Three Piece Ball Valve AC-305MF User Manual English Version
Contents
1. Butt amp Socket Weld Valves To avoid damaging seats and seals by exposure to welding temperature the Center Section must be removed while the end caps are welded separately into line Both butt and socket weld valves may be tack welded in place assembled as long as the Center Section is removed while the welds are completed Seal temperature must never exceed 400 F Care must be taken when cutting a valve into a line that the gap created to accept the valve is the correct practically in the case of butt welded valves The socket stop dimension for socket weld valves are listed in the adjacent chart For socket weld valves it is good practice to provide a gap of approximately 1 6 mm between the end of the pipe and the bottom of the socket before welding d Systems hydrostatic test Before delivery valves are tested 1 5 times the allowable pressure at ambient temperature in open position After installation the piping system may subject to system tests as condition not to exceed the above mentioned pressure 6 4 Operation a For manual operation shift the handle in counter clockwise direction for close and clockwise for opening b Ifthe handle is in parallel position with the flow direction the valve is open If the handle is in right angle position with the flow direction the valve is close c When installing actuator or the valve is operated with removable handle the user should ensure the position of the valv2. t E yas OD Pansinciuded in O nng ke 1s 16 405k ov 1 2 When disassembly of actuator is required for maintenance firstly remove the actuator from the valve Before performing any disassembly operations it is important to verify that the actuator is not pressurised Always use caution and double check that the ports 2 and 4 are vented and are free from any accessory and or device When the actuator is a spring return unit make sure that the actuator is in the failed position before disassembling A Removal of position indicator Part No 79 figure 01 3 Remove cap screw 39 if fitted Lift position indicator 19 off shaft it may be necessary to pry gently with a screwdriver B Removal of stop cap screws Part No 02 figure 02 Remove both stop cap screws together with nut 04 and washer 03 4 Remove stop screw O rings 11 and discard if replacing all soft parts C End Caps disassembly Part No 30 right and 31 left figure 03 Before proceeding to the end caps disassembly put the actuator in vertical position and proceed as below described first on one side and then on the other side of the actuator Remove cap screw End cap 13 in the sequence shown in the figure 03 Caution when disassembling a spring return actuator the end cap 30 and 31 should be loose after unscrewing end cap bolts 13 4 5 turns If there s still force on the end cap after 4 5 turns of the end cap bolts this may indicate a
3. To lift the ball by hoist it must make the protection on corner to avoid the ball damaged by metal contacted The right position for store the valve is put the open end on to the ground This procedure is protecting the surface of the ball Form No QF 21 01 9 Vas i y S i lezz on B f NO PART NAME MATERIAL H j I CAP ASTM A351 CF8M _ e 2 BODY SEAT PTFE X 4 3 BALL ASTM A351 CF8M was H A 4 ASTM A351 CF8M i Jeane Ve O 5 BALL SEAT PTFE ot 6 WASHER SS304 ecm 7 IT SS304 l 8 STEM SEAL PTFE 4 9 RING VITON HZ 4 Z 10 STEM PACKING PTFE RE BZ 1 GL SS304 i 12 BELLEVILLE WASHER SS301 i 13 IT SS304 14 SS316 E 15 BODY BOLT SEn EH A 16 SS304 A 2 IERI 17 GRIP VINYL K 4 ie N 18_ STOP PIN SS304 PERN AGT 19 SNAP RING 55304 j 3 PI VA Size 3 4 4 Size 1 8 1 2 7 3 Parts inspection maintenance and replacement a Check the surface of ball is it scraped It may use the PT for inspection if necessary If there is any damaged on the surface than found out the root cause such as the dirt fluid etc It must avoid the damage factors as far as possible The damaged of the ball surface to gauge is it located on the contacting area of ball and ball seat If it is the case than the ball must take a fine milling Ifit cause a heavy damaged than it must welde
4. 6 1 Handling During the ball valve installation it must follow the procedure to handle at the both side of the bodies If using cable for big size valve be make sure the cable must be strong enough to ensure the safety during the installation 6 2 Cleaning Even the valves was transported under a clean environment operator must check is there any foreign body or dusts inside the bore If yes clean it before installation Operator clean the valves by water compression air or steam automation valve shall be cleaned only with water or steam the compression air is not allowed For cleaning operation first step is put the valve bore perpendicular to the ground and Form No QF 21 01 6 clean ensure all the dusts can be removed from the bore The second step is checking and clean all the connecting pipe bore and connection area No flush rust and foreign bodies allow to avoid the blocking and leakage 6 3 Valve Installation Install to the pipeline system a Direction Most of the valves do not restrict the flow direction b Position The body cap and gasket are in the connection area of ball valve and pipeline The bear weight ability and gradient are very important to the pipe installation Do not make the pressure from the pipeline and stress to concentrate on the connecting area of body and cap It will cause the deformed and leakage and the ball seat and stem will stick leaking and damaged c Fittings Select the cor
