SPLIT BODY BALL VALVE

OPERATION and MAINTENANCE INSTRUCTIONS

B

VA-IM-E600.3R0/2013

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Table of Contents

1.0.0 BS6683 COMPARISON 1.1.0 INTRODUCTION 1.2.0 PURPOSE 1.3.0 GENERAL 1.4.0 PACKING, STORAGE AND TRANSPORT 1.5.0 MARKING 1.6.0 MOUNTING LINE CONNECTION 1.7.0 RISK ANALYSIS 1.8.0 START UP AND LINE TEST PROCEDURE 1.9.0 OPERATION 1.10.0 PERIODICAL CHECK AND OVERHAUL 1.11.0 VALVE PROBLEMS AND SOLUTION ADVICES

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COMPARISON OF 1.0.0 BS 6683:1985 WITH VA-IM-E600-3R0

BS 6683:1985 ARTICLE VA-IM-E600-3R0 ARTICLE Page 1.0 General 1.3.0 General 6 1.1 Purpose 1.2.0 Purpose 4 2.0 Service and Environmental Factors -------

2.1 Fluid

2.2 Pressure-temperature ratio

2.3 Layout and positioning

2.4 Bend test

2.5 Fire test 5

2.6 Pressure fluctuaton and cycle -------

2.7 Throttling 1.5.0 10 2.8 Flow coefficient Kv Cv (Table 2) 20 2.9 Temperature effect -------

2.10 Traped pressure -------

2.11 Corrosion

2.12 Stem sealing 1.9.2, 1.11.4 22 to 25 & 34 to 37 2.13 Cryogenic services -------

2.14 Operating force Torque (Table 3) 21 2.15 Vibration -------

3. Storage and Handling 1.4.0 Packing, Handling 8, 9 3.1 General 1.4.1, 1.4.2, 1.4.3 8 3.2 Handling 1.4.5, 1.4.7, 1.4.8 8 3.3 Storage 1.4.4, 8 4. Connecting to the Line 1.6.0 11 4.1 General 1.6.1 11 4.2 Inspection 1.6.0 11 to 14 4.3 Threaded valve assembly -------

4.4 Flanged valve assembly 1.6.3-1.6.4-1.6.5-1.6.8 13-14 4.5 Welded valve assembly

4.6 Test and adjustment 1.8.0 17,18 5. Operation and maintenance 1.8.0 17,18,19 5.1 General -------

5.2 Operating manual valves 1.9.0 19 5.3 Operating valves with actuators -------

5.4 Operating quarter turn valves

5.5 Noise -------

5.6 Maintenance 1.10.0 25 to 46

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1.1.0 INTRODUCTION

Do not take any action regarding the Valve without reading the information corresponding to the symbol in this manuel

Do not perform the relevant operation without reading the information corresponding to the symbol in this manuel

Index hereby has been arranged according to the headings defined by the standards. If the content does not satisfy you, you should search it under another heading.

1.2.0 PURPOSE

The purpose is fulfillment of functions by valves manufactured in compliance with API 6D Standard and achieving a long operational life. Procedures are established for information and operations providing appropriate conditions and indictating actions preventing to achieve aforementioned purposes. The user is solely responsible for problems and their consequences arising from behaviors contradicting to the issues stated here. Valves belong to pressurized vessel class and life security should be considered and measures should be taken in full.

Important note This procedure can be applied for all Split Body type ball valves in general. We kindly request you to take our following comments and advices into consideration. If our procedure or advice is against your company policy, we recommend your management or supervisor to contact us for discussing which maintenance procedure you will follow and about the differences.

Explanation

Properties of Vasta ball valve

They have been designed in compliance with API 6D standard. All types between NPS 2 and NPS 60 have API Monogram. They have API 6FA Fire test certificates. They have antistatic designs. (ASD) They conform to ISO 14313 and TS 7843 standards.

They have steel construction. Watch is the safest material against frast and earthquake accidents causing shock and deformations.

They have trunnion Ball design. They have float ring seats. Seats are spring supported and create an increasing sealing force line Optional features;

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(DPE) Bi-directional sealing ring (two-way sealing rings are not solf-reliving the pressure and an extra adjustable safety valve should be attached to the body cavitation.)

(SRS Uni directional sealing ring (one-way sealing ring meansa design of self-relied.

Attention !

Seat design with Double Piston Effect (DPE) is applied to DBB & DIB-1

featured Valves.

Self-relief seat design (SRS) is used for DIB-2 featured Valves.

Pressure trapped in body cavity of DPE seated Valves might be relieved due

to thermal aspects. In such cases, pressure relief Valve option should be

offered, in addition to existing vent Valve.

Vent & Relief Valves create gas emission to the environment. When free

emission is not acceptable, down stream of such Valves has to be

connected to a separate line.

Anly leakape could be momtored alter the cavity is dralnetd.This feature also allows safe operation on each side through bleeding the valve body.

o Split Body Ball Valves Flanged Valves These valves are used on the line throughout the operational life (provided that periodical maintenance is performed). Closure tightness is carried out from drain and vent outlet, benefiting from DBB feature. They require periodical maintenance when needed or once in 14 months at the latest. During maintenance, leakage check is carried out and lubrication is performed to provide cleaning or sealing.

It is offered asequipped with Operator types as well as with manual operation. Mode of operation conforms to MSS SP91 standard. Therefore manual operation type is recommended in accordance with limits specified by the standard. However, different operators may be equipped if required by the customer.

1.3.0 GENERAL

(DBB)Double block&bleed feature:Venting / bleeding the body cavitiy whwn the two seating surfaces are in clused position underup &down stream pressures.

1.3.1 The user will find compliance for the valves within the scope of this manual with acceptance conditions of API591 standard.

1.3.2 The manual hereby conforms to procedure of BS6683 Maintenance and operation standard procedure.

1.3.3 If the customer has placed the order with special terms, these terms will be valid. The manual hereby is complementary to customer sequrements .

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1.3.4 If the valve is driven by a gear box manualy conformity declaration by Vasta is limited with the connecting flange of valve to gearbox.

1.3.5 The valve is designed for the minimum life period stated in the contract. If period such a period is not specified, Vasta defines the operational life of valve as minimum 30 years.

1.3.6 If the valve is used with continuous opening and closing actions, such period is 100000 hours. The valves have been designed according to the fatigue life (opening-closing) cycle number specified in the contract. If such information is not specified during the design stage, fatigue life (opening-closing) cycle number is considered as 500.

1.3.7 Vasta guarantees that the valves will stay in service throughout the Economic life of the facility if procedures in the manual hereby are fulfilled.

1.3.8 If fluid type is not specified by the order, responsibility of providing conformity of the flowing fluid with valve materials belongs to the firm installing the valve on the line. Vasta A.. rejects all of the adverse effects on the valve ceated by the solid particles within the flowing fluid on the valve.

1.3.9 The valves have not been designed for underwater applications as well as for environment with external pressure higher than atmospheric pressure.

1.3.10 In case of exceeding operating pressure and temperature values or line contamination or damages by metallic particles within the flowing fluid valves should not be forced,to forther operation an immediate maintenance should be carried out and service should be requested.

1.3.11 In case of damage due to unwanted conditions, Vasta service should be applied for and spare part support should be requested.

1.3.12 Vasta recommends that all valves are sent to Vasta in case of malfunction whether they are under warranty or not. The result of inspection at the plant will be communicated to you and up on your agreement it will be returned to you after maintenance and repair.

1.3.13 If cost of repair exceeds its economic value, a new valve is recommended. 1.3.14 If faults are under warranty, they are eliminated free of charge. 1.3.15 Only authorized Vasta personnel may provide service for valves under warranty. 1.3.16 Vasta is not responsible for decrease in performance in case of intervention to

the valve apart from issues allowed in the procedure. 1.3.17 The following contacts may be referred to any time. 1.3.18 In this procedure, if the non-compliance issues, and will be deemed to have been

void the warranty conditions will be demanded on the cost of transactions.

Vastas Valf Armatur Sanayi Ticaret A.S.

.O.S.B Sabanci cad. No:22, 59500 Cerkezkoy / Tekirdag / Turkiye

0282 758 36 50 (Pbx) Fax. 0282 758 36 59

http://www.vastas.com , vastas@vastas.com

After sale service is provided 7/24.

