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E N G I N E E R E D & P R O C E S S V A L V E S

Hi-Integrity

Trunnion Mounted Ball Valve

Installation, Operation and Maintenance Manual

Содержание TK

Страница 1: ...ENGINEERED PROCESS VALVES TK Hi Integrity Trunnion Mounted Ball Valve TK Installation Operation and Maintenance Manual ...

Страница 2: ...igure 3 TK Valve Three piece Trunnion Mounted Ball Valve 8 Nameplate Information 10 Storage 11 Long term Outside Storage 11 Long term Enclosed Storage 11 Installation 12 Hydrostatic Testing 13 Piston Action Seats 13 Self Relieve Seats 13 Mounting a Gear Box Actuator 14 Scope 14 Mounting and Setting Stops 14 Routine Maintenance 16 Stem Lubrication 16 Checking for Seat Leakage 16 Seat Sealant 17 Dis...

Страница 3: ...ze in Inches 1 5 150 300 600 900 1500 2500 2 150 300 600 900 1500 2500 3 150 300 600 900 1500 2500 4 150 300 600 900 1500 2500 6 150 300 600 900 1500 2500 8 150 300 600 900 1500 2500 10 150 300 600 900 1500 2500 12 150 300 600 900 1500 2500 14 150 300 600 900 1500 2500 16 150 300 600 900 1500 2500 18 150 300 600 900 1500 20 150 300 600 900 1500 22 150 300 600 900 1500 24 150 300 600 900 1500 26 15...

Страница 4: ...ENGINEERED PROCESS VALVES 4 01 2011 IOM TK TMBV 01 Installation Operation and Maintenance Manual BILL OF MATERIALS Figure 1 TK Valve Two piece Non Trunnion Mounted Ball Valve ...

Страница 5: ...ing 341 1 Gear Bonnet 352 Gear Bonnet Socket Head Cap Screws 371 1 Gear Bonnet O ring 372 1 Gear Bonnet Zerk Fitting 5 400 1 Trunnion Flange 5 451 4 Trunnion Flange Hex Head Cap Screws 500 1 Ball 3 601 2 Seat Insert 610 2 Seat 611 2 Seat Holder O ring 621 2 Seat Holder Flat Spring 630 2 Seat Holder Fire Seal 631 2 Seat Holder Fire Seal Compression Ring 721 1 Gear Stem 4 722 1 Gear Stem Key 741 2 S...

Страница 6: ...ENGINEERED PROCESS VALVES 6 01 2011 IOM TK TMBV 01 Installation Operation and Maintenance Manual BILL OF MATERIALS Figure 2 TK Valve Two piece Trunnion Mounted Ball Valve ...

Страница 7: ... Flange 451 Trunnion Flange Hex Head Cap Screws 500 1 Ball 1 610 2 Seat Holder 611 2 Seat Holder O ring 3 622 Seat Holder Coil Spring 630 2 Seat Holder Fire Seal 631 2 Seat Holder Fire Seal Compression Ring 4 632 2 Seat Holder Fire Seal Wave Spring Belleville Spring 721 1 Gear Stem 2 722 1 Gear Stem Key 741 2 Stem O ring 761 1 Stem Bushing 762 1 Stem Thrust Washer 780 1 Stem Fire Seal 781 1 Stem F...

Страница 8: ...ENGINEERED PROCESS VALVES 8 01 2011 IOM TK TMBV 01 Installation Operation and Maintenance Manual BILL OF MATERIALS Figure 3 TK Valve Three piece Trunnion Mounted Ball Valve ...

Страница 9: ...n 400 1 Trunnion Flange 451 4 Trunnion Flange Hex Head Cap Screws 500 1 Ball 1 610 2 Seat Holder with Seat Insert 611 2 Seat Holder O ring 622 Seat Holder Coil Spring 3 630 2 Seat Holder Fire Seal 3 631 2 Seat Holder Fire Seal Compression Ring 3 632 2 Seat Holder Fire Seal Wave Spring 721 1 Gear Stem 2 722 1 or 2 Gear Stem Key 741 2 Stem O ring 761 1 Stem Bushing 762 1 Stem Thrust Washer 763 4 Ste...

Страница 10: ...eplate Item Description Stamp Description 1 Size Full port valves will be stamped as flange end x flange end Ex 12 x 12 Reduced port valves will be stamped as flange end x ball bore x flange end Ex 12 x 10 x 12 2 API API 6D or API 6A 3 S N Valve s unique serial number 4 Body Body material 5 Impact Impact requirements 6 DOM Date of manufacture 7 Ball Ball material 8 Stem Stem material 9 Seat Seat i...