5. damaged spring cartridge and any further disassembly should be discontinued Further disassembly of the end caps may result in injury Return actuator to AIR TORQUE for further maintenance For spring return actuators remove the external spring set 17 then remove the spring disk 182 then remove the internal spring set figure A O Remove end cap O rings 14 and discard if replacing all soft components m Head office and works AIR TORQUE S P A AIR TORQUE SPA Via Palazzo 2406 Albano S A 8g Italy www airtorque it ee MAN 4thG058 01 ISSUE 02 02 Pag 2 D Pistons disassembly Part No 40SR figure 04 3 Holding the body 50 in a vice ar similar device rotate the drive shaft 60 unt the pistons 40 are released Caution Air pressure should not be used to remove the pistons from the body QO Remove piston O rings 16 using a small screwdriver remove the piston back 05 and piston head 15 bearings Discard o rings and bearings when replacing all soft components E Pinion shaft disassembling Part No 60 figure 05 OQ Remove spring clip 18 carefully using nap ring pliers remove extemal thrust bearing 08 and thrust washer 10 O Apply downward force to top of drive shaft 60 until Ris partially out of the bottom of the body when it is possible to remove the octi cam 01 and internal thrust bearing 08 then push the pinion 60 completely out of the bottom of the body If pinion does not remove freel
6. head 15 bearings Grease the internal surface of the body 50 and the piston 40SR rack teeth Hold the body 50 in a horizontal position by inserting the top of the shaft into a vice or the bottom of the shaft connection into a male drive fitted in a vice as shown in figure 08 Ensure that the octi cam is in the right position as shown in figure 09 For standard rotation assembly clockwise to Close rotate the body 50 about 40 45 counter clockwise from bottom view or clockwise fram top view depending on which way the shaft has been linked as shown in figure 10 Press the two pistons 40SR simultaneously inside the body 50 until the pistons are engaged and rotate the body clockwise from bottom view or counter clockwise from top view until the stroke is completed O Ensure that when the pistons are inserted they both mesh at the same time Check fully closed and open positions as shown in figure 11 HUW oo a Via Palazzo 24061 Albano A Bg italy www girtorque it MAN 4t 1 U Pag 3 9 Head office and works AAIR TORQUE ss torcue sa Spring set assembly Only for Spring Return Actuators Before proceeding to the end caps assembly put the actuator in vertical position and proceed as below described first on one side and then on the other side of the actuator Insert the proper quantity of spring cartridges of the internal spring set according to the pattern shown in figure 12 referring to the to
7. d and re machined again If it cannot be repaired than change a new ball If the scraped area is not at the location described in the item b above than it must re fine milling the damage area again Otherwise the ball will damage the soft seat during the open and close operation or it will dig out the ball seat and cause a heavy damage to ball and seat Check the wall thickness of valve body and cap The minimum thickness shall be maintained in according to EN12516 1 table 10 To inspect the surface of soft seat has it any scrape mark concave dusts including weld dregs iron bit sands etc abrasion abnormal press scrape and a tiny scrape Usually the scrape mark and damage by dusts will occur the same time as ball damaged It is the root cause for leakage If leakage occur before repairing than suggest to change a new soft seat PTFE or RTFE The mark from press or fine scrape is happen in an abnormal operation pressure It Form No QF 21 01 10 must reconsider to choice a right valve The stem packing may be replaced by the new parts after dismantle the valve User shall make sure that the your distributor able to serve the same packing of your valve if you do not have a service pack To tight the gland nut please see Section 8 for torque data To do the final inspection for a valve it must operate 10 times of open and close to ensure all the parts are assemble correctly To ensure the torque in a same value duri
