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Force

– Two Piece Trunnion

Mounted Ball Valve

Document Number:

Revision:

Release Date:

EDC 514

05/09/2022

IOM: Installation, Operation and Maintenance Manual

3/43

Index

Page

Ⅰ.

Construction and Design features

･･･････････････････････････････

Ⅱ. Operator

･･･････････････････････････････････････････

Ⅲ.

Shipping, Handling and Storage

･････････････････････････････････

Ⅳ. Valve

installation

･･････････････････････････････････････････

Ⅴ. Valve operation

･･････････････････････････････････････････

Ⅵ.

Periodic inspection

･･･････････････････････････････････････････

Ⅶ.

Disassembly and Reassembly

････････････････････････････････････

Содержание CNC BTN Series

Страница 1: ... Ball Valve Document Number Revision Release Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 1 43 Installation Operation and Maintenance Manual API 6D Two Piece Cast Trunnion Mounted Ball Valves BTN Series ...

Страница 2: ...o be installed in observance of the pressure rating and design temperature Prior to installation the valves and nameplates should be checked for proper identification to be sure the valve is of the proper type material and is of a suitable pressure class and temperature limit to satisfy the application requirements Indicating potentially hazardous conditions which may result in injury to personnel...

Страница 3: ...Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 3 43 Index Page Ⅰ Construction and Design features 4 Ⅱ Operator 9 Ⅲ Shipping Handling and Storage 12 Ⅳ Valve installation 15 Ⅴ Valve operation 19 Ⅵ Periodic inspection 26 Ⅶ Disassembly and Reassembly 35 ...

Страница 4: ...Force Two Piece Trunnion Mounted Ball Valve Document Number Revision Release Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 4 43 Ⅰ Construction and Design features ...

Страница 5: ...the valve less impact on its operationtorque 1 5 This is a bi directionalvalve This illustration shows typical construction NOTE This figure is for reference only as components may vary according to size class and design Consult CNC Flow Control for appropriate component list NO NAME OF PARTS 1 BODY 4 END CAP 5 STEM 6 BALL 11 GLAND FLANGE 14 SEAT INSERT 16 TRUNNION 18 SEAT CARRIER 20A O RING 20B G...

Страница 6: ...ats Single valve with two seating surfaces each of which in a closed position provides a seal against pressure from a single source with a means of venting bleeding the cavity between the seating surface Valve seat designed to seal against pressure source in either direction Double Piston Effect DPE DPE DPE 2 3 Double isolation and bleed 2 DIB 2 One seat unidirectional x one seat bidirectional A c...

Страница 7: ...ant fire the edge of the metal seat retainer preloaded by the seat spring comes into contact with the ball to shut off the line fluid to minimize internal leakage through the valve bore Before exposure to fire After exposure to fire 2 6 Drain port The valve has the block and bleed structure that allows a valve or other types of connections to be installed at the drain port through which the fluid ...

Страница 8: ...Piece Trunnion Mounted Ball Valve Document Number Revision Release Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 8 43 P T rating for class 150 to 600 P T rating for class 900 to 2500 ...

Страница 9: ...Force Two Piece Trunnion Mounted Ball Valve Document Number Revision Release Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 9 43 Ⅱ Operator ...

Страница 10: ...rator 1 1 The lever handle is directly mounted on the valve stem 1 2 Rotate the lever handle clockwise by 90 to close and counterclockwise by 90 to open the ball 1 3 Rotation of the stem by 90 fully opens and fully closes the valve for Bare Stem Type An appropriate tool or handle shall be applied to operate the valve and the flow direction shall be checked by the top orientation of stem ...

Страница 11: ... through reduction gear 2 2 The gear operator shall be mounted directly to the valve 2 3 There should be an arrow or letter on the gear handwheel to indicate the proper direction to rotate the wheel for opening counterclockwise or closing clockwise valves 2 4 Handwheel operation forces differ in the valve opening position and fluid pressure and or temperature Gear operator shall be correctly sized...

Страница 12: ...Force Two Piece Trunnion Mounted Ball Valve Document Number Revision Release Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 12 43 Ⅲ Shipping Handling and Storage ...

Страница 13: ...ed by the unsecured valves Unstable stacking may also result in personal injuries Lifting equipment s safe working load SWL shall always be double checked prior to any lift Recommended handling procedure when lifting with slings shown in figure 1 Pay attention not to damage painted valve surfaces during transportation which may subsequently cause corrosion to the valve Repair is required if the su...

Страница 14: ...on them Overloading may cause damage to valves DO NOT pile up products carelessly to avoid damage to the products and personal injury caused by unstablepiling Keep the valves in the opened position during storage Storing the valves in halfway position may deform the ball seats leading to cause of the seat leakage And storing the valves in fully closed position may damage the ball when the flange p...

Страница 15: ...Force Two Piece Trunnion Mounted Ball Valve Document Number Revision Release Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 15 43 Ⅳ Valve installation ...

