FCT Ball Valves, Model HPA/HRA/DB
Contents
1. S m J 7 NI La A MIN AL Remove the valve from the line see Section 4 Open the vent valve Close the valve The valve has to be maintained in closed position see also point 5 Remove the operator from the top flange unscrewing the relevant bolts To remove the actuator follow the relevant instructions included in the actuator manual In case of ESDV with a fail open actuator ask the manufacturing plant specific instructions before disassembling the actuator from the valve 6 Place the valve with the end flange pos 2 on the floor and horizontal stem see fig 3A Make sure not to damage the flange sealing surface 7 Remove the upper valve lifting pos 157 the support leg pos 164 and the end flange pos 2 unscrewing the nuts pos 9 Lift the upper flange pos 2 end from the body pos 1 See fig 3B Verify that the ball pos 5 is in closed position and that the bonnet pos 12 is assembled to the body 10 Lift the ball pos 5 and the ball trunnion plates 86 from the body Remove the antistatic device springs See fig 3C 11 Remove the key pos 115 12 Remove the stem pos 6 from the body 13 Remove the lip seal gasket pos 13B from the body Make sure not to damage the sealing surface on stem and body 14 Remove the top flange pos 11 unscrewing the nuts Remove bonnet pos 12 We PONS or Gr 7 c VAA 15 QUILT EEE EEE 16 Disassemble2. recondition the sealing surface this operation has to be performed by Mfg plant or nominated service company only Jerky operation 1 Not enough feed pressure 1 Increase the actuator feed pressure Pentair reserves the right to change the contents without notice Ball valves side entry Installation and Maintenance Instructions Section 3 Maintenance Our split body ball valves have been designed to require minimum maintenance This manual describes on site repairs as Stem Bonnet Gasket replacement Full Gasket Trunnion Bearings replacement All the other repairs major repairs should be performed by the manufacturing plant or Nominated Service Company 3 1 Stem Bonnet Gasket Replacement Please refer to figures no 2 and 2A Warning Depressurize the line before starting any maintenance Failure to do so may cause serious personal injury and or equipment damage 1 Place the valve in fully open or fully closed position 2 Open the vent and discharge the pressure The vent valve has to be in open position during all operations 3 Remove the operator from the top flange unscrewing the relevant bolts To remove the actuator follow the relevant instructions included in the actuator manual Remove the key pos 115 Remove the top flange pos 11 and the thrust bearing pos 121 unscrewing the nuts Remove the bonnet pos 12 unscrewings the nuts Remove the lip seal gasket pos 13b Make sure not to dam
3. above 200 C 392 F thermal insulation of the valve body is recommended Handling and lifting of the valves during installation MUST be performed following the same criteria and instructions described in previous points 1 2 Handling Requirements and 1 3 Storage and Preservation before Installation Buttweld Valves Position the valve and check the alignment with the pipe Proceed with welding in accordance with the applicable welding procedure It is 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 with flushing For buttweld end valves To avoid any damage to the gaskets the temperature during the pipe welding and the heat treatment has to be monitored by a thermocouple placed in the seat grease injector holes Make sure to limit the temperature at maximum of 200 C This instruction has to be carefully followed especially in case there are not any transition piece pup piece welded to the valve The use of a transition piece shall be prescribed in case the welded pipe strength is greater 1 5 times the valve strength 2 3 Valve Verification Before Start Up 1 Verify the tightness of the drain plug and of the vent valve Since all gaskets are self energized tighten the bolts enough to assure the contact between the surfaces and to avoid any nuts disassembly which may be caused by possible line vibrati
4. air line Ensure that there are no solid objects such as pieces of wood plastic or packing materials within the valve or on the valve seat 3 Confirm that the materials of construction listed on the valve nameplates service and temperature are appropriate for the service intended and are as specified 4 Define the preferred mounting orientation with respect to the system pressure If any see arrow on the body identify the upstream side high pressure and downstream side low pressure Warning e Verify that the direction of the flow in the line corresponds to the arrow indicated on the valve body Valves without the arrow are bi directional e See the actuator user manual for the actuator preparation e Verify the assembly of the overpressure relief device in case of liquid service and double piston effect option 2 2 Installation Instructions Ball valves are normally installed in horizontal pipe with vertical stem These valves can also be installed with no limitation regarding the pipe or stem orientation However in this case the actual pipe stem orientation should be advised to allow for the right position of the drain plug Unless otherwise recommended by the manufacturing plant the valve should be installed with the ball in the open position to ensure that the seat rings are not damaged during installation Particular care should be taken with those valves equipped with fail close actuators For operating temperatures
