USER`S MANUAL - Assured Automation
Contents
1. 14 UNC 288 3 16 UNC 180 V2 13 UNC 439 2 1 2 7 1g 14 UNC 288 n a n a 3 7 1g 14 UNC 288 1g 12 UNC 636 34 10 UNC 1548 4 V2 13 UNC 439 34 10 UNC 1548 7 9 UNC 2200 6 S g 11 UNC 876 71 9 UNC 2200 n a 8 34 10 UNC 1548 1 8 UNC 3600 n a 10 g 9 UNC 2200 n a n a O Retest valve assembly per API 598 or ASME B16 34 P Re install per Section Il2. b Remove Snap Ring 19 and Stop Plate 18 c Remove Packing Nuts 16 Belleville Washers 17 Packing Bolts 15 and Gland Flange 14 d Remove Gland 11 e Push Stem 5 down into body cavity and remove from body bore f Remove Packing 8 and Packing Washer 9 with packing hook DO NOT DAMAGE PACKING BORE g Remove Stem Bushing 10 from Gland 11 h Discard Seats 3 Packing 8 Packing Washer 9 Thrust Washer 7 and Body Seal 6 New parts are included in repair kit Reassembly A LAC B C D E Inspect Ball 4 and Stem 5 for any damage or wear replace if required Apply lubricant to 1 new Seat 3 and install in Body 1 press into seat recess Install new Thrust washer 7 on Stem 5 and insert through body bore and up through stem bore seat thrust washer against recess face Move stem to closed position so that internal stem tang is parallel to body length centerline and install Ball 4 Apply lubricant to second Seat 3 and install into Adaptor 42 press into seat recess Install new Body Seal 6 onto Body counterbore and apply anti seize compound to Stud Bolts 12 Lift Adaptor 2 and align flange bolting with opposite body flange while aligning cast stiffening ribs on Adaptor to be located aligned with stem and body base Use caution to protect Body Seal 46 and to insure Seat 3 stays in seat recess Hand tight
3. on a weekly basis In high cycle applications check stem packing area regularly to confirm there is no leakage from stem packing If leakage occurs follow step 1V B to correct VI Repair amp Reconditioning F2 Series Split Body Flanged End Ball Valves NOTE Refer to Assembly Drawings and Parts Lists as shown in Quadrant Folder F2 CS F2 SS this can be downloaded at www QUADRANTVALVE com or see Quadrant Engineering Binder under Flanged End Ball valves A B C w I Qnm Depressurize line drain fluid Remove flange bolting slide valve from between piping flanges discard spiral wound flange gaskets Place valve assembly on a secure table surface with Part 2 Adaptor facing up and opposite body flange contacting table surface Table or bench must be equipped with studs or bolts to engage body flange holes and must have a protective surface to prevent damage to body flange face Note Significant torques are required to be applied to Body Nuts 13 to disassemble amp reassemble valve secure table or bench to floor or wall Using six point sockets loosen Body Nuts 13 and remove Carefully lift Adaptor 2 upward away from Body 1 Move handle to closed position and remove Ball 4 and Seat 3 from body cavity Handle ball carefully to prevent damage Remove second Seat 3 from Adaptor 2 For 1 to 10 sizes a Remove Handle 20
4. 6 F G Engage male hexagon driver into female hexagon drive in Part 2 Insert Using six point sockets of 3 4 or 1 drive size to engage male drivers or large pipe wrench apply counter clockwise torque to drivers to remove Part 2 Insert Move handle to closed position and remove ball and seats from body cavity Handle ball carefully to prevent damage For 72 to 1 sizes a Remove Handle 12 b Remove Packing Nut 9 c Push Stem 4 down into body cavity and remove from body bore d Remove Packing 8 with packing hook DO NOT DAMAGE PACKING BORE For 1 1 2 to 6 sizes a Remove Handle 15 b Remove Snap Ring 14 and Stop Plate 13 c Remove Packing Nuts 12 Belleville Washers 11 Packing Bolts 10 and Packing Plate 9 Push Stem 4 down into body cavity and remove from body bore Remove Packing 8 with packing hook DO NOT DAMAGE PACKING BORE oa Reassembly A OU O m Inspect Ball 3 and Stem 4 for any damage or wear replace if required Apply lubricant to 1 new Seat 5 and install in Body 1 press into seat recess Install new Thrust washer 6 on Stem 4 and insert through body bore and up through stem bore seat thrust washer against recess face Move stem to closed position so that internal stem tang is parallel to body length centerline and install Ball 3 Apply lubricant t
