caused by incorrect usage of

valves, incorrect or maintenance not strictly carried out in line with these procedures, unskilled personnel

or non observance of safety rules.

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M03 rev.9 Pag 3 / 11

In case Valbart Srl is not aware of the final use of the valve (e.g. valve ordered and stocked by a third

party) it is responsibility of the third party or of the user to verify the suitability of the valve material

combination for the medium and/or service the valve is to be used.

Unless specifically requested the valves are furnished without thermal and noise insulation.

Even if the valves are provided of antistatic device is strongly recommended to ground the line.

Plant operating personnel must be equipped with the proper safety equipment (e.g. glass, gloves, reinforced

boot, hear plugs) according to local regulation.

Warning

Carefully verify that the direction of the flow in the line corresponds to the arrow indicated on the valve

body. Valves without arrow are bi-directional.

Carefully verify the assembly of the overpressure relief device if any.

Carefully see the actuator user manual for the actuator preparation.

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M03 rev.9 Pag 4 / 11

- VALVE WORKING CONDITION

The valves describe in this manual have been designed to control flow for on/off service only, so the valve

working conditions are always fully open or fully closed.

Do not use the valve for flow control neither in partly open nor for throttling service to avoid damaging on

the sealing surface.

The ensure longer life of the valve it is recommended to perform periodic check and maintenance

operation.

M03 rev.9 Pag 5 / 11

- VALVE LEAKAGE

For valve of standard application any leakage on the stem and/or on the seat can be temporarily and easily

reduced or stopped, before the maintenance shut down operation, injecting sealant grease through the stem

(18) or seat grease fitting (16) (if present). The choice of the grease is related to the service of the valve

(media, temperature, pressure) and it is customer responsibility.

Warning

It is mandatory that this operation will be carried out by skilled personnel aware of safety rules and field

techniques. For any special application, such as hydrogen or oxygen service, no grease shall be used at

all and the injection points are not present.

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M03 rev.9 Pag 6 / 11

- MAINTENANCE

Warning

Depressurize the line before starting any maintenance. Failure to do so may cause serious personal

injury and-or equipment damage.

A - Disassembly

Disassembly procedure:

1. If the valve is installed MAKE SURE TO RELEASE THE PRESSURE FROM THE LINE.

2. Rotate the ball (3) to fully closed position.

3. OPEN THE VENT VALVE (19) TO RELEASE ANY RESIDUAL PRESSURE FROM THE BODY CAVITY, remove the vent valve (19) and the drain plug (20).

4. Remove the valve from the line.

5. For operated valve remove the nut (100a), the operator (100) and the key (9).

6. Place the valve on the end of the closure (2) being careful do not damage the ends surface.

7. Remove the cap screw (14) the pin (24) and the upper flange (8).

8. Remove the cap screw (14a) the stem cover (7), the stem (5) and the stem grease fitting (18), if present, for cleaning it. At this point it is possible to remove and replace the following components:

Stem gasket (10a);

Stem cover gasket (10b);

Stem o-ring (11c);

Stem cover o-ring (11d);

Stem thrust washer (22).

9. Remove the nut (13) first side, the valve support (31) first side, the lifting lug (30) first side, the closure (2) first side and the seat grease fitting (16), if present, for cleaning it. At this point it is

possible to remove and replace the following components:

Body gasket (10) first side;

Body o-ring (11) first side;

Stop seat socket screw (90) first side (only for dn >8);

Stop seat washer (91) first side (only for dn >8);

Seat ring (4) first side;

Seat o-rings (11a) and (11f) first side;

Seat spring (15) first side.

10. Extract the ball (3) with bearing retainers (6). At this point it is possible to remove and replace the following components:

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M03 rev.9 Pag 7 / 11

Stop seat socket screw (90) second side (only for dn >8);

Stop seat washer (91) second side (only for dn >8);

Seat ring (4) second side;

Seat o-rings (11a) and (11f) second side;

Seat spring (15) second side;

Ball bushing (21).

In case it would be necessary to remove also the second closure (2) from the body (1), it is necessary to go

on as follow:

11. Place the disassembled valve on the end of the body (2) being careful do not damage the ends surface.

12. Remove the nut (13) second side, the valve support (31) second side, the lifting lug (30) second side and the closure (2) second side. At this point it is possible to remove and replace the following

components:

Body gasket (10) second side;

Body o-ring (11) second side.

B Inspection and maintenance

Inspection and maintenance procedure:

1. Wipe the metal parts with solvent by means of soft cloth.

2. Wipe o-rings and gaskets by means of soft cloth.

3. Check o-rings and gaskets, seat rings, stem and ball.

4. Replace the defective part with a new one.

Note

After every disassembly is recommendable to replace the o-rings and gaskets. Do not use o-rings and

gasket with dimensions different from the original ones.

C Re-assembly

For re-assembly the valve repeat the same disassembly operation but contrary wise. For bolting tightening

ref. to section Bolting.

Note

During re-assembly be very careful do not cause o-rings cutting. In case of valve equipped with operator

do not move absolutely the operator end stop.

If the valve is for oxygen or hydrogen application please reassemble the valve in controlled environment

and not use any grease at all.

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M03 rev.9 Pag 8 / 11

- BOLTING

Recommendation

1. Put some grease on both the bolting thread and nut bearing surface.

2. Tighten the bolts in a cross position (an example of sequence is indicated in par. A as follow).

3. During tightening make sure that the faces of flange remain perfectly parallel.

Note

For a better performance of the joint carry out the tightening step by step, starting with the sequence

using a torque value approx. 1/4 of the max. torque than repeat the sequences increasing the torque

until achieve the maximum torque value.

