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C&C API 6D, Installation, Operation And Maintenance Manual

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C&C API 6D Installation, Operation And Maintenance Manual Download Page 2

 

API 6D Two - Piece

 

Cast Trunnion  

Mounted Ball Valve  

Atlas Series 

 
Document Number: 

Revision: 

Release Date:               

 

EDC 506 

0 

01/03/2018 

 

 

 

 

 

 

 

IOM: Installation, Operation and Maintenance Manual

 

 

                

2/17

 

TABLE OF CONTENTS  

1

 

SCOPE

 ............................................................................................................................................................................................. 3 

1.1

 

RESPONSIBILITY FOR VALVE APPLICATION

 ................................................................................................................... 3 

1.2

 

RECEIVING INSPECTION, HANDLING AND STORAGE

 .................................................................................................. 3 

2

 

BILL OF MATERIAL

 ....................................................................................................................................................................... 5 

3

 

INSTALLATION

 .............................................................................................................................................................................. 7 

3.1

 

NAMEPLATE

 .............................................................................................................................................................................. 8 

3.2

 

HIGH TEMPERATURE SERVICE

 ........................................................................................................................................... 8 

3.3

 

LOW TEMPERATURE SERVICE

 ........................................................................................................................................... 8 

4

 

OPERATION

 ................................................................................................................................................................................... 8 

4.1

 

INITIAL START-UP/COMMISSIONING

 .................................................................................................................................. 8 

4.2

 

NORMAL OPERATING ACTIVITY

 .......................................................................................................................................... 8 

4.3

 

DOUBLE BLOCK AND BLEED OPERATION

 ....................................................................................................................... 8 

4.4

 

BODY CAVITY RELIEVING SYSTEM

 .................................................................................................................................... 9 

5

 

MAINTENANCE

 .............................................................................................................................................................................. 9 

5.1

 

VALVE MAINTENANCE IN OPERATION

 .............................................................................................................................. 9 

5.1.1

 

STEM LEAKAGE

 ................................................................................................................................................................... 9 

5.1.2

 

SEAT LEAKAGE

 .................................................................................................................................................................. 10 

5.2

 

SCHEDULE OF ROUTINE MAINTENANCE

 ....................................................................................................................... 10 

5.3

 

VALVE CLEANING

 .................................................................................................................................................................. 10 

5.4

 

EMERGENCY REPAIR

 ........................................................................................................................................................... 10 

6

 

DISASSEMBLY AND REASSEMBLY INSTRUCTIONS

 ........................................................................................................ 11 

6.1

 

DISASSEMBLY

 ........................................................................................................................................................................ 11 

6.2

 

RECONDITIONING

 ................................................................................................................................................................. 13 

6.3

 

REASSEMBLY

 ......................................................................................................................................................................... 13 

7

 

PROPER VALVE TESTING

 ........................................................................................................................................................ 14 

7.1

 

SHELL TEST

 ............................................................................................................................................................................ 14 

7.2

 

HYDROSTATIC SEAT TEST

 ................................................................................................................................................. 14 

7.3

 

DOUBLE BLOCK AND BLEED (DBB) TEST

 ...................................................................................................................... 14 

7.4

 

SUPPLEMENTAL AIR SEAT TEST

 ...................................................................................................................................... 15 

8

 

BOLTS TIGHTENING TORQUE

 ................................................................................................................................................ 15 

9

 

TROUBLESHOOTING

 ................................................................................................................................................................. 15 

 

Summary of Contents for API 6D

Page 1: ...l Valve Atlas Series Document Number Revision Release Date EDC 506 0 01 03 2018 IOM Installation Operation and Maintenance Manual 1 17 Installation Operation and Maintenance Manual API 6D Two Piece Cast Trunnion Mounted Ball Valve Atlas Series ...

Page 2: ...8 4 1 INITIAL START UP COMMISSIONING 8 4 2 NORMAL OPERATING ACTIVITY 8 4 3 DOUBLE BLOCK AND BLEED OPERATION 8 4 4 BODY CAVITY RELIEVING SYSTEM 9 5 MAINTENANCE 9 5 1 VALVE MAINTENANCE IN OPERATION 9 5 1 1 STEM LEAKAGE 9 5 1 2 SEAT LEAKAGE 10 5 2 SCHEDULE OF ROUTINE MAINTENANCE 10 5 3 VALVE CLEANING 10 5 4 EMERGENCY REPAIR 10 6 DISASSEMBLY AND REASSEMBLY INSTRUCTIONS 11 6 1 DISASSEMBLY 11 6 2 RECOND...

Page 3: ...chase order requirements Correct type pressure class size body trim seal material and end connections This information may be found on the nameplate or may be stamped on the body of the valve Each C C valve has unique serial number hard stamped on the closure of the valve This shall be always be quoted for any enquiry related to a particular valve Condition of valve paint and location of required ...

Page 4: ...fting equipment s safe working load SWL shall always be double checked prior to any lift During lifting handling always keep valve flange protection in place to avoid foreign material from entering the valve bore Pay attention as not to damage the valve paint during lifting handling procedures Special care to the marking applied on the crates and particularly to piling instructions must be taken d...