5. ASSURED 1 800 899 0553 AUTOMATION assuredautomation com 4100 Series Standard Port Class 150 amp 300 ANSI Unibody Ball Valve USER S MANUAL Installation amp Maintenance Assured Automation 19 Walnut Avenue Clark New Jersey 07066 Tel 732 381 2255 e Fax 732 381 2383 Valve amp Actuator Engineering Specification Number IOM 11 Date 7 24 2004 Title Unibody Flanged End Ball Valve IOM for 4100 l Initial Inspection A Remove valve from packaging remove flange protectors and discard if so equipped B Inspect flange faces for any damage caused in shipment or handling C Confirm Valve Size and Class is correct for installation ll Installation A Confirm flanges installed on adjacent piping are correct pressure class and match valve flange pattern B Confirm lay length between piping flanges matches valve lay length C Slide valve between piping flanges then insert first spiral wound flange gasket between one valve flange and piping flange D Insert flange bolts and hand tighten flange nuts on first side E Insert second spiral wound flange gasket between opposite valve flange and piping flange F Insert flange bolts and hand tighten flange nuts on second side G With a torque wrench having capacity to apply torque as recommended by flange gasket manufacturer start to torque first side flange bolts to 25 of recommended final torque using an alternating across flange torqueing sequ
6. acking adjustment in applications where many cycles of on off operation occur on a weekly basis In high cycle applications check stem packing area regularly to confirm there is no leakage from stem packing If leakage occurs follow step IV B to correct VI Repair amp Reconditioning F1 Series Unibody Flanged End Ball Valves NOTE Refer to Assembly Drawings and Parts Lists as shown in Quadrant Folder F1 CS F1 SS this can be downloaded at www QUADRANTVALVE com or see Quadrant Engineering Binder under Flanged End Ball valves A Depressurize line drain fluid B Remove flange bolting slide valve from between piping flanges discard spiral wound flange gaskets C Place valve assembly on a secure table surface with Part 2 Insert facing up and opposite body flange contacting table surface Table or bench must be equipped with studs or bolts to engage body flange holes and must have a protective surface to prevent damage to body flange face D Note Significant torques are required to be applied to Part Z2 Insert to disassemble amp reassemble valve secure table or bench to floor or wall E Obtain male hexagon drivers of the following sizes Valve Size Hexagon Driver Valve Size Hexagon Driver Across Flats Across Flats v2 10 4MM 13 32 3 64 5MM 2 17 32 y 15 8MM 5 87 4 86 5MM 3 13 32 1 20 8MM 13 16 6 131 0MM 5 5 32 1 1 2 31 7MM 1 1 4 2 42 7MM 1 11 1
7. e torqueing sequence to insure correct gasket compression H Using same across flange torqueing sequence increase torque to 5096 of recommended flange bolt final torque l Using same across flange torqueing sequence increase torque to 7596 of recommended flange bolt final torque J Using same across flange torqueing sequence increase torque to recommended flange bolt final torque K Perform steps G through J on opposite flange connection Ill Operation A After Installation confirm handle has adequate clearance by rotating 90 degrees from open to closed position and back to open B C All Quadrant ball valves are designed for on off operation only DO NOT attempt to throttle with Quadrant ball valves unless they are specifically designed for and tagged FOR THROTTLING SERVICE If application is in STEAM PIPING be cautious when operating valve handle will be HOT IV Initial Pressurization of System A B Upon initial pressurization of piping system check all connections for leaks and correct if required Once system reaches Steady State conditions of operating pressure and operating temperature it will be necessary to make initial stem packing adjustment Evenly tighten the two Packing Nuts Part 16 to 30 40 In Lbs V Maintenance A Quadrant Ball Valves require no maintenance other than periodic stem packing adjustment in applications where many cycles of on off operation occur
8. en Body Nuts 13 to Studs 12 Install new Stem Packing 8 using caution to prevent damage to packing rings NOTE for PTFE Packing the chevron points upwards toward handle and upper amp lower rings are flat on one side Install new Packing Washer 9 using caution to prevent damage Install new Stem Bushing 10 into recess in Gland 11 For 1 to 10 Sizes a Install Gland Flange 14 Packing Bolts 15 Belleville Washers 17 and Packing Nuts 16 torque evenly to 30 40 In Lbs b Install Stop Plate 18 Snap Ring 19 and Handle 20 Place valve assembly on table or bench with Adaptor 2 facing up and opposite body flange engaged with studs or bolts protect flange surfaces Using a torque wrench capable of producing the required final torques listed below torque Body Nuts 13 to Studs 12 as follows a Using an alternating across flange torque sequence torque Body Nuts to 25 of final recommended torque b Using same procedure torque to 50 of final torque c Using same procedure torque to 75 of final torque d Using same procedure torque to final torque BODY NUT ASSEMBLY TORQUES Assembly Torque Assembly Torque Assembly Torque Ft Lbs Ft Lbs Ft Lbs Valve Size Class 150 Class 300 Class 600 1 5 18 18 UNC 101 Y 4 16 UNC 180 s 16 UNC 180 1 1 2 3 16 UNC 180 ig 14 UNC 288 V2 13 UNC 439 2 7 1g