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1.4.0 PACKING, STORAGE AND TRANSPORT

1.4.1 Inside of Vasta valves are protected from foreign materials by means of end covers. They should not be opened until they are connected to properly cleaned pipe line.

1.4.2 They are delivered on pallet/parcel packed unless otherwise is specified by order.

1.4.3 They are fixed on pallets safely and they are suitable for transport.

1.4.4 Wooden containers are not suitable for outdoor storage unless their exteriors are covered with water-proof barriers. End covers of the valves should not be removed for any reason during storage. Whic do not prevent humidity;but only prevent dust & foreign materials from entering into the valve. All ferric surfaces without a permanent coating should be protected with an anti-corrosive coating. External surfaces of the valves are coated with a suitable protector indicated in the contract.

1.4.5 Storage period is two years unless overseas transport is made. During such period, it is preferred to open end covers,and relubricate the un painted surfaces and close the cover again within 6 months intervals according to the depot conditions.

1.4.6 If the valves are to bestored outdoors, they should be kept above the ground by placing om supports and they should be protected with a water- and humidity-proof cover.

1.4.7 After transport, the valves should be checked against any damage caused by transport.

1.4.8 Receiving inspection should be carried out by customer with Packing list, Operating instructions and Certificatex for conformity ..

1.4.9 Refer to the weight details before handling the parcel and do not convey the without providing a suitable carrier.

1.4.10 Use fabric lifting slings for conveying and take care that the coating is not damaged.

1.4.11 Ball valves are conveyed and stored in open position. They are painted differently for under- and above-ground application . Underground paints do not resist to UV rays; protect them from sunlight. Prefer indoors for long-term storage.

1.4.12 You should perform repair procedure in accordance with the type of coating in case of paint and coating damage.

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1.4.13 Accessory hardware (vent and drain valve-pipe-fitting, operating system gearbox-actuator, lubrication,-fittings-,pipe-indicator,qauqes etc) should be protected from crushing, jamming and shocks.

1.4.14 If it is impossible to protect accessories, they should be demounted for transport and storage in stored separate packings.

1.4.15 You are recommended to ask Vasta service in order to.get assembly of demounted accessories.

1.4.16 The valves and accessories should be protected from contamination (being affected from external factors such as dust, sand and mug etc).

1.4.17 Packing should be prepared in accordance with the conveying road, storage area and period, and sufficient measures should be taken to fix the valves in transport vehicle if there is no packing.

1.4.18 The valves should be protected from adverse weather conditions such as humidity, rain etc during storage. It is preferred to store valves in dry & closed areas with sufficient ventilation.

1.4.19 Keep the valves with cleaning and protecting lubricant (valve-flush) dipending on storage duration. Sealing lubricants should not be used until start-up and before the test.

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1.5.0 MARKING

1.5.1 Each valve has a name plate. If its size does not allow fixing of the plate, it may be attached.

1.5.2 Name plate details are as follows.

VASTA FIGURE No. SIZE CLASS Body Material Trim

Material Design

Standard End type and

Standard MOP

max. operating pressure

MOT max. Operating

temperature Date of man. & Serial number

Customer marking details

Read the plate details and do not use the valve under exceeding conditions. These details should be checked separately during receipt, installing to the pipeline and at the beginning of start-up.

Check the fluid type and its conformity with the valve material, and do not perform any mounting without consulting to the manufacturer if you have any suspect.

1.5.3 Marking details on the body are as follows.

Vasta Size Class

Material Standard logos

Flow closure sigins

Charge no.

TWO WAY SEALING

ONE WAY SEALING

FLOW DIRECTION

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1.6.0 MOUNTING LINE CONNECTION

1.6.1 Preparation;

- Provide appropriate tools.

- Perform line conformity tu ensure that correct valve is solected comparing the valve spesifications with the line specifications with the line details.

- Determine flow direction or closure direction if any. The valve can be installed in both directions if there is no flow direction and closure direction sign on the valve.

- Check cuitability of the valve operating conditions with the information on the name plate. If the valve is purchased with bare stem, follow instructions of the manufacturer for mounting the gearbox.

- Clean the mounting location once more and remove any dirt.

- Lifting equipment needs to be used depending on the weight of the valve. Refer to Vasta product catalogues for valve weights.

1.6.2 Review of valve inspections and mounting criteria before assambley ;

- Does the mounting position have operational easiness?

- Can maintenance and repair be made easily?

- Is there enough space over the valve for demounting the cover for maintenance purposes?

- Is there any dirt, sand etc to be cleaned in the valve when protective end covers are ta ken away?

- Has any measure been taken to prevent any metal parts remaining inside the pipe after installing?

- Is it communicated that maintenance shall be carried out after first cleaning of the filters?

- Is there any mounting position against unwanted situations? (Please refer to the following figures)

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OK

OK

(Dreyn yaplamaz, hat kirlilii Valfezarar verir.)

Tasviye edilemez

(Dreyn yaplamaz, hat kirlilii Valfezarar verir.)

Tasviye edilemez

Pos: H

Pos: V1

Pos: H

Pos: V2

Figure 1- Recommended operating positions for ball valves

Not recommended (It cannot be drained, line contamination gives may cause damaqe harm to the valve)

Not recommended (It cannot be drained, line contamination gives harm to the valve)

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1.6.3 The valve wilth counter flanges

a) Equivalent flanged pulley with end to end dimension should be used instead of the valve or.

b) If it has to be made with the valve itself , it is recommended to add gasket both ends to provide correct positioning axial conformity and parallelism of valve center flange . (The valve should be demounted after tack weld is made.)

1.6.4 Parallelism tolerance of the flanges should not exceed 1 degree and also a total of 2 mm axial eccentricity should not be exceeded.

0.5

Yanl Yanl Doru

1

11

1

1

Figure 2- Allowable parallelism errors

1.6.5 Flange stud bolt or bolt should be tightened at the torque values specified in Table 1 after all procedures finish.

Size (inch) Torque (Nm)

Size (inch) Torque (Nm)

Size (inch) Torque (Nm)

Size (inch) Torque (Nm)

61 1 984 2 4193 3 18419 5/8 117 1 3/8 1323 2 6013 3 28427 203 1 1731 2 8292 3 7/8 30157 7/8 324 1 5/8 2217 2 5/8 9622 4 34565 1 489 1 2785 2 11085 4 49367

1 1/8 708 1 7/8 3441 3 14443 4 58135

Table 1-Counter flange stud bolt/blot tightening torque values

1.6.6 Mounting positions making larper angle than 90 derege With flow direction will not alow drolining of the valve cavity .Therefore after performing line cleaning and chemical washing procedures, valves should be demounted and cleaned manually.

1.6.7 In general, drain connections should be used for cleaning purpose at the beginning of start-up procedure and driving first maintenance process.

Correct Incorrect Incorrect

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1.6.8 Before start-up, tightness of the flanges (Table 1) and body-bonnet flange bolts should be checked and should be tightened according to torque values,if necessary.

1.6.9 Steel valves have usually flanges with raised faces (RF) . Counter flanges should also be RF. For ease of demounting, 3-6 mm of pipe flexibilitiy should be maintained in order to take away the valve from.

1.6.10 If the valve has RJ ring-gasket connection, the counter flange should have RJ face g too. For RJ connections a flexibility between the connecting pipes olf atleast 20mm.should be maintained for easy dismantling.

The same openings are required for connections with SG - LG type canals.

1.7.0 RISK ANALYSIS

1.7.1 General

The valves should be operated under conditions written on the name plate. Hazardous situation may emerge even ione of these conditions is exceeded.

The following conditions may be dangerous given the situation. Ask for ones that might be affected by checking compliance. Valve gives Vasta Datasheet'lerde explanation.

Wind, snow and ice;

Acoustic vibration and/or vibration caused by the fluid;

Water hammer;

Chemical effect;

Decomposition or deterioration of the fluid;

Uncontrolled chemical reaction;

Electrical current;

Shock waves;

Pressure change;

Adiabatic compression;

Induction current;

Acoustic energy emission;

Flame;

Lightning

Contamination;

Power interruption;

Electromagnetic waves from 3x10^11HZ to 3x10^12 Hz.