Страница 11: ... fitting covers should be replaced and remain in place during storage Valves should be skidded and covered with a plastic film bag to prevent dust accumulation and any ingress of sand dirt or moisture from entering into the valve A Vapor Corrosion Inhibitor VCI should be inserted into the envelope of the valve to assist in removing moisture from the valve Records of valve maintenance should be kep...

Страница 12: ...h the stem in the down position Actuator and Gearbox stops are preset at the factory and should require no further adjustments With the exception of fail safe closed valves all other valves are shipped in the open position Valves should not be closed until the bore of the valve has been cleaned of all debris Take caution with the fail safe closed valves The ball surface is exposed and particularly...

Страница 13: ...e to form an effective seal Line pressure against the seat area A1 see below illustration is not equalized by pressure against seat area A2 The difference in areas piston action which forces the seat unit against the ball surface The net result of this piston action is the formation of a tight effective seal In the absence of line pressure coil springs around the seat unit provide a tight seat by ...

Страница 14: ...ligned with each other On small gearboxes it is possible to install the key on the stem prior to sliding the operator onto the valve shaft Install the square key into keyslot until it is below the surface of the operator hub Do not use excessive force to drive the key If the key does not fit properly recheck the alignment of the slots Another key or pin punch should be used to drive against the ke...

Страница 15: ...ction to set the open stop so that all slack will be taken out of the gearing This ensures a more accurate stop setting After setting the open stop a quick check should be made to ensure that it has been set correctly This is accomplished by turning the handwheel shaft several turns towards closed then returning it until it hits the open stop There should be no more than 1 16 of the ball radius ex...

Страница 16: ... O ring is a weather seal All TK Valve sizes and models will incorporate this bonnet stem grease fitting Weather Seal Vented Grease Fitting Primary Pressure Seal Caution In the unlikely event of a primary stem seal failure leaks will occur through the grease fitting To temporarily fix the leak the vented grease fitting can be replaced with a 1 8 NPT pipe plug This will cause the weather seal to be...

Страница 17: ...njected the body cavity area around the ball is filled with grease The amount of grease will vary from 2 ounces for 1 1 2 valves up to 10 ounces for a 4 valve No damage can result from over greasing c Stroke the valve several times to distribute the grease to the surface of the ball Then return the valve to the desired position either fully open or fully closed 2 For 6 valves and larger a Close th...

Страница 18: ... the seat will allow the seats to become free 9 Collect and retain seat springs Two Piece Trunnion Supported 4 Remove bonnet and stem from valve 5 Remove trunnion flange It is not necessary to separate the trunnion from the flange 6 Remove adapter 7 Remove ball from body cavity CAUTION Before removing the valve from the line make sure that the line has been fully depressurized For valve designs wh...

Страница 19: ...asses is a sealing surface Before removing the stem from the bonnet dress the exposed portion of the stem by remove all rust nicks burrs ect and spray with penetration oil Then gently tap the stem out of the bonnet Do not use a hard face hammer 11 For all valve designs inspect the bushing in the body bonnet bore If damaged or worn replace before reassembly 12 Remove all O rings and replace if nece...

Страница 20: ... prior to installing seat holders The outside of the belleville spring bears on the seat holder 6 Replace each fire safe seal for all fire safe certified valves Two Piece Seat Supported non trunnion 7 Taking care not to damage the seat sealing surface install one seat in the body and one seat in the closure 8 Install stem into the bonnet 9 Install the bonnet and stem assembly onto the body 10 Rota...

Страница 21: ...ll 9 Install stem 10 Install bonnet and make sure the ball rotates freely 11 Taking care not to damage any sealing surfaces install seats into the closures 12 Install the closures onto the body Continue Assembly for all Valve Designs 13 On lever operated valves make sure of correct location of the stop socket head cap screw 14 Tighten all bolting on the assembled valve 15 Reinstall operator onto t...

Страница 22: ...r and check stem adapta tion and linkage for damage Lubricate actuator with suitable industrial grease Apply heat or inject antifreeze solution into valve but consult with authorized dealer prior to using remedy on operators Clean the seat area as outlined in Routine Seat Cleaning Remove bore restrictions or check stop in worm gear actuator and or actuator limit switches Replace broken or damaged ...

Страница 23: ...ENGINEERED PROCESS VALVES 01 2011 IOM TK TMBV 01 Installation Operation and Maintenance Manual ...

Страница 24: ... 2011 IOM TK TMBV 01 Installation Operation and Maintenance Manual VALVES MEASUREMENT 3250 Briarpark Drive Suite 300 Houston TX 77042 USA Toll 800 323 9160 For the most current contact and location information go to www c a m com ...

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