9. ence to insure correct gasket compression H Using same across flange torqueing sequence increase torque to 50 of recommended flange bolt final torque Using same across flange torqueing sequence increase torque to 75 of recommended flange bolt final torque J Using same across flange torqueing sequence increase torque to recommended flange bolt final torque K Perform steps G through J on opposite flange connection Ill Operation A After Installation confirm handle has adequate clearance by rotating 90 degrees from open to closed position and back to open B C All Quadrant ball valves are designed for on off operation only DO NOT attempt to throttle with Quadrant ball valves unless they are specifically designed for and tagged FOR THROTTLING SERVICE If application is in STEAM PIPING be cautious when operating valve handle will be HOT IV Initial Pressurization of System A B Upon initial pressurization of piping system check all connections for leaks and correct if required Once system reaches Steady State conditions of operating pressure and operating temperature it will be necessary to make initial stem packing adjustment Tighten Part 9 Stem Packing Nut to 20 25 in Ibs on 74 1 Sizes On 1 1 2 to 6 sizes evenly tighten the two Packing Nuts Part 12 to 30 40 In Lbs V Maintenance A Quadrant Ball Valves require no maintenance other than periodic stem p
10. ion Il ASSURED 1 800 899 0553 AUTOMATION assuredautomation com 4200 Series Standard Port Class 150 amp 300 ANSI Two Piece Ball Valve USER S MANUAL Installation amp Maintenance Assured Automation 19 Walnut Avenue Clark New Jersey 07066 Tel 732 381 2255 e Fax 732 381 2383 Valve amp Actuator Engineering Specification Number IOM 12 Date 7 24 2004 Title Split Body Flanged End Ball Valve IOM for 4200 l Initial Inspection A Remove valve from packaging remove flange protectors and discard if so equipped B Inspect flange faces for any damage caused in shipment or handling C Confirm Valve Size and Class is correct for installation Il Installation A Confirm flanges installed on adjacent piping are correct pressure class and match valve flange pattern B Confirm lay length between piping flanges matches valve lay length C Slide valve between piping flanges then insert first spiral wound flange gasket between one valve flange and piping flange D Insert flange bolts and hand tighten flange nuts on first side E Insert second spiral wound flange gasket between opposite valve flange and piping flange F Insert flange bolts and hand tighten flange nuts on second side G With a torque wrench having capacity to apply torque as recommended by flange gasket manufacturer start to torque first side flange bolts to 25 of recommended final torque using an alternating across flang
11. o second Seat 5 and install into Insert 2 press into seat recess Install new Body Seal 7 onto Insert 2 and apply anti seize compound to Insert threads and or Body threads Hand tighten Insert into Body using caution to protect Body Seal 7 and to insure Seat 5 stays in seat recess Install new Stem Packing 8 using caution to prevent damage to packing rings NOTE for PTFE Packing the chevron points upwards toward handle and upper amp lower rings are flat on one side For 77 to 1 Sizes a Install Packing Nut 9 torque to 20 25 In Lbs b Install Handle 12 Lock washer 10 and Handle Nut 11 For 1 1 2 to 6 Sizes a Install Packing Plate 9 Packing Bolts 10 Belleville Washers 11 and Packing Nuts 12 torque evenly to 30 40 In Lbs b Install Stop Plate 13 Snap Ring 14 and Handle 15 Place valve assembly on table or bench with Insert 2 facing up and opposite body flange engaged with studs or bolts protect flange surfaces L Using a torque wrench capable of producing the required final torques listed below torque Insert 2 into Body 1 using male hexagon drivers noted in VI Section E ASSEMBLY TORQUES Valve Size Assembly Torque Ft Lbs y 140 Ya 150 150 4 1 2 500 2 800 3 1200 4 6 1800 3000 M Retest valve assembly per API 598 or ASME B16 34 N Re install per Sect
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