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Radio frequency (RF) electromagnetic waves from 10^4 to 3x10^12;

Radiational ionization;

Optical ionization;

Thermal reaction;

Vortex formation;

Humidity formation;

Ultrasound;

Environmental variations;

Other external damaging factors.

1.7.2 Information That Should Be Specified by the User

If the following dangerous situations are not specified in contract documentation, they shall not be taken under consideration during the design stage.

Possible dangerous situations;

Thermal fatigue Seismic loads Friction Vacuum depression External corrosion Contaminated fluid Abrasion Cavitation and flashing External fire Piping loads exceeding the specified values

1.7.3 Measures and Points to Take into Consideration

The installer and/or the end user shall analyse the possible hazardous situations initiated by one or more of the following causes and take appropriate protection measures:

The surface temperature of the valve is a function of the temperature of the process fluid, the maximum allowable surface temperature is shown on the name plate.

External solar radiation with the line at atmospheric pressure causes the internal temperature of the line to increase.

External temperature will redound the Valve internal pressure.

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None of the pressure containing parts shall be changed when the Valves is under pressure.

If it is necessary, Valve shall be dismantled in half open position otherwise there can be pressure jamed in Valve while dismantling in closed position.

Deposits of flammable dust may form on the valve. Vastas recommends limiting the thickness of dusts deposits by periodically cleaning the external body of the valve, and in particular the areas near moving parts (stem).

The frequency of this operation shall be so as to prevent dust deposits greater than 5 mm. Wastes resultant because of cleaning must be checked environment expert and must be eliminated properly.

The valve may release to the atmosphere gases and/or flammable dust that, in extreme cases, can cause an explosive atmosphere. The probability of the formation of an explosive atmosphere is greater during venting and draining operations.

Wastes accured because of Valve repair and maintenance, must be properly eliminated according to environment standards and regional reguletions.

After completion of service life of Valve parts can be delivered to recycling by decompasing the hazardus wastes.

1.8.0 START UP AND LINE TEST PROCEDURE

1.8.1 Inspection and control

Depending on the type of the valve and mounting conditions, all of the following points are followed and checked before pressurizing the valve after mounting process.

Check plugs, vents and drains and verify their tightness. Verify tightness of the bolts on the stuffing box, body and flange. Grease stem bearing and stem threads.

Check body/body flange connection bolts and tighten up to the value in accordance with the test pressure.

1.8.2 After all connection controls are finished, in order to eliminate possibility of foreign substance leftovers, allow flow of compressed air or cleaning fluid through opening and closing the valve. Open,close cycles of the valve causes removal of the deposit accumulated in valve cavity and line on the flow direction. At the end of such procedure, deposits accumulating on the filter should also be removed.

1.8.3 Liquid used for pressure test of the line and successive start-up procedures should be sultable for the soft and metallic parts of the valve. Usage the following products and fluids may cause problems on the valve.

Amine corrosion inhibitors , Fluorocarbon may be harm ful to O-rings. Methanol used to dry the pipes may give harm to o-rings. Untreated water may increase rusting effect on the steel surlaces . Chlorine within the waler may cause corrosion on stainless steel parts.

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1.8.4 In order to perform line test, fill the line with the fluid while the valve is wide open.

1.8.5 When performing line test, bring the ball valve to and open position. 1.8.6 Ensure that there is no trapped air within the valve or if any release

the trapped air through the vent-relief valve. 1.8.7 Ensure that the tightness is very well after pressurizing the system.

The test ensures that all connections under pressure are correct.

1.8.8 In order not to give harm to the sealing surface, differential pressure between opening and closing should be 7 bar or less. For this purpose, by-pass should be used. This is not important for valves that do not require by-pass.

1.8.9 If valves remain at the same position for a long time, you may encounter operating difficulty. Lubricant loss might have happened and sealing elements faces contact dimension might have changed. Therefore we recommend programmed opening/closing.operations. Use a suitable lubricant hrough greasex fitting which lubricates the stem and seatrings.

1.8.10 Test pressure should not exceed 1.5 times of the maximum operating pressure under half-open position of the valve.

1.8.11 1.1 times of the operating pressure should not be exceeded during closure test.

1.8.12 Before the test, the pipe line should be physically cleaned and chlorine in the test water should be less than 2ppm. During disharge of the test water, the valve must be wide open.

1.8.13 At wide open position of the valve you can use the body drain valve discharge water in the body cavitation.

1.8.14 Valve-flush should be used to clean lubrications grooves, fittings and pipes after the test. After cleaning sufficient lubrication should apply with lubricant suitable for the flowing fluid.

1.8.15 Lubricant amounts given in the table are minimum values. Besides, lubricant required for the extension pipes and additional lubricant installation should be loaded.

1.8.16 In case of any problem regarding gearbox settings, refer to Operating system problems section.

1.8.17 In case of any problem regarding sealing, refer to Sealing problems section.

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1.9.0 OPERATION

1.9.1 Trunnion Ball Valve

Never apply excess force on the lever or handwheel while the stem and sealing surface (if there is foreign substance in the valve ) may get damaged.

The following figure shows regular operation of the Ball Valve.

Figure 3-Open and closed positions of the ball valve

OPEN Opening direction (Counterclockwise)

CLOSED Closing direction (Clockwise)

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Kv / Cv Coefficients Cross diameters and cross areas

Table 2- Kv table

Kv : Flow factor Q : Flow rate m3/h P : Pressure drop Kg/cm2 S : Specific gravity (1 for water)

NPS (inch)

ID (mm) Kv

2 49 326 3 74 816 4 100 1540 6 150 3720 8 201 6800

10 252 11950 12 303 18600 14 334 23500 16 385 30900 18 436 40900 20 487 49300 24 589 78000 28 684 102000 32 779 141000 36 874 178500 40 976 225500 42 1020 252000 44 1070 280000 46 1120 301500 48 1166 326000 56 1362 442500 60 1458 509500

SP

QKv

=

865.0KvCv =

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Opening (Take off )Torque values in Ball Valves

NPS DN ID mm

22 bar Nm

56 bar Nm

112 bar Nm

2 50 49 120 140 150 3 80 74 160 180 280 4 100 100 230 350 540 6 150 150 480 750 1200 8 200 201 750 1200 2300

10 250 252 1200 2200 3600 12 300 303 1900 3200 6200 14 350 334 2700 4400 8000 16 400 385 3700 6400 11200 18 450 436 4800 8200 14000 20 500 487 6900 11300 19000 22 550 538 8200 14000 22500 24 600 589 12000 18000 32000 26 650 633 13000 23000 38000 28 700 684 18000 26000 48000 30 750 735 20000 32000 58000 32 800 779 22500 34000 64000 34 850 830 27500 40000 75000 36 900 874 30000 45000 85000 38 950 925 35000 60000 105000 40 1000 976 43500 70000 115000 42 1050 1020 50000 85000 125000 48 1200 1166 64000 105000 165000 54 1350 1312 75000 120000 180000 56 1400 1360 110000 175000 250000 60 1500 1458 150000 200000 425000

Table 3- Torque values in ball valves

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1.9.2 Operating Problems and Maintenance

1.9.2.1 Frosting

Frosting may occur in ball valves due to external weather conditions and quick discharge if discharge and drying is not performed after the pipeline test. In such a situation, operation of the valve gets more difficult or completely jammed. You have to wait if atmospheric temperature is at the level that may eliminate frosting. In case of weather conditions can not melt the frost, you have to provide service through heating or using valve-Flush cleaner until frost is removed. Never try to overcome the jamming caused by the frost through exceeding regular torque value. If the valve is not of lubricated type, you have to dissambly the valve and perform maintenance if frost does not thaw.

1.9.2.2 Seat-ball sticking

When the ball valve remains unused for a long time, sealing ring and the balls stick to each other. The same situation occurs for o-rings between the body bearing and the ring. In case of sticking, the valve cannot be operated just as in the frost case. It is jammed at open or closed position. Staying within the upper torque values, try to make opening and closing movements and if this fails, perform maintenance immediately. In order to remove sticking, apply valve-flush through all lubricating fitting slowly. Avoid excessive lubricant pressure, otherwise damage may occur. When amount of lubricant given for the valve is reached to the max level indicated,apply opening and closing movements again. Continue applying valve-flush until relief is achieved. After the desired result is achieved, lubricate with the sealing lubricant suitable for the fluid at required flow rate. If the valve is not of lubricated type, you have to demount the valve and perform maintenance if sticking is not removed.