5. gt PENTAIR FCT Caution For valve handling and or lifting the lifting equipment fasteners hooks etc must be sized and selected while taking into account the valve weight indicated in the packing list and or delivery note Lifting and handling must be made only by qualified personnel Do not use the lifting points located on the actuator if any to lift the valve These lifting points are for the actuator only Caution must be taken during the handling to avoid that this equipment passes over the workers or over any other place where a possible fall could cause damage In any case the local safety regulations must be respected a pep aa ea laa aes www pentair com valves Ball valves side entry Installation and Maintenance Instructions Installation and Maintenance Instructions Ball valves trunnion mounted side entry Section 1 Valve Storage 1 1 Preparation and Preservation for Shipment All valves are properly packed in order to protect the parts that are subject to deterioration during transportation and storage on site In particular the following precautions should be taken 1 The valves must be packed with the ball in the open position 2 The weld ends surface shall be protected with suitable protective like Deoxaluminite The end shall be closed with plywood or plastic disc fixed at the edge by straps 3 All actuated valves mus
6. it grease through the stem grease Injector Use the seat injectors device to stop the leakage of the valve in close position The sealant injection is to be considered as an emergency operation to stop the leakage up to the next planned maintenance job If the leakage does not stop follow the maintenance procedure for the replacement of the gaskets in Section 3 2 For actuated valves in addition to the above please refer also to the warnings in the actuator manual Do not overtighten the bolts to assure gasket tightness The gaskets are self energized B Preventive Actions 1 Every 3 months verify the tightness of bolts drain vent 2 Every 5 years disassemble the critical service valves and or actuated valves verifying the sealing surface and lapping them again if necessary Change all the gaskets 3 For the actuator proceed as indicated in its maintenance manual 2 6 Troubleshooting Guide Symptom Possible Cause Solution Stem gasket leaking 1 Gasket damage 1 Sealant injection temporary 2 Gasket replacement see section 3 Body closure leaking 1 Gasket damage 1 Gasket replacement see section 3 Body bonnet gasket 1 Gasket damage 1 Gasket replacement see section 3 leaking Valve leaking 1 Valve not fully closed 1 Close the valve 2 Debris trapped in valve 2 Cycle and flush with valve open to 3 Sealing surface damaged remove debris 3 Temporarily perform sealant injection As a further operation
7. the seat pos 4 from the end flange pos 2 17 Remove all the gaskets springs and thrust bearings Figure no 3D Pentair reserves the right to change the contents without notice Ball valves side entry Installation and Maintenance Instructions 18 Carefully clean all the sealing surfaces by using proper removing products Visually check all the sealing surface If they are damaged they should be repaired The sealing surface repair job has to be performed under direct supervision of manufacturing company or nominated qualified company only 19 Change all the gaskets and bearings 20 Reassemble the topwork of the valve in this sequence stem bonnet and top flange For the bonnet follow the instructions at point 3 1 Make sure to lubricate all the relevant surfaces with suitable grease Make sure to rotate the stem in the right position in order to allow the ball assembly 21 Assembly the new seat gaskets pos 4a 4b 4c on the seat 22 Put the springs pos 44 in the end flanges holes 23 Assemble the seat ring to the end flange 24 After having changed the thrust bearings pos 109 assemble the trunnion plate pos 86 to the ball pos 5 25 Let down the assembled ball plus trunnion plates see fig 3D in the valve body Make sure to put the stem in the slot placed on the top of the ball trunnion Remember to place the two antistatic springs between the stem and the bottom surface of the slot 26 Make sur
8. age the sealing surfaces on the stem and body 8 Carefully clean all the sealing surfaces using proper remover products Visually check all the sealing surfaces if damaged they should be repaired For lip seal assembling use the conical ring special tool 9 Change all the gaskets and reassemble all parts following backwards the above mentioned steps 10 Close the vent valve oe aS Warning The stem has been designed as antiblow out to improve safety during the service This means that the stem cannot be disassembled from the valve by simply removing the valve top flange and bonnet You need to disassemble all the valve Figure no 2 Figure no 2A Pentair reserves the right to change the contents without notice page 4 Ball valves side entry Installation and Maintenance Instructions Figure no 3 Gu OL QO mow ES p Ws A f I Q T A A AS Wee wy AN it uA 09 es i 40 44 ID O IN Natt KORU HA ss Z V s KN e See W q e fz LM LELEEL Z 3 2 Full Gasket Trunnion Bearings Replacement Please refer to fig no 3 3A 3B 3C 3D Warning Depressurize the line before starting any maintenance Failure to do so may cause serious Figure no 3C personal injury and or damage to the valve j Figure no 3B