A Bolting tightening sequence

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M03 rev.9 Pag 9 / 11

B Operator/Valve top flange bolting or Gland Plate Cap-Screws tightening torque values

C Body/Closure flange bolting (12 13) tightening torque values

NOTE: If threads are PTFE coated (e.g. XYLAN or eq.) apply 0.6 torque reduction factor.

M10 M12 M16 M20 M24 M30 M36x3 A193 B7 33 80 157 272 433 932 1739

L7 " " " " " " " L43 " " " " " " " B7M 25 61 120 208 331 712 1328

B8 cl. 2 " " " " " " " B8M cl. 2 " " " " " " "

L7M " " " " " " " B8 cl. 2 " " " " " " "

B8M cl. 2 " " " " " " " A453 660 " " " " " " "

B8 cl. 1 13 31 61 106 169 364 679 B8M cl. 1 " " " " " " " B8 cl. 1 " " " " " " "

B8M cl. 1 " " " " " " "

Cat 5

BOLT TIGHTENING TORQUE [Nm] for OPERATOR / VALVE TOP FLANGE - GLAND-PLATE / BODY

A193

A320

A193

A320

A320

STUD OR CAPSCREW SIZE

MATERIAL GRADE

Cat 1

Cat 3

1/2" 5/8" 3/4" 7/8" 1" 1"1/8 1"1/4 1"3/8 1"1/2 1"5/8

A193 B7 80 157 272 433 644 932 1294 1739 2275 2910 L7 " " " " " " " " " "

L43 " " " " " " " " " " B7M 61 120 208 331 492 712 988 1328 1422 2223

B8 cl. 2 " " " " " " " " " n/a B8M cl. 2 " " " " " " " " " n/a

L7M " " " " " " " " " " B8 cl. 2 " " " " " " " " " n/a

B8M cl. 2 " " " " " " " " " n/a A453 660 " " " " " " " " " "

ref

T6

a R

0

BOLT TIGHTENING TORQUE [Nm] BODY / CLOSURE FLANGE / COVER [Nm] - Size 1/2" to 1"5/8

STUD SIZE (UNC form 1/2" to 1" _ 8UN from 1"1/8 to 1"5/8)

A193

A320

MATERIAL GRADE

Cat

1

Cat

3

A320

1"3/4 1"7/8 2" 2"1/4 2"1/2 2"3/4 3" 3"1/4 3"1/2 3"3/4 4" A193 B7 3654 4515 5501 7883 10868 13212 17209 21941 27467 33851 41154

L7 " " " " " " " " " " " L43 " " " " " 14523 18917 24118 30193 37210 45238

A193 B7M 2792 3449 4202 6022 8302 11094 14451 18423 23064 28425 34557 A320 L7M " " " " " n/a n/a n/a n/a n/a n/a A453 660 " " " " " " " " " " "

ref

T6

a R

0

Cat

3

BOLT TIGHTENING TORQUE [Nm] BODY / CLOSURE FLANGE / COVER [Nm] - Size 1"3/4 to DN 4"

STUD SIZE (8UN) MATERIAL GRADE

A320

2

Cat

1

M03 rev.9 Pag 10 / 11

M03 rev.9 Pag 11 / 11

RECOMMENDED VALVE INSPECTION AND MAINTENANCE

PREVENTIVE ACTIONS

Warning

1. Verify at least once a year the tightness of bolts, drain, vent and any other device fitted to the valve

2. Every five years disassemble the critical service valves and/or actuated valves, verifying the sealing surface and lapping them again if necessary. Change all gaskets and sealing

elastomers.

3. For actuated valves, in addition to the above please refer to the actuator maintenance manual.

VALVE TESTING AND INSPECTION

Warning

1. Perform a Visual inspection at least once a year in order to verify that there are no external leakages and, with valve in closed position, check if there are leakages between ball and seats.

If yes use a seat and /or stem sealant injector devices to stop the leakage. The sealant injection

is to be considered as an emergency operation to stop leakage up to the next planned

maintenance job. If the leakage does not stop, follow the maintenance procedure for the

replacement of all gaskets and sealing elastomers.

2. For actuated valves, in addition to the above please refer to the actuator maintenance manual. 3. Verify in a safety way at least once a year that there is no external and or internal corrosion. 4. In order to verify the correct operability of the valves/actuators, once a year carry out a full

stroke test (From Fully OPEN to Fully CLOSE to fully OPEN position or from Fully CLOSE

to Fully OPEN to fully CLOSE position) starting from the normal valve operation position.

5. In order to improve the reliability of the valve, its suggested to perform a partial stroke test (from fail position OPEN or CLOSE to approx 15).

This document is propriety of Valbart Srl. The use and/or the reproduction also partial of it without the permit of Valbart Srl

is not allowed.

Valbart Srl reserves the right to make changes without notice.

Rev. / date 0 / 05-05-03 1 / 27-08-04 2 / 18-10-04 3 / 23-05-05 4 / 22-08-05 5 / 16-11-05 6 / 14-12-05 7 / 12-01-06 8 / 14-02-07 9 / 05-07-08

Signed F.P. L.M. L.M. S.C. F.P. A.C. A.C. F.P. P.G. A.P.

Approved S.L. S.L. S.L. S.L. S.L. S.L. S.L. S.L. C.S. A.S.

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