Страница 16: ...e functions may be hampered by outer forces such as vibrations 1 4 It is recommended to install valves to horizontal pipes with stem in the upright position Check the valve specifications with the identification plate or tag and the relevant catalogue to ensure that the exact valves specified in your piping arrangement plan was provided The service fluid pressure and temperature determine the comp...

Страница 17: ...ld be within the range of the relevant valve specification 2 1 2 Valve flanges should correspond with pipeflanges 2 1 3 Gasket contact surfaces of pipe and valve flanges must be free from scratches or any other damages 2 1 4 The appropriate length should be kept between pipe flanges for the valve face to face dimensions including the gasket thickness 2 1 5 Pipes and valves should be accurately ali...

Страница 18: ... holes and tighten them lightly This will support the valve during the remaining steps of installation 3 4 Insert gaskets between the valve and pipe flanges It is recommended to apply lubricant gasket paste to gasket faces 3 5 Make sure the correct alignment of gaskets which are held in place with the bottom bolts 3 6 Thread bolts through the other holes of flanges and slightly tighten them 3 7 Ev...

Страница 19: ...Force Two Piece Trunnion Mounted Ball Valve Document Number Revision Release Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 19 43 Ⅴ Valve operation ...

Страница 20: ... the test may deform the seats leading to the occurrence of internal through bore leakage In case service temperature fluctuates retighten all bolts and nuts after the temperature is stabilized against occurrence of stress relaxation of the gland packing and or gasket DO NOT EXCEED TORQUE MORE THAN RECOMMENDED IN SECTION 5 2 Gradually open valves to prevent damage of pipe when high temperature flu...

Страница 21: ... the flange bolts Replace the O rings Threaded areas Visual check Soapy water Retighten each threaded area Replace the relevant components Body Visual check Soapy water Replace the valves Abnormal noises Valve body Auditory check Consult a piping engineer Loosened bolting Auditory check Retighten bolting Pipe Vibration Auditory check Consult a piping engineer Loosened bolting Bolts and nuts Visual...

Страница 22: ... gland Tighten only enough to stop the leak Operators should always take protective measures to prevent direct exposure to the media including wearing protective goggles gloves and safety shoes a minimum More stringent protective measures may be necessary when handling toxic inflammable or corrosive media Ensure to reduce the line pressure to the atmospheric level before retightening gland or flan...

Страница 23: ...ce Manual 23 43 If the leak cannot be stopped by tightening the gland nuts it is necessary to add additional packing rings or completely repack the valve DO NOT repack valve under pressure Over tightening will cause the packing to fail prematurely as well as increasing the force required to operate the valve Uniform loading Non uniform loading ...

Страница 24: ...2 1918 1744 1640 9 16 64 57 51 48 1 7 8 2671 2349 2135 2745 5 8 87 77 70 66 2 3328 2928 2662 2503 3 4 154 136 124 116 2 1 4 4803 4226 3841 3613 7 8 246 216 197 184 2 1 2 6659 5858 5325 5009 1 354 312 283 266 2 3 4 8914 7843 7130 6705 1 1 8 531 467 425 399 3 11630 10233 9301 8747 STD FASTENING TORQUE Bolt Size Torque Values ft lbf Bolt Size Torque Values ft lbf Metric B7 B8 B8M B7M SS 630 Metric B7...

Страница 25: ...y the media with the ball slightly open Disassemble and inspect the valve The gland bolts may have been over tightened In case of valves with the gland packing structure Loosen the gland bolts once and adequately retighten them so that the leakage through the gland does not occur Leakage from the gland area Loosen the gland Retighten the gland Damage of O rings Replacement of O rings Uneven tighte...

Страница 26: ...Force Two Piece Trunnion Mounted Ball Valve Document Number Revision Release Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 26 43 Ⅵ Periodic inspection ...

Страница 27: ...ng are not daily inspected or not operated for a long period time a periodic inspection is recommended A periodic inspection should be carried out on all valves 1 5 It is particularly important to thoroughly check the valves used for the following service a Where performance failure of valves could result in a major shutdown of an entire plant unit b Where the media contain high viscosity and may ...

Страница 28: ... case fluid is toxic inflammable or corrosive remove the fluid completely from pipes and internals of the valves Take protective measures to prevent direct exposure to the fluid and catching fire Keep off the working area to prevent personal injury if valves are installed at higher places Wear personal protective gear such as goggles gloves and working boots Keep a secure footing while dismantling...

Страница 29: ...ack Visual check Measuring flange thickness No appearance of corrosion damage or crack Welding repair or scrap Fluids contact surfaces Corrosion Scratch Crack Visual check Measuring wall thickness N D E No appearance of corrosion Propriety of wall thickness Welding repair or scrap Ball seat Ball Seat surface Corrosion Scratch Crack Visual check No appearance of wear or damage Replacement of ball s...