Page 5: ... does not take any responsibility unless this requirement has been agreed on the purchase order Lubrication during storage is not recommended 2 BILL OF MATERIAL ITEM Component ITEM Component 1 Body 24 Segment Ring Retainer 2 Closure 25 Stem Keys 3 Ball 26 Stem Pins 4 Stem 27 Stem Retaining Pin 5 Trunnion Support 28 Stem Fire Safe Seal 6 Seat Rings 29 Gland Flange 7 Seat Inserts 30 Gland Pin 8 Fire...

Page 6: ...o Piece Cast Trunnion Mounted Ball Valve Atlas Series Document Number Revision Release Date EDC 506 0 01 03 2018 IOM Installation Operation and Maintenance Manual 6 17 Figure 2 Atlas Series Ball Valve Sizes 2 4 ...

Page 7: ...lve in system using proper size and type mating flanges and appropriate gaskets for RF or seal rings for RTJ Valve design allows for line flow in either direction The pipeline where the valve is to be installed shall be clean free from sand welding slags debris pieces of wood and or any other foreign material that can damage the valve seats during operation Actuator and Gear stops are pre set at t...

Page 8: ...se fitting will prevent accumulated water from freezing It is also advisable to inject a sufficient amount of valve lubricant into the grease fittings of valve and operator if present prior to extended cold temperature exposure 4 OPERATION 4 1 INITIAL START UP COMMISSIONING Once installed in the line the valve should be left either in the fully open or fully closed position depending on the start ...

Page 9: ...ty must be protected from overpressure by means of a Pressure Relieving Valve PRV set to relieve excess pressure The standard PRV connected to the body cavity has been pre set and tested in the factory to relieve at approximately of 1 33 times the maximum operating pressure MOP of the valve It is a mandatory requirement to keep body cavity pressure relieving system functioning correctly Failure of...

Page 10: ...ient valve operation the valve shall be inspected on a regular basis during the operation and subject to scheduled maintenance Qualified person shall do all maintenance work Table 1 Recommended Lubrication Quantities Valve Sizes Lubricant by valve size ounces 2 2 3 2 4 2 6 3 8 3 10 3 12 3 14 4 16 4 18 4 20 6 24 8 5 3 VALVE CLEANING Valve cleaning is required when the valve does not seal properly a...

Page 11: ...lly open position Always use the safety plug or bleed fitting provided either at the drain connection to release the body cavity pressure Remove the valve from the line Before disassembling the valve it is important to mark all the parts in order to correctly reassemble the valve The valve shall be positioned to have the flow axis along the horizontal axis and the upper part shall be easily access...

Page 12: ...e Remove the stem 4 from the body through end entry Extract the lantern ring 20 from the body 1 through top It is possible to remove the stem injection fitting 38 for cleaning Stem Retaining Pin design 6 larger for class 150 and 300 Remove the stem injection fitting 38 Using an allen wrench unscrew the stem retaining pin 27 provided inside the fitting 38 Extract the stem 4 and lantern ring 20 grou...

Page 13: ... into the body 1 and closure 2 When pressing the seat into the body and closure pay attention that the seat moves correctly parallel to the body and closure surfaces For this operation we recommend using clamps and a rubber hammer It is not possible to replace the seat insert 7 only b Assemble the stem lantern ring group as follows Insert in the upper part of the stem 4 into the stem thrust washer...

Page 14: ...ll valve for leakage f Depressurize the valve 7 2 HYDROSTATIC SEAT TEST Valves are to be subjected to a hydrostatic seat test There is to be no leakage under test pressure Test pressure is to be applied to the appropriate end of the valve Testing pressures 1 1 times maximum operating pressure Test durations are 2min for 4 and under valves 5min for 6 to 18 and 10mim for 20 and larger valves a Opera...

Page 15: ...87 7 16 416 381 1 5 8 M42 25800 24286 1 2 M12 602 549 1 3 4 M45 32394 27756 9 16 M14 903 841 1 7 8 M48 39607 34695 5 8 M16 1204 1106 2 M52 49210 41634 3 4 M20 2168 2036 2 1 4 M56 71957 61761 7 8 M22 3629 3469 2 1 2 M64 99571 86914 1 M24 5532 5222 2 3 4 M68 134531 113113 1 1 8 M27 7877 7125 3 M76 175245 147808 Note Tightening Torque Values 10 9 TROUBLESHOOTING Issue Possible Cause Solution Valve wi...

Page 16: ...air section 2 Check the gear operator for fully closed position 3 Disassemble the valve and replace damaged component s 4 Disassemble the valve and replace the O Ring Leak around the stem 1 Worn or damaged O Ring seals 1 Grease the stem Disassemble the valve and replace the O Rings Leak around trunnion 1 Worn or damaged trunnion O Ring and or gasket 2 Trunnion cap screws not properly tightened 1 D...

Page 17: ...he installation operation and maintenance of C C Flow Control Atlas Series API 6D two piece trunnion mounted ball valves CNC Flow Control reserves the right to change information contained in this manual without any notice Contact CNC Flow Control at the above address for specific questions regarding this manual or valve Although this manual has been checked for accuracy the Purchaser or End User ...

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