1.9.2.3 Stem leakage

Any leakage observed in the ball valve stem should be quickly stopped by means of lubricating. Again, lubricant should be applied with care, pressure should not be increased and you should stop when leakage stops. Excessive lubricating may damage the sealing.

If the valve is not of lubricated type, you have to demount the valve and perform maintenance.

Stem Maintenance under Pressure

Such procedure is applied when stem leakage is observed on operating valve . Observing the stem leakage means that all sealing elements of stem damaged or they cannot fulfill the required function. Pre-packing Under pressure removes damaged such leakage. However, general stem maintenance is recommended during line break.

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12d

7

12a

4d

1e

17 d

1, 1a

Figure-4 Demounting Diagram for Stem Maintenance under Pressure for Valve with Handwell

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12d

7

12a

4d

12b

17c

1e

Figure-5 Demounting Diagram for Stem Maintenance under Pressure for Valve with Gearbox

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12d

7

12a

4d

1e1, 1a

17d

Figure-6 Demounting Diagram for Stem Maintenance under Pressure for Valve with Safety Shut-Off Scotch Yoke Actuator

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1 Such procedure applies for only Full Welded valves having Anti-blowout type stem.

2 Gearbox is removed from its place through unscrewing 12c screws . 3 4d key is removed from its place. Stem by hitting slightly to the side of it using a

hammer and a chisel.mpacts and strong impacts to unsuitable direction may damage the key form and make it unusable.

4 Screws no. 12b are unscrewed and connection flange no. 12a is takon away from its place through slight hits from the opposite side using a plastic hammer.

5 Packing no. 6 is demounted and renewed.

6 Mounting is finished reversing the procedures.

7 After these procedures, Val-tex sealing lubricant is applied at suitable lubricating pressure through lubricating fitting no. 1e on the gland.

Scale 1:1

Figure -7 Stem lubricating nozzle

1.9.2.4 Closure leakage

If there is leakage in the ball valve to the body cavitation at open or closed position and leakage does not stop, you have to apply suitable lubricant to the system from the lubricating fittings. When leakage stops, continue lubricating making opening-closing movements. If leakage does not stop, it means that there is damage. In such situation, ask for service enclosing damage record or use damage eliminating lubricant by means of specialized personnel if any. This procedure should not be confused with opening-closing position error. Otherwise, the procedure will not be useful.

1.9.2.5 Gasket leakage

In order to ensure that the flange connection, where external leakage is seen, is not loose, tighten all bolts on the side with leakage. If leakage does not stop, release the pressure and replace the entire gasket set. (Note: Check whether there is axiality and /or parallelism errors in connection flanges on the line correct it if there is any. Besides, free opening should not exceed 2-4 mm except the gasket thickness.

1e

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1.10.0 PERIODICAL CHECK AND OVERHAUL

1.10.1 Inspection In order to realize the design life of a valve, regular maintenance program should be applied. In order to verify proper operation of the valve, the following checks should be made on site partly and / or complety depending on service conditions and operation frequency of the valve.

Integrity of the coating Dust deposit Rust, external corrosion and oxidation signs Status of the vent, drain parts Lubrication of screw threads and bearings Internal and external leakage.

1.10.2 Periodical Check, Routine maintenance check should be made biennially at the latest beginning from the date of delivery. Trained personnel of Vasta A.. would make the aforementioned intervention at required dates with suitable documentation. Regular maintenance activities are not carried out for underground valves but preventive maintenance and inspection program is required once a year. Before any maintenance procedure, the valve pressure is velieved and temperature is checked from vent and drain lines. Electrical connections are separated and the valve is cleaned.

Failing to perform any of the aforementioned procedures causes very serious personnel health and safety issues.

In general, stem and seatring lubrication, gearbox operation check andend-connections, body flange gasket leakage checks as well as relief and vent valves and drain plugs leakage checks (if any) are made. If you encounter nonconformity signs during checks, record them in reports. Communicate them to the authorities and require the troubleshooting services help.

1.10.3 Additional Maintenance

Additional maintenance procedures are not carried out according to the calendar; these operations mean intervention in case of failure of the valve. Trained personnel should make the aforementioned intervention whenever necessary with suitable documention. Before any maintenance procedure, the valve pressure is eliminated and temperature is checked from vent and drain lines. Electrical connections are seperated and the valve is cleaned.

Failing to perform any of the aforementioned procedures causes very serious personnel health and safety issues.

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1.10.4 Lubrication and cleaning of the stem,

The stem has to be lubricated periodically depending on the environmental conditions a heast once a year. Vasta recommends you to select type of the lubricant according to the medium. Lubricating and friction-reducing properties of the lubricant are of great importance. Besides, if grease fitting is not suitable, replace the grease nozzle. In valves with stem protector, clean the protector and reinstall the indicator, having checked whether open-closed positioning is correct. If you detect leakage from the stem, apply the emergency procedure mentioned in the manual hereby.

If scratch and porosity has dimensions around Rms 250 (6.3 Ra ) depending on the size of the stem (rough turning surface), it should be recorded on the report that the stem should be repaired or replaced as soon as possible.

1.10.5 Gasket Replacement

Gasket (13) (if any) replacement should be as follows. Phases mentioned in figure 6 are for Ball valve and can be used for other valves;

1. Isolate the line or eliminate pressure and work at open position of the valve. 2. Mark the body (1)/Body flange (1a) from the left of right at the same alignment with

a permanent coating or marker, so that such marks provide connection at the same position during reassambley. Such marking is very important since it ensures tightness at the same surface. Unscrew and remove body stud bolts (15) and nuts (14).

3. Remove the installed cover and carry out position marking of the ball in accordance with the marked side (do not make marking on the surface contacting Teflon or SWG seat). Remove the old gasket (13) and discard it to the universal waste collection place.

4. Check the gasket contact surface against damage and deterioration. Clean the surfaces and remove any foreign substance and/or deposit. Clean the gasket seat with hard and rough fabric. Any leakage through the gasket may cause damage. In order to obtain good tightness, smoothness of the contact surfaces should be between 1.6 and 3.2 Ra.

5. Insert the new gasket without using any filling material during such replacement. 6. Attach body flange (1a) of the valve to the body (1) while the ball is in open

position. Tightening torque values of the body stud bolt-nut (14) or bolts (15) shall be according to Table 4.

Bolt size (inch) Torque Ft.lb

Torque Nm

Bolt size (inch) Torque Ft.lb

Torque Nm

3/8 15 20 1 3/8 900 1220 7/8 25 34 1 1200 1627 40 54 1 5/8 1600 2170

5/8 75 102 1 2000 2712 135 183 1 7/8 2500 3390

7/8 200 271 2 3000 4068 1 350 475 2 1/8 3600 4882

1 1/8 500 678 2 4400 5966 1 675 915 2 6000 8135

Table 4-Tightening torque values of the Body /Body flange bolts

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1a

1e2i

2c

3

12g

22e

3f

3h3g

14, 15

Figure-8. Body Gasket Replacement

1.10.6 Maintenance preparation

1 Find DS or DRWG drawing numbers ref. no. and instructions of the valve Subject to the maintenance. Maintenance should not be carried out without drawings and instructions.

2 Check security of the area of maintenance.

3 If there is inflammable, explosive, air pollutive or, poisoning materials and unprotected electric or pressure sources within the medium, warn the authorities to remove them.

4 Provide the required maintenance devices and hand tools as well as those seen on drwg.

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5 Ensure that you have sufficient equipment for demounting and mounting torque (details are attached).

6 Provide enough amount of required lubricant types (refer to Valtex product catalogue)

7 Provide enough amount of required cleaners (refer to Valtex product catalogue)

8 If there are gearbox and actuator, keep catalogues and maintenance instructions ready in hand.

1.10.7 Maintenance and lubricating procedure

Emergency sealing system with large and special type connection head made from NPT steel material has been mounted on side cover flange on both sides of the body (Refer to figure-5).