Страница 30: ... the valve bore is in the partially open position C Verify the location of the drain fitting Note the direction of the hole where the fluid will exit the fitting and make sure the hole is free of dirt or debris D Apply a backup wrench to the body of the fitting to prevent the fittings itself from being unscrewed and with the port of the bleed fitting pointed in the opposite direction from your bod...

Страница 31: ...the seat and the ball which will ultimately degrade sealing performance 2 4 4 Field Repair of a Seat Leak If a seat leak develops the first step in attempting to remedy the problem should be to flush the valve Follow these steps to flush the valve A Purchase a valve flushing compound from a reputable grease sealant manufacturer Verify that the flushing compound purchased is compatible with the val...

Страница 32: ...equivalent Required one 1 oz ounce per inch of valve size in case of emergency seal B Place the valve in the fully closed position and drain the valve body using the steps given in section Chapter Ⅵ Periodic inspection Section 2 4 1 Draining Procedure fitting C Remove the cap from the grease zerk taking care not to unscrew the actual grease fitting D Load the g s into your grease gun Note Thorough...

Страница 33: ...e valve should be promptly repaired by a qualified valve repair specialist The lubricant sealant must be displaced before the heavier sealant fills the sealant system The same calculations used for injecting valve cleaner are applicable one 1 oz ounce per inch of valve size into each seat ring plus riser pipe quantities 2 4 6 Recommended spare parts for repair Table A Recommended Spare parts for R...

Страница 34: ...assembled with the ball 3 Ensure that there should be no offset of the ball ports and ball seats at the fully open position The ball should not be protruded into the valve port other than the rounded surface of the ball port edges 2 5 3 Shell test and seat leakagetest 1 Care for shell test and seat leakage test Wear personal protective gear such as goggles gloves and working boots Before shell tes...

Страница 35: ...Force Two Piece Trunnion Mounted Ball Valve Document Number Revision Release Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 35 43 Ⅶ Disassembly and Re assembly ...

Страница 36: ...r safety operation 1 2 Before disassembly 1 2 1 Place the valve in adust free area 1 2 2 Take care not to damage the flange surfaces ball and stem 1 2 3 Give identification marks on edges of the coupled flanges for adequate and easy coupling of the body and the body cap on subsequent reassembly 1 2 4 If bolting is found seized or stuck each other because of rust apply some lubricant and leave it f...

Страница 37: ... the upper stem from the body 1 4 7 Remove the end plate Pull out the sub assembled small parts first and then the bottom stem The stem and trunnion is also provided with threaded tap for easier removal 1 4 8 Place the valve on a sturdy flat surface with the body flange facing to the floor 1 Loosen the cap nuts evenly and alternately in a star pattern until the seat springs lose their loading forc...

Страница 38: ...e ball surface from damage or scratch during disassembly storage and subsequent reassembly 1 4 10 Remove the seat retainer sub assembly from the body Mark the removed seat retainers for proper identification with the body or the body cap 1 4 11 Remove the O rings from the body and body cap or seat retainer 1 4 12 Remove the seats from the seat retainer sub assembly as described below Unthread the ...

Страница 39: ...g parts and O rings 2 2 Before reassembly 2 2 1 New parts for replacement should be prepared beforehand 2 2 2 The consumables gland packing rings gaskets O rings backup rings ball seats thrust washers stem bearings gland bushes retainer packing and retainer rings should be replaced for new ones Reuse of these parts may cause leakage 2 2 3 Be sure to clean the parts to remove dust oil and other for...

Страница 40: ...sub assembly into the valve body Lift the ball with a cloth belt and place it into the valve body slowly with care to protect it from damage or scratch 2 4 4 Adjust the location of the stem hole of the ball by means of a hydraulic press machine for correct centering with the stem hole of the valve body Protective measures such as a soft pad should be taken to prevent ball surface from contact to t...

Страница 41: ...roved drawing for assembly and disassembly NO NAME OF PARTS 1 BODY 4 END CAP 5 STEM 6 BALL 11 GLAND FLANGE 14 SEAT INSERT 16 TRUNNION 18 SEAT CARRIER 20A O RING 20B GASKET 22 STEM FIRE SAFE SEAL 25 THRUST WASHER 30 CAP STUD 31 CAP NUT 32 GLAND BOLT 49A O RING 49B 49C 49D 49E 51 SEAT SPRING 54 SEAT FIRE SAFE SEAL 67 LANTERN RING 69A DU BUSHING 69B DU BUSHING 69C DU BUSHING 82 GASKET 83 TRUNNION STU...

Страница 42: ...elease Date EDC 514 A 05 09 2022 IOM Installation Operation and Maintenance Manual 42 43 Ⅶ Disassembly and Reassembly 4 Exploded view drawing This drawing represents only a typical construction of the valve Please refer to the approved drawing for assembly and disassembly ...

Страница 43: ...installation operation and maintenance of Force BTN 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 is ultimately re...

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