8. e whether open or close There is sign at the top of stem for square type stem Following with the fig showing how to access the position of ball valve OPEN CLOSE Form No QF 21 01 8 7 Maintenance 7 1 Maintenance frequency The maintenance frequency is determined upon the application of ball valve User shall consider the time interval depend on the kinds of fluid flow velocity operation frequency high pressure effect and high temperature effect etc 7 2 Disassembly a The user should check the service kit of AC 305MF if available in the local market if not please do not disassembly the valve otherwise please make a order from the original manufactory for the service kit To dismantle the valve must follow the procedure and drawings and be take care as mentioned below It doesn t matter where is the position of valve located usually it contained the seal up fluid so operator must be very carefully when remove the valve on the pipe It must open the ball a little and let the fluid come out slowly it also need to watch out the poisonous and inflammability objects if there is any It must turn the ball in the close position before dismantle the valve The ball cannot be taken out from valve body if the ball is in the open or semi open position To dismantle the valve body release the end cap carefully It must be take care to dismantle the ball to avoid the seat retainer fall down from end cap
9. ibration f Bottom Entry Blow Out Proof Stem Provides Maximum Safety g Heavy duty body amp end cap construction with traceable heat number h Pressure balance hole in ball slot i Pressure self relief seat to prevent pressure built up j Lock design on the handle is optional requirement 2 2 Product specification The scope of product specifications are as following Item No PN No CE Marking Category I Category II DN 8 10 15 DN 32 40 50 AGAME o3 20 25 65 80 100 2 3 Common dimension x 5 y H1 S pi 2 ao i y 9 9 1 2 pe JE A aN 5 12 ZZR al Wn p 11 11 22 i TEEI 42 1 3 14 14 55 j 9 17 17 78 A A BY ITI 17 17 120 K X 22 22 150 K Form No QF 21 01 3 Design Specification Items Standards Codes Standards of Design P T rating prEN 12516 1 Testing prEN 12266 1 Material of Casting Body Cap Ball EN 10213 4 for 1 4308 amp 1 4408 EN 10213 2 for 1 0619 Bolt and Nut ASTM A193 A194 Mounting Pad ISO 5211 4 Pressure Temperature Ratings The pressure temperature rating of ball valves are determined not only by valve shell materials but also by sealing materials used for ball seats stem packing and body seal Sealing materials may be high molecule elasticity and hardness however the choice is limited by the characteristics of the service flu
10. id temperature pressure velocity of fluid frequency of valves operation and sizes of ball valves etc Followings are the general rating charts for non shock fluid service for floating ball valves distinguished by sizes and seating materials please refer to section 1 General precaution Form No QF 21 01 FLOW CHARACTERISTICS The approximate flow rate through a valve can be calculated as follows Where Q flow rate in gallons U S Std per minute Cv valve constant AP Q Cv P pressure drop across the valve in pounds per square inch G G specific gravity of the media of relative to water Note The values derived from the flow equation are for estimating purposes only Product variances or systemic factors may alter actual performance Valve Size 1 4 3 8 1 2 3 4 1 1 1 4 1 1 2 2 2 1 2 3 4 Cv Value 6 7 10 25 35 46 80 110 310 360 820 5 Delivery Condition and Storage 6 Valves stay in the open condition during the transportation For incoming QC it must check a Packing condition Is there any damaged during the transportation b The bolts of cap and yoke to make sure the bolt does not loose tightness when it arrived Valves must store in an indoor warehouse to avoid dusts and other foreign object do not exposed in an open space without to put a cover over or take off the packing under an unnecessary situation Installation and Operation
11. ion given in these maintenance instructions is the information necessary to make the maintenance of 4 generation actuators 180 rotation double acting and spring retum and the replacement of the spare parts as per standard 90 rotation actuators important as concerns other information like waring working conditions operating function and direction of rotation actuator installation instruction tightening torque for screw and storage instruction see the instruction manual IMAT 4thG01 99 1 MAINTENANCE INSTRUCTION With the information given below AIR TORQUE provides the end user with all the required information necessary for maintenance Under norma operating conditions the actuator requires only periodic observation to ensure proper adjustment Rebuilding of the AIR TORQUE actuators is allowed only to the personne of AIR TORQUE or to personnel which are properly instructed By contravention the guarantee expires Spare kits for maintenance are available to replace all seals and bearings Soft components listed in table that may be necessary between 300 000 and 1 000 000 cycles depending on operating and or environmental conditions and actuators size 1 1 Ni P ARTS figure A os so 411018 39 19 08 RING iSto iew E C ANG fng zop rane Corvage PANO CUP jProri A D DOUBLE ACTING S SPRING RETUR Suggesied SPARE PARTS for manteranse D Parts eauded in spare pats