Seats of the all Split Body series Vasta valves have been designed with full sealing feature, requiring no additional sealing substance. However, foreign solid particles in the installation may enter between the seat and ball and may damage the sealing surfaces. Damaged sealing surfaces have a negative effect on the tightness of the valve. Furthermore, foreign solid particles in the installation may cause erosion damage in the valve due to the effect of the ultra rapid flow. Valve circuit leakage arising as a result of the damaged high flow faces of the seat and /or ball may be temporarily eliminated using a special valtex sealing material. Which is injected into the seat and ball area using valve emergency sealing system.

1 Cleaning shall be made after safety measures are approved. Take measures for cleaning waste and avoid spreading them to the environment.

2 Special purpose and quality Vasta seat flush cleaning agent is injected into the emergency sealing system. This process provides aged lubricant and other foreign substances that may cause lakage and high level of operational torque, to be eliminated from the critical sealing area.

3 When the valve is at full closed position, additional special purpose Val-tex sealing lubricant selected according to the type of the fluid flowing is slowly injected into the emergency sealing system on the high pressure side of the valve.

4 Read the lubricating procedure mentioned on Drwg or DS of the maintained valve or Valtex lubricating procedure and perform the recommended process.

5 If possible, provide that the additional sealing lubricant is spread evenly on the all ball surface by means of moving the ball slightly.

6 Damaged or faulty emergency sealing fittings can be replaced when the valve is under the line pressure. However, first of all ensure that the check-valve works.

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7 Lubracation Vastas should be discarded according to the Waste Management procedure.

Split Body Sealing Lubricant Usage Amount

Ball Valve Size ( oz ) ( gr ) 2 3 85 3 4 113 4 5 141 6 6 170 8 8 226

10 10 282 12 12 339 16 14 395 20 20 565 24 32 904 28 36 1017 30 40 1130 36 48 1356 40 64 1808 48 80 2260 56 96 2712

Table 5. Sealing Lubricant Usage Quantity [ounces ~gram]

Lubricating Process of the Split Body Ball Valve:

Such process should be carried out by a technical person specialized on valves or by Vasta A.. technical service.

Lubricating procedure cannot be realized when there is no pressure in the line.

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Quantity of lubricant to be used for Split Body ball valve is indicated in Table 5. Quantity of lubricant specified in the table should be used.

Pressure should be read between 2000 6000 Psi at lubricating gun during lubrication.

If pressure value is exceeded without using lubricant at quantity mentioned in the table, you have to consult Vasta A.. technical service.

1.10.8 Checking procedure

1 Approve safety measures for checking and Live test.

2 If it is possible to measure the system pressure for the test, obtain information from the source.

3 For DBB type valve, open drain or vent valve and begin to release the pressure from the body cavitation.

4 If pressure within the body is released, make leakage measurement with in API 6D leakage tolerances. For this purpose, it would be sufficient for you to make bubble measurement using the tube.

5 If a measurement exceeding standard values is made, take leakge record and recommend repair service (gearbox adjustment, seat and stem sealing adjustment or seat repair lubrication etc).

1.10.9 Dismantling procedure

1 Cleaning shall be made after safety measures are approved. Take measures for cleaning waste and avoid distributing them to the environment.

2 Make cleaning and especially get areas to be maintained thoroughly cleaned

3 In case of heavy and oversized objects that cannot be lifted and demounted manually, install lifting mechanism.

4 Follow the recommended order, referring to the detailed drawings for the demounting procedure to be performed. During demounting, mark the parts without separating them from each other, make signs with a pen or paint and number them in such a way that directions will be understood easily and the same direction will coincide when installing.

5 During demounting, check the parts and if you face any damage such as corrosion or deformation, photograph them.

6 Record procedures to be made to eliminate the damage and add photos as evidence.

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7 Clean rust and/or dirt without giving damage to the demounted parts.

8 Set apart parts to be replaced and check their conformity with their spare parts.

9 Check measurements and tolerances specified in drwg and DS images and instructions, record your measurements on opposite of the instructions or arrange a report.

10 There is ball and o-ring damage in valves failing to satisfy tightness. The valve has to be taken out of the line.

1.10.10 Recollecting mounting

You have to perform the demounting procedure from the reverse. You must take into account of the warning on the relevant Drwg and Ds and their attachments for body mounting. When you are unsure for anything, you must consult to Vasta technical service or request service.

1.10.11 Final adjustments and checks

1 Verify accuracy of opening-closing direction signs.

2 Measure and record opening-closing torque.

3 Carry out full opening-closing check (you can do this with tightness control).

4 Approve safety measures for checking and Live test.

5 If it is possible to measure the system pressure for the test, obtain information from the source.

6 For DBB type valve, open drain or vent valve and begin to release the pressure from the body cavitation.

7 If pressure within the body is released, make leakage measurement with API 6D leakage tolerances. For this purpose, it would be sufficient for you to make bubble measurement using the tube.

8 If a measurement exceeding standard values is made, make there is leakage record and recommend repair procedure (gearbox adjustment, seat and stem sealing adjustment or seat repair lubrication etc).

1.10.12 Maintenance marking

Copy the records you made on maintenance document on the file regarding the valve. Add it to the service attachment if service has been made. Record and sign maintenance approval made on Drwg and Ds.

If any spare part is used, add spare part entries to the valve file and service form attachment.

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Adjustment and measurement records and comments of the person performing the maintenance and recommendation for the next maintenance will be stated in service form.

Make labeling regarding the field service and record the latest maintenance date. Such period should not exceed 12 months.

1.10.13 Taking out of the Line and Discarding

At the end of operating life, the valve is uninstalled from the line through a procedure in accordance with the type of the valve and mounting conditions. In order not to contaminate the environment during valve uninstalling, you have to use equipment preventing the leakage on the inlet and outlet of the valve from contaminating the surrounding. Bring the valve to a suitable place conforming to European, national and regional standards and keep them until disposal date. The valve may contain toxic, corrosive and dangerous substances. They must be cleaned with high pressure steam before being demounted.

The personnel must wear protective equipment suitable for contamination during performing such procedures.

Waste occurring during the procedure should be destroyed under European, national, regional and municipal directives and/or laws regarding waste and/or laws regarding hazardous substances. Coating on the valve is removed through sanding process.

Waste metallic parts can be recycled in a steel plant. Plastic parts (O-ring, ring packing etc) should be destroyed under European, national, regional and municipal directives and/or laws regarding waste and/or laws regarding hazardous substances.

Additional documents

Mounting drawing with Gear Box (This is a special order document, refer to the order file) Part list and definitions (This is an order document, refer to the order file)

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1.11.0 VALVE PROBLEMS AND SOLUTION ADVICES

3 different valve problems and procedure to be followed for these problems are described below.

-Difficult to operate or non-working valves

-Stem leakage

-Seat leakage

If you have valve problems, you can always inspect downwards beginning from the top. For example, the area to be inspected is valve adjustment you think as reason for seat leakage, beginning from the operator. Things to be done for these procedures:

Determining the type of procedure;

1.11.1 Manually operated valves

As a rule, external reasons may be observed obstructing operation of the valve. They can be corrected or replaced. If the valve continues to be operated with difficulty after these corrective procedures, it is understood that the problem stems from the inside.

1.11.2 Gearbox commanded valves

Perform error check for all internal parts of the gearbox:

Bearing checks

Gear checks

Set screw checks

Check to see whether the gears are lubricated and all metal-metal contact surfaces are coated with grease.

Grease used in such surfaces is petroleum-based and may be exposed to water contamination. Such water freezes under cold weather conditions and blocks the valve. In such situation, demount the gearbox, remove all ice and water and wipe water contaminated grease. Apply new grease. If working medium is very cold, you can prefer glycol based grease due to its resistance against cold weather. Ensure that gearbox is well-connected to the valve and stud bolts will not get loose.

1.11.4 Difficult to operate or non-working valves

Internal causes

After reviewing all external causes that you think to be blocking valve operation, you have to review internal causes in four areas mentioned below.

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Frosting

If your valve is connected on a gas line, most gas lines contain water in small quantities (condensate). Water accumulates at the lowest part of the valve. This water turns into ice under cold weather conditions.