9. e the ball is in closed position Assemble the end flange with the seat ring to the body Put the valve lifting pos 157 and support leg pos 164 Remember to position the fire safe gasket pos 7a in the body grove and screw the nuts pos 9 27 Rotate the valve and place with the other flange end on the floor with horizontal stem see fig 3A 28 Repeat the instructions 7 8 9 16 17 18 19 21 22 23 26 29 Rotate the valve and place it on its feet 30 Reassemble the valve operator 31 Close the vent valve Section 4 Valve Removal If the valve needs to be removed from the line for some extraordinary reason the user should ensure the following Warning Depressurize the line before starting any maintenance Failure to do so may cause serious personal injury and or damage to the valve 1 The valve is depressurised 2 The pipe shall be cut as far away from the valve as possible Section 5 Greases and Special Tools 5 1 Sealant Greases The suggested sealant grease is MOLYCOTE 111 valve lubricating and sealing silicone compound by DOW CORNING 5 2 Special Tools The only tool required is the conical ring suitable for the gasket assembly pos 133 See fig 2A Pentair reserves the right to change the contents without notice page 6
10. ed out in a controlled way and has to be performed in accordance with the following criteria 1 The valves have to be stocked in a closed clean and dry storage room 2 The ball must be in the open position and the end faces must be protected with plastic or wooden discs fixed with straps If possible keep the original protection 3 Periodical checks have to be carried out in the storage area to verify that the above mentioned conditions are maintained For actuated valves in addition to the above please refer to the warnings in the relevant actuator manual 1 Note Storage in an open area for a limited period can be considered only in case the valves have appropriate packing packed in cases lined with tarred paper and contents well protected with barrier sacks Do not place consignment packages directly on the ground Do not expose consignment packages to the weather or directly to the sun Check the packaging every two months Figure no 1 FCTLT 0002 EN 1307 Pentair reserves the right to change the contents without notice Ball valves side entry Installation and Maintenance Instructions Section 2 Installation 2 1 Preparation before installation 1 Carefully remove the valve from the shipping package box or pallet avoiding any damage to the valve or in case of automated valves to the electric or pneumatic hydraulic actuator or instrumentation 2 Clean the inside of the valve using an
11. ons There is no need to overtighten the bolts to assure gasket tightness 2 Check the valve operability by stroking it to full open and full close If piping system is pressurized with water for testing and in case the piping system has been shut down after testing for a long time the following recommendations should be adopted a Use corrosion inhibitor with water to pressurize the piping system b After testing the piping system should be depressurized and the test water completely drained Pentair reserves the right to change the contents without notice Ball valves side entry Installation and Maintenance Instructions 2 4 Operations Instructions 1 Split Body Ball Valves do not require special care to work properly The following instructions will help provide a satisfactory and long life service 2 Make sure to perform periodic valve verification as described in paragraph 2 5 3 In case of actuated valves always follow the specific instructions given by the actuator s manufacturer 4 Never change the setting of torque and or limit switches which have been carefully set during the final test at our workshop 5 Never change the setting of the mechanical stops of the gearbox 2 5 Periodic Valve Verification During Service A Normal Check 1 Verify monthly that there is no leakage from the gaskets or through the seats If the leakage has been detected in the stem bonnet area inject the proper seal as
12. t be carefully securely palleted or crated in order to ensure that the parts of actuator especially pneumatic piping or accessories do not extend beyond the skid crate 4 The type of packing must be defined in the Customer s Order and shall be appropriate to ensure safe transportation to final destination and eventual conservation before installation 1 2 Handling Requirements A Packed Valves Crates Lifting and handling of the packed valves in crates will be carried out by a fork lift truck by means of the appropriate fork hitches Cases The lifting of packed valves in cases should be carried out in the lifting points and at the center of gravity position which have been marked The transportation of all packed material must be carried out safely and following the local safety regulations B Unpacked Valves 1 The lifting and the handling of these valves has to be carried out by using appropriate means and by respecting the carrying limits The handling must be carried out on pallets protecting the machined surfaces to avoid any damage 2 With valves of large dimensions the sling and the hooking of the load must be carried out by using the appropriate tools brackets hook fasteners ropes and load balancing tools in order to prevent them from falling or moving during the lifting and handling 1 3 Storage and Preservation before Installation In case the valves have to be stored before installation the storage has to be carri
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