12. ng the open close operation If the torque is not the same in operation than it may has some parts in a not corrected position or interference It must dismantle and re assembly Otherwise it is easy to damage if let this valve works on a pipeline under higher pressure 7 4 Assembly For assembly process it takes the opposite way of dismantle process The valve must in the close position during assembling the body and end cap the stopper must be located at the right place otherwise the open and close operation will be opposite When tightening the bolts it is important to tight them in a cross serial order to prevent a unbalance fitting 8 Torque Data Size DN8 DN10 DN15 DN20 DN25 DN 32 DN 40 DN 50 DN 65 DN 80 DN100 Stem Nut N M 12 12 12 17 24 24 35 35 40 Body Bolt N M 17 5 34 34 59 113 113 113 9 Corrosion Data The following corrosion data is just for information only Form No QF 21 01 Head office and works AIR TORQUE toraues Via Palazzo 24061 Albano A 8g Italy www girtorgue it A MAN 4thG058 01 ISSUE 02 02 Pag 1 3 MAINTENANCE INSTRUCTIONS FOR 4 GENERATION ACTUATORS 180 ROTATION DOUBLE ACTING MODELS ATOS8 D AT608 D AND SPRING RETURN MODELS AT058 S AT308 S SEE ALSO INSTRUCTION MANUAL FOR STANDARD ACTUATORS IMAT 4thG01 99 The informat
13. rect specification of pipeline Tight the ball valve to the pipeline adequately THREADED valves The following serves as a guideline for those experienced in pipe joint makeup Otherwise services of a certified pipe fitter should be utilized for installation 1 Ensure that both the male pipe and female valve threads are free from dirt debris and corrosion Wire brushing of the male pipe threads is recommended to ensure a good metal to metal joint 2 Apply a good quality thread lubricant pipe dope on the male threads Lubricant reduces friction when pulling up the pipe joint Note thread lubricant is not intended to seal the joint and will not compensate for poor quality male pipe or fitting threads 3 Turn the female valve threads onto the male pipe threads by hand Upon free engagement of the threads continue to turn the valve as far up as it will go by hand With the use of a wrench continue to tighten the valve onto the pipe The pipe joint seal should occur within 1 to 3 turns Care should be taken not to exceed 3 turns in which damage to the threads can occur n IMPORTANT When installing a threaded valve fully assembled apply the wrench first to the Pipe Connector being engaged by the male pipe thread fully make up pipe joint See Figure 1 Complete Form No QF 21 01 7 the installation by assembling pipe to the other connector while that connector is securely held against rotation with a second wrench Figure 2
14. rew 02 until the desired stop position is achieved then tighten the stop adjustment nut 04 and lock it in place F Assembly of position indicator Parts No 19 and 39 figure 16 Fit position indicator 19 on the shaft verifying that it indicates the correct actuator position Then fit cap screw 39 where fitted Tool Size for Maintenance Mode EX mm EX2 mm 2d mm
15. s AC 305MF Series Three Piece Ball Valve PED Category II AC 305MF User Manual English Version Use for company in Europe who will place the product on the market please amend which necessary Document No Date 2004 01 10 Version 1 0 PREPARED BY DATE REVIEWED BY DATE APPROVED BY DATE DIE ERSTE INDUSTRY CO LTD 5F 1 No 936 WEN SIN ROAD SEC 4 TAICHUNG TAIWAN 406 R O C Form No QF 21 01 Contents 1 Zz General Precautions Product Description Design Specification Pressure Temperature Ratings Delivery Condition and Storage Installation and Operation Maintenance Torque Data Corrosion Data Form No QF 21 01 1 Page 2 3 Page 4 Page 5 Page 4 Page 6 Page 6 8 Page 9 11 Page 11 Page 11 1 General Precautions a Material Selection The possibility of material deterioration in service and the need for periodic inspections is depended on the contained fluid Carbide phase conversion to graphite oxidation of ferrite materials decrease in ductility of carbon steels at low temperature even in applications above 29 C are among those items Even information about corrosion data is provided in this user manual the user is requested to take attention or consideration to determine the suitability of material in their application b Pressure Temperature rating The Pressure Temperature rating is considered for static pressure Please refer to P amp T rating sec
