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Jamesbury 3-Piece Ball Valves, Series 4000, Threaded End, Socket Weld, Butt Weld, Rev 2.0, Safety Manual
4.
Installation
The Series 4000 3-piece ball valves must be installed into the pipeline according to Metso’s instructions given
in the Installation, Maintenance and Operation manual. Possible standards relevant to applications, local re-
quirements, etc should be also considered. Installation must be done by competent persons. In case a bare
shaft valve (not supplied as an assembly by Metso) is to be used in a valve assembly, by adding the actuator
and other components, the installer is responsible to verify the suitability of all linkage parts (see more details
in IMO). It is particularly important to confirm that all components are working properly together.
Incorrect installation may jeopardize the validity of the reliability data given in Paragraph 3.5.
In cases where the complete valve assembly is supplied and shipped by Metso, the complete valve assembly
is tested and configured according to Metso internal procedures, except where project specific procedures are
used.
5.
Operation
5.1
Recommended proof test
The purpose of proof testing is to detect failures of the complete final element subsystem. Metso recommends
the following proof test procedure:
• Conduct an initial visual inspection. Check that there are no unauthorized modifications to the SIS valve
assembly. Verify that there is no observable deterioration in the SIS valve such as pneumatic leaks, visible
damage, or impurities on the SIS valve.
• Bypass the SIS valve if full stroke could cause an unnecessary process shutdown.
• Perform the safety action (full stroke), preferably using the system. Verify that the SIS valve achieves safe
position within the required time specified by the application. Verify also the shutoff tightness for tightness
critical applications. Note that a tightness measurement might require removing the valve from the pipe-
line. If the valve must be removed from the pipeline, verify proper full stroke operation after re-installation.
• Restore the SIS valve to it’s normal position.
• Conduct a final visual inspection. Check that the SIS valve is in the normal position, and verify that all ac-
cessories are operating according the specification for the SIS valve normal operation. Inspect visually that
there is no observable deterioration of the SIS valve.
• Record all results and observations into the corresponding database with necessary audit trail information.
• Remove the SIS valve bypassing, if used.
5.2
Recommended partial stroke test
A partial stroke test is a verified movement of an emergency valve from the normal operating position toward the
safe state. Partial stroke testing can be done in most cases while the process is on-stream without disturbing the
process. The purpose is to provide early detection of automated block / vent valve failure modes, and to reduce
the probability of failure on demand.
Metso recommends using the testing capability available with intelligent partial stroke devices such as the Neles
ValvGuard. In order to obtain the full benefit of diagnostics provided by partial stroke devices, ensure first that the
device is calibrated and configured correctly according to the manufacturer’s guidelines.
Before initiating the partial stroke, ensure that the partial stroke will not cause a process hazard. If needed, the
possible pressure disturbance can be further estimated by using Metso’s Nelprof valve sizing software.
The required partial stroke test interval may depend on application and targeted SIL level, but test intervals from
1 month to 6 month are generally recommended. Partial stroke size is typically from 10 to 20% of full travel start-
ing from fully open, in shutdown service and from 3 to 5 % starting from fully closed in blowdown (vent) service.
In these 3-piece ball valves, the partial stroke test can be done within the valve’s dead angle value, thus maintain-
ing tightness in blowdown service.
A partial stroke test can be initiated either manually or automatically. The test interval is set by the user. The user
can be reminded by a partial stroke scheduler system in manual mode, and the test interval is controlled by the
intelligent partial stroke test device in the automatic mode. Contact the partial stroke test device manufacturer
for more details on how to select and set parameters to control the partial stroke size and frequency.