Corrective actions;

Block the valve to the body cavitation from body bleed fittings and make the water get out of the valve. (You may discharge the water by opening the drain valve) Or: If frosting occurs, use a suitable and accepted method to melt the ice. For example, spread a heated part around the valve or inject a non-icing liquid (e.g. alcohol) into the valve.

Seat-ball sticking

Seats in valves with free-seat on lines that are idle for a long time tend to form a set against the ball. This situation requires an additional force to release the ball and continue operation. This will increase operating torque required for high line pressure.

Corrective action;

Exert appropriate additional force and operate the valve. If your valve is of lubricated type, inject flush into the valve to separate valve sealing element and seats from the ball and if possible, open and close the valve for many times.

Seat ring

Sticking of the waste, sand, dirt or aged hard lubricants coming from the line may increase at seat ring area and blocks movement of the seats. Seat-ring sticking usually causes leakage between the seat and the ball.

Corrective action

If your valve is of lubricated type, inject Valve flush in the valve to solve and degrade the waste as much as possible. If possible, open and close the valve for many times to degrade such waste.

If your valve is not of lubricated type, demount the valve, remove the rings and make required cleaning. O-ring and Teflon rings may need to be replaced.

Note: Vasta recommends you to request service.

Stem leakage

Vasta valves have been designed with three stages of stem sealing. If there is no leakage in the valve stem, do not tamper the stem. Performing unnecessary maintenance on the stem causes problems. In general, if there is leakage in stem area of the valves,

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the cause is reaching of pressure from the seat leakage to the upper stem sealing element. If your valve is of lubricated type;

If there is leakage in stem area, inject the sealing lubricant from the fitting

Until the leakage stops and do not inject more.

Danger: Excessive pressure in stem area may block the valve.

Always take care of the line pressure in performing any procedure. If leakage cannot be eliminated, demount the valve, remove the stem, make the

required cleaning and replace the O-rings. Follow the following procedures.

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1a

14, 15

1

1e

7

4

12d

12a

17a

17

4d

7a

3c

6

4c

Figure-9. Stem Maintenance Demounting Diagram for Valves with Handwell (For unpressurized lines)

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1a

14, 15

1

4

4c

6

3c

7a

7

12d

12a

4d

12b

17c

Figure-10. Stem Maintenance Demounting Diagram for Valves with Gearbox (For unpressurized lines)

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4

4c

6

3c

7a

7

1e

12d

12a

4d

17d

1a

1

Figure-11. Stem Maintenance Demounting Diagram for Valves with Safety Shut-Off Scotch Yoke Actuator (For unpressurized lines)

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1 Such procedure should be carried out by a technical person specialized on valves or Vasta A.. technical service.

2 First of all, the valve should be put in closed position and drained.

3 Gearbox is removed from its place through unscrewing 12c numbered screws in valves with gearbox. 4d wedge is removed from its place. During such procedure, the wedge is removed from its place through hitting slightly to the side of it looking to the stem by means of a hammer and a chisel. Firm impacts and impacts with unsuitable direction damage the wedge form and make it unusable.

4 Screws no. 12b are unscrewed and connection flange no. 12a is demounted from its place through slight hits from the opposite using a plastic hammer.

5 Packing no. 6 is demounted and replaced.

6 4e centering pin and 12c bolts are unscrewed in their places and gland no. 7 is demounted.

7 7a gasket (SWG) and 7b o-ring on the gland are replaced.

8 1e lubricating fitting on the gland is demounted and gland and lubricating fitting canals are cleaned.

9 The stem is removed from its place and three no. 4c o-rings and no. 4b washer (PTFE) elements on the stem are replaced.

10 The procedure is reversed and stem elements of the valve is mounted. During mounting, ensure that the 3c anti-static device element is positioned properly.

11 After these procedures, Val-tex sealing lubricant is applied at suitable lubricating pressure over lubricating fitting no. 1e on the gland shown in Figure-5.

Seat leakage

A general ball valve problem is leakage from valve seats. Seats of the Vasta ball valves are positioned opposed to passing.

Seat leakage may occur when the valve is at open or closed position. Therefore valve seats may be checked at both situations.

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Test procedure for seat leakage

1-) For quick check, ensure that the valve is wide open. This will reduce the pressure within the valve body and shorten the time required for valve draining. Repeat the same process while the valve is at closed position without performing any operation towards the reverse direction.

2-) Verify that the ball rotates in full and keep in mind that the ball rotates 90. If any ball remains open for 3 it causes leakage regardless of its being open or closed. Your error ratio should be minimum.

3-) For manually operated ball valves, you can verify from the indicator on the valve that the ball has completed its turn.

4-) Check the stem stopper;

a- In small sized ball valves you can see the stem stopper.

b- In great sized ball valves, check the foreign substances squeezed or accumulated between the stem stopper and the stem itself from the area next to the stem area. Such dirt formation may cause full rotation of the valve and leakage.

If the valve is embedded, dust preventing full rotation of the valve may fill inside from the extension and this may cause leakage. If stem stoppers cannot be seen and you cannot see the stem head, sometimes listening to the increasing or decreasing sound inside of the valve may be effective to understand that the valve completes 90 turn.

5-) For valves with gearbox, mostly it can be checked whether the ball returns to its place in full rotation. When gearbox is mounted on ball valve, stoppers are removed from the valve. Sometimes stopper is in the valve. Incorrect adjustment of any of these stoppers causes leakage.

Causes of seat leakage If seats in the valve are stuck/cannot move, this is probably because previous hard

dirt in the line combined with waste blocks movement of the seat and this causes leakage. Waste caused due to the same reasons leads leakage between the ball and the seat. In case of damaged or scratched ball and/or seat, replacement or repair is made after inspection of Vasta service personnel.

Seat leakage repair and overhaul

Note: First of all, the valve should be taken out of the line by means of pipe cutting and it should be demounted, having processing one side of it on the weld connection point according to the instructions.

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1a

1e2i

2c

3

12g

22e

3h3g

14, 15

3f

4

4c6

7a

7

12a

17a

17

1e

12b

Figure-12. Demounting diagram of the valve with Lubring and Handwell

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1a

1e2i

2c

3

12g

22e

3 f

3h3g

4

4c

6

7a

7

12d

12a

4d

12b17c

3c1e

14 , 15

Figure-13. Demounting diagram of the valve with Lubring and Gearbox

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Figure-14. Demounting diagram of the valve with Lubring and Safety Shut-Off Actuator

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1 Such procedure should be made at Vasta A.. by Vasta technical personnel.

2 If there is leakage in the stem, stem leakage procedures apply.

3 If each demounted part will be reused, they are subjected to dust and oil removal procedure.

4 If demounted 2e springs are deformed or have lost their elasticity, they have to be replaced with suitable ones.

2g

2

2e

2c

2i

Figure - 15. Diagrammatic view of seatring application

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1 No. 2c o-rings on the Lubring and seat ring should be replaced.

2 Replacement should be made only when there is deformation on 2b seatface (PTFE) on the seatring and deformation on 2b seatface (PTFE) on the valve with size greater than 30 inch and additionally deformation on 2g secondary ring (PTFE). Such procedure should be made manually. Any tool that may give harm to lubring and seatring location should not be used.

3 After o-ring and seal of valve sealing rings are replaced, 3g Drybearing and 3h washer must be replaced in ball area.

Figure-17 Primary Soft Seal Secondary Metal to Metal Figure-16 Primary Metal to Metal Soft Seal

2i 2c

2e

2

2b

2

2i

2c

2d

2c

2g

2b

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3

4

3h

3g

3f

1

2

2b

Figure-18 Valve ball assembly

4 1e seatring lubricating plug is removed from its place and lubricating canals on 1a bonnet are cleaned.

5 Mounting is performed reversing the procedures.

6 Finally Val-tex sealing lubricant is injected into seat assembly canals at suitable lubricating pressure through 1e seat lubricating fitting on 1a bonnet.

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1e

Figure-19 Seat lubricating fitting

Fitting problems

Vasta valves are shipped optionally up on request of the customer with blind plugs and fittings installed or with fittings (in box or bags) with plugs installed on them. Fittings are installed before valves are connected on the line. Reason for shipping valves in such status is to prevent fittings from breaking during transport. If installing fittings is forgotten and blind plugs are left in place, the following procedure is followed.

Note: Vasta recommends replacing blind plugs only when there is no pressure in the line. If you want to remove such plugs when the valve is under pressure, you should pay maximum attention.

In such situation and when installing body bleed fittings, you will be directly exposed to line pressure. Do not install fittings when the valve is under pressure.

Carry out the following procedures after you examine the instructions and policy of your firm: In some situations emptying the whole line is required to install the fitting. This is the safest and always recommended method.

If you will replace the blind plug under pressure:

A. Ensure that no substance that may come out of the valve will jeopardize you, your personnel or the environment.

B. Never stand against the blind plug.

C. If body pressure continues due to seat leakage, hold a valve at open position with the same thread as the fitting on its one end in your other hand.

D. Release the pressure in the valve body. Open the blind plug with spanner and allow the pressure within the valve to be released. Do not open the blind plug quickly; this procedure requires care and patience. When the pressure inside begins to decrease, open the plug slowly, so that the pressure remaining inside gets out through the threads.

D. After blind plug is opened install the valve stated in article c.

1e

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Venting and draining Vasta ball valves:

Valve spaces are pressurized when performing valve vent procedures. It is recommended that experienced personnel perform such dangerous process.

Vasta A.. recommends using a bleed fitting vent for operator safety. Vent plug should not be removed unless all pressure between spaces of the body is completely released.

Valve spaces are pressurized when performing valve drain procedures. It is recommended that experienced personnel perform such dangerous process.

Vasta A.. recommends using a bleed fitting and minimum drain for operator safety. Drain plug should not be removed unless all pressure between spaces of the body is completely released.

In both situations, the fluid in the line may be toxic, corrosive or inflammable. Operator should decontaminate the valve under a suitable standard before working on the valve.

The operator must use protective equipment in accordance with chemical and physical effects he will be exposed to.

If there exists a safety valve that will prevent uncontrolled release of the fluid with temperature and pressure at a high level giving harm to human health, it is recommended to connect such safety equipment to a suitable manifold to take released fluid under control. If there is no bleed fitting, do not use vent and drain plug to release pressure out of the body spaces.

Tools used on external surfaces of the valve (grinding, welding, cutting etc) should have anti-sparkling feature. Usage of such tools should be subjected to permission. Such permission is not valid for explosive medium forming in and out of the valve as well as for combustible deposit medium. Such deposit situation should be eliminated before beginning to the procedure.

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12a7

1e

14, 151a

43c3g3f3h

3, 3a

1

1313a

X

Y

17c

18

19

1g

1e

1i

2b

2e2c

X DetailPrimary Metal to Metal Secondary Soft Seal

2k2h

2f 2b

2e2c

X DetailPrimary Soft Seal Secondary Metal to Metal

2k2h

Y Detail

6

7a

4c

41e

Figure-20 Split Body Ball Valve Part List

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Spare for Part Name; Maintenance Repair

1 Body

1a Bonnet

1b Mapa ve destek

1e Lub. fittings X X

1g Drain X

1i Vent X

1m ek valve X 2 Seat ring

2a Seat ring face

2b PTFE ring X

2c O-Ring X

2e spring X

2i Fire Safety Ring

3 Ball

3a Ball Face

Spare for Part Name; Maintenance Repair

3c Anti statik device (ASD) 3f Retainer (Tayc) 3g Yatak DB (Trunnion) X 3h Pul (PTFE) X 4 Mil

4b PTFE X

4c O-Ring X

6 Packing X

7 Gland

7a Gasket X

7b O-ring X

12a Mountaing Flage

18 Ticket

19 Paint

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Declaration of conformity

According to Directive 97/23/EC for a pressure equipment

The manufacturer herewith declares, that the pressure equipment

Description: Ball Valves; Split body and Full welded, Floating and Trunnion type, Top entry & side entry, Soft seated & metal to metal seated, from Class 150 upto Class 2500.

Type-, Serial-, Identification-No: E610-E61 / E620-E62 / E630-E63 / E640 / E650 / E660

max. allowable pressure PS: 20 bar / 51 bar / 102 bar / 153 bar / 255 bar / 425 bar

Allowable min. / max. temperature TS: - 46 / +100 C

Volume V: 0,4 to 3.500 Liter

Year of manufacturing: 2010 & following years

Test pressure PT: 30 bar / 77 bar / 153 bar / 230 bar / 383 bar / 638 bar

Test fluid: Water

Corresponds to the Pressure Equipment Directive 97/23/EC.

Applied conformity assessment

procedures: Module H+H1

Applied standards and technical

specifications: API 6D

Other applied EC-Directives: NA

Engaged notified bodies:

Surveillance of the QS-System: TV Rheinland

Examination / inspections / test

during manufacturing: TV SD, Bau und Betrieb GmbH

Certificates which are included

EC- modul H/H1 Full quality assurance / Full quality assurance with design examination and special

surveillance of the final assessment.

Cert. No: DGR-0036-QS-1072-12

Location, Date: Tekirdag / Cerkezkoy, 01.04.2013

Signature

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A Signed 01.12.2006 K.KORKMAZ .KOAK N.ERGN

REV. Description Date Prepared by Control by App. by

Technical Instructions Assembly, Operating and Maintenance

VASTA

1/2" ~ 2" (NPS15 ~ NPS50)

COMPACT VALVES

OPERATING AND MANTENANCE NSTRUCTON

Location

DES Document

VA-IMS-0-R1

Scale

A4 B

Valf Armatr Sanayi Ticaret Anonim irketi .O.S.B. 59500 Tekirdag TURKEY tel. 0282 758 36 50 fax. 0282 758 36 59

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Contents

INTRODUCTION 1.0.0 GENERAL 1.1.0 PACKAGING STORAGE AND TRANSPORTATION 1.2.0 BRANDING 1.3.0 ASSEMBLY LINE LINK 1.4.0 START UP and LINE TESTING 1.5.0 OPERATION 1.6.0 PERIODIC CONTROL AND GENERAL MAINTENANCE 1.7.0 EMERGENCY MAINTENANCE 1.8.0 SPARE PART ORDERING 1.9.0 PERSONNEL QUALIFICATION 1.10.0 CALIBRATION 1.11.0 REVISION HISTORY

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BS 6683:1985 AND VA-MS-0-R1 CROSS REFERANCE

BS 6683:1985 ITEM VA-IMS-0-R1 Page 1.0 General 1.0 General

4 1.1 Spore 1.0 General

4 2.0 Service & Environmentol Factors -------

2.1 Fluid 1.2.0 Marking 6

2.2 Pressure-Temprature Rating Pressure-Temprature Table (Table 1) 7

2.3 Laydut & Erection 1.3.0 Mounting 9

2.7 Throttling 1.5.0 Operation 11

2.11 Corrosion 1.1.4 Storage 5

2.12 Stem Fightness 1.4.0 Line Test 10

2.14 Operating Power Torque Table (Table 3) 9

2.15 Vibration -------

3. Storage & Handling 1.1.0 Packing, Storage & Transport 5

3.1 General 1.1.1, 1.1.2, 1.1.3 6

3.2 Handling 1.1.5, 1.1.7, 1.1.8 6

3.3 Storage 1.1.4, 6

4. Erection 1.3.0 Assembly Erection in Line 7

4.1 General -------

4.2 nspection 1.3.1 7

4.3 Threaded Valve / Pipe Connection Figure 1, Figure 2 8

4.4 Flanged Valve Mounting Figure 3 9

4.5 Mounting By Welding 1.3.6 9

4.6 Test and Adjustment 1.4.0 Line Test 10

5. Operation & Maintenance 1.5.0 Operation 11

5.1 General -------

5.2 Operation of Manual Valves 1.5.1-1.5.2-1.5.3-1.5.4-1.5.5 11, 12, 13

5.4 Quarter- Turn Valves 1.5.5 13

5.6 Maintenance 1.6.0 14

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INTRODUCTION

Do not perform any actions on the valve without reading the information marked with symbol in this manual.

Do not perform the related operation without reading the information marked with symbol in this manual.

This index has been arranged in accordance with the titles defined by the standards. If the content does not meet your requirements, make sure you search for this content under another title.

Content and Valve definition Design features Usage features Photograph and Data sheet Disassembly drawing and part list and spare parts (For further information, please refer to related valve catalog and Drwg)

Maintenance preparation Maintenance scope drawing numbers with ref. no. Maintenance equipment and hand tools Disassembly and assembly information

Disassembly procedure Cleaning Examinations and controls

Reassembly assemblage Body assembly - warnings Disk assembly - warnings Gasket assembly - warnings Cap assembly - warnings Complete assembly warnings

Adjustments and controls On-off adjustments warnings Full on-off control Tightness control Tests (For further information, please refer to Drwg and DS)

Maintenance branding Recording in maintenance document Adding spare part input (See warranty and service document) Adjustment and measurement records (see service document) Opinions of the service man (see service document) Field labeling and latest maintenance record (this is the service document)

Additional documents Assembly drawing (This is a custom order document) Part list and definitions (This is an order document)

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1.0.0 GENERAL

1.0.1 This manual can be applied to all Standard valves produced by Vasta.

1.0.2 The user shall find the suitability to API591 standard acceptance conditions in the valves that are within the scope of this manual.

1.0.3 This manual is in conformity with BS6683 Maintenance and usage Standard" procedure.

1.0.4 If the customer has ordered with special conditions, those conditions shall prevail. This manual is the complement of those conditions.

1.0.5 Provided that the procedures in this manual are followed, Vasta guarantees that the valves will be in service during the "economic live of the facility".

1.0.6 The valves should not be constrained in case the pressure and temperature values are exceeded or in case there is line pollution and damages in metal parts and maintenance should be carried out immediately and service should be requested.

1.0.7 In case the valves are damaged by undesirable conditions, Vasta service should be applied and spare part support should be requested.

1.0.8 Whether under warranty or not, Vasta recommends you to send the valves to Vasta in case of malfunction. In this case, you will be notified about the control results of the valve and the valve will be delivered to you after maintenance and repair with your consonance.

1.0.9 If the repair costs exceed the value, a new valve is recommended.

1.0.10 If any defects are determined within the scope of warranty, these defects are repaired free of charge.

1.0.11 The valves under warranty can only be repaired by authorized Vasta services.

1.0.12 In case there are any interruptions with the valve apart from the conditions allowed by the procedure, Vasta will not be responsible for any performance problems.

1.0.13 You can apply to the following resources anytime.

Vasta A.. .O.S.B 59500 Tekirdag Turkey 0282 758 36 50 (Pbx) Fax. 0282 758 36 59

http://www.vastas.com , vastas@vastas.com Directorate of after-sale services is at your service.

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1.1.0 PACKAGING, STORAGE and TRANSPORTATION

1.1.1 Vasta valves are protected with caps. 1.1.2 Unless otherwise specified in the order, the valves are delivered in parcels /

packages over palettes. 1.1.3 They are securely placed on the palette and suitable for land / air transportation. 1.1.4 Storage retention period is 2 years provided that the valves have not been transported

abroad. Within this period, the valves and their caps should be opened, the unpainted parts should be lubricated and the valves and caps should be closed within 12 months in accordance with the storage conditions.

1.1.5 Watch out for any damages on the package after transportation. Package

damage means there may be damages inside of the package, as well. Transporter and the insurance company should be immediately notified.

1.1.6 Instruction book and Certificate are in the package. Order conformity control

must be performed from the Package list during delivery.

1.1.7 Please check the weight info before removing the package and do not

remove the package without providing the proper carrier.

1.2.0 BRANDING

1.2.1 Each valve has its own identification label. If the size of the valve is not suitable for labeling, the label might be clipped on the valve.

1.2.2 The label information is as follows.

VASTA FIGURE No. SIZE CLASS Body Material INTERNAL COMPONENTS Material

Design Standard Tip type ans Standard

MOP primary max. Operation pressure

MOT max. Operation temperature

Production date and Serial number

Customer branding information (May be provided separately upon request)

Please read the label information and do not use for the conditions exceeding these values. This information should be separately controlled during delivery acceptance, while connecting to the pipeline and during hot start up.

Check the fluid type and Valve material compatibility, and do not assemble without consulting the producer in case of any doubt.

Check the compatibility of your valve connection (especially cogwheel) type and the connection type of your pipe, incompatible screw threads will break the threads of your valve or pipe. (such as NPT or R type threads) Unless otherwise specified, the thread valves are in NPT (ASME B1.20.1) standard.

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1.2.3 The branding information on the body is as follows.

Vasta

Size

Class

Material

Standard logos

Cut off sign

Charge no.

FLOW DIRECTION

Pressure & temperature ratings

-29 TEMPERATURE C 38 50 100 150 200 250 300 325 350 375 400 425

150

CLASS bar 19,6 19,2 17,7 15,8 13,8 12,1 10,2 9,3 8,4 7,4 6,5 5,5

300

CLASS bar 51,1 50,1 46,6 45,1 43,8 41,9 39,8 38,7 37,6 36,4 34,7 28,8

600

CLASS bar 102,1 100,2 93,2 90,2 87,6 83,9 79,6 77,4 75,1 72,7 69,4 57,5

900

CLASS bar 153,2 150,4 139,8 135,2 131,4 125,8 119,5 116,1 112,7 109,1 104,2 86,3

1500

Mate

rial G

r. 1.

1

ASTM

A

105

CLASS bar 255,3 250,6 233 225,4 219 209,7 199,1 193,6 187,8 181,8 173,6 143,8

Not: recommended touse over 427 C

Table 1- pressure temperature ratings

1.3.0 ASSEMBLY LINE LINK

1.3.1 Preparation;

- Provide the proper equipment. - Perform line conformity control and compare the label information and line information

to ensure that the correct valve is used. - Determine the flow and cutoff directions. Find the proper direction to the flow and cutoff

directions specified on the valve that you use. - Clean and purify assembly location and pipe-flange-washer- screw threads-connection

components for the last time. - In case the valve is welded to the line, make sure that PTFE seat and washers will

endure the heating, if necessary, do not weld without taking proper cooling precautions. - In straight or slip-on flange pipe connections, you may only perform welding by method

welding until adjusting the connection position. - Perform welding electrode selection and procedure compatibility control. - follow the welding procedure instructions strictly for tip welded or socket welded type

valves. Please check the external temperature that reaches the seat materials during operation.

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The following table shows the frequently used materials.

MATERIAL TYPE MOT.

MAX. TEMPERATURE MOP.

MAX. PRESSURE PTFE PTFE 260 C 100

Buna-N NB 130 C 100 Viton FP 220 C 100

Table 2- MOT and MOP values of frequently used materials

1.3.2 Review the valve control and assembly criteria before the assembly;

- Does the assembly position have ease of operation? - Can the maintenance and control be easily performed? - Is there a cap demountable area for ease of maintenance? - Is the location suitable for gasket control and addition? - When the protective caps are disassembled, are there any dirt-sand in the valve that

have to be cleaned? (If yes, you can clean the valve with pressure air) - Any precautions taken to prevent any metal parts remaining in the pipe after

assembly? - Have you been informed about the maintenance that will be performed after the first

cleaning of the filters? - Are there any undesired assembly positions? (See the following figures)

Figure 1- Allowable operation positions of Gate and Globe valves

Correct Correct

Incorrect Incorrect

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Yanlis

Yanlis

Dogru

5 5

Dogru Dogru

Yanlis Yanlis Yanlis Yanlis

Figure 2- Allowable operation positions of Check valves

1.3.3 If flange assembly will be performed:

a) An equivalent flanged spool must be used instead of the valve, or... b) If you have to make connection with the valve, it is recommended to use 1.5 3 mm of

puller support, excluding the washer, in order to ensure axiality and parallelism in flange connections.

1.3.4 Parallelism tolerance of flanges must not exceed 1 degree and total of 2 mm axial radial run out.

0.5

x

x

Figure 3- Allowable parallelism and axial errors

1.3.5 Sporting of entry and exit pipes must be complete. Valve can be used as pipe carrier neither before nor after the welding.

1.3.6 In connections with necked flanges, make sure there are no strains or radial run out by loosening the flange connection components after the root weld.

Incorrect

Correct

Incorrect

Correct

Correct

Incorrect

Incorrect

Incorrect

Incorrect Incorrect Correct

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1.3.7 Flange screws must be loosened for the post-welding heat treatment (PH).