16. tal number of springs individual springs should be inserted as shown in figure 13 Insert spring disk 182 on the springs making sure of the correct orientation figure A Insert the proper quantity of spring cartridges of the external spring set according to the pattern shown in figure 12 referring to the total number of springs Individual springs should be inserted as shown in figure 13 Then proceed in the same way for the other side 0 oO O D End cap part 30 right and 31 left assembly figure 14 Fit end cap O ring seal 14 into the groove in the end cap on both end caps O Fit end caps onto the body 50 verifying that the O ring remains in the groove QO Insert all the cap screws 13 and tighten each only partially Complete tightening by following the sequence indicated in figure 14 E Assembly of stop cap screws Part 02 and stroke adjustment figure 15 Insert on both the stop cap screw 02 the nut 04 the washer 03 and the O ring 71 D Fit the stop cap screw 02 in the body Stroke adjustment for standard rotation actuator Clockwise to close QO 0 Close position stroke adjustment with actuator in close position screw or unscrew the right from top view stop cap screw 02 until the desired stop position is achieved Then tighten the stop adjustment nut 04 to lock it in place O 180 open position stroke adjustment with actuator in open position screw or unscrew the left from top view stop cap sc
17. tion on page 9 for working precaution The allowable temperature is between R T and 200 C do not exceed the temperature range to avoid danger accident happen c Fluid thermal expansion It is possible when the ball valve is in closed condition the sealed cavity within the valve body to be filled with liquid If this liquid is not released by partially opening the valve or some other means and it is subject to a temperature increase excessive pressure sufficient to cause pressure boundary failure can be generated However our products have pressure self relief seat to prevent pressure built up user is recommended to prevent that the pressure in the valve will not exceed that allowed pressure by means of piping design installation or operation procedure d Static electric effect The ball valves are provided with anti static devices for ball stem body When service conditions require electrical continuity to prevent static discharge the user is responsible for specifying static grounding e Fire safe condition Generally the application of the valve shall comply with the Pressure Temperature rating range If the risk of fire is major effect user is recommended to select our fire safe products which with API 607 approval Contact to the valve distributor or manufacturer for details f Liquids with high fluid velocity Form No QF 21 01 2 When ball valves must be operated frequently on liquids with very high velocit
18. y a check shall be made with the valve distributor or manufacturer for appropriate advice to minimize the possibility of seat deformation especially when they are highly pressurized on high temperature line g Throttling service Ball valves are generally not recommended for throttling service where both the fluid flow and the leading edge of the ball can damage or deform the resilient ball seats causing leakage High fluid velocity or the presence of solid particles in suspension will further reduce seat life in throttling applications h Do not open the bonnet or cap when bearing pressure Valve is not equipped with pressure access device User should check it by other method through its piping system i Do not touch the surface of valve on high temperature j Not allowed for unstable fluid otherwise specified with catogory II in Declaration of conformity or and in this user manual k Lock design on the handle to avoid the valve operated by non related people is optional requested by the user Form No QF 21 01 3 2 Product Description 2 1 Feature a 3 PC Full Port 1000 WOG Ball Valve b Direct Mounting Of Actuators To Valves No Need Bracket amp Adaptor c Multiple ISO Hole And Well Machined Mounting Pad in One Valve Simplify Installation of DA amp SR Actuator d Three Piece Swing Out In Line Maintenance Design e Self Adjusting Stem Packing Assembly With Belleville Spring For Temperature Fluctuations V
19. y gently tap the top of the shaft with a plastic mallet O Remove top and bottom pinion bearings 06 and 07 and top and bottom pinion O rings 21 and 22 O Discard bearings 06 and 07 internal and external thrust washer 0B and O rings 21 and 22 if replacing al soft components When ali components are disassembled those not being replaced should be properly cleaned and inspected for wear prior to being greased and re assembled 1 3 ASSEMBLY Prior to assembly ensure all components are perfectly clean and free from damage Please see standard instruction manual N IMAT 4thG01 99 at point 3 for recommended lubricants gt Drive shaft assembly Part No 60 figures 06 and 07 instal top and bottom pinion bearings 06 and 07 and top and bottom pinion O rings 21 and 22 onto the shaft Grease the outside surface of the drive shaft on top and bottom as shown in figure 06 insert partially the drive shaft 60 in the body 50 install octi cam 01 in the corect position as shown in figure 07 related to the bottom and top of the drive shaft and the rotation of the actuator when energised and install internal thrust bearing 08 Insert completely the drive shaft in the body Fit external thrust bearing 08 thrust washer 10 and then extemal circlip 18 using snap ring pliers ooo u B Pistons assembly Part No 40SR figures 08 09 10 and 11 Install piston O rings 16 the Piston skirt 05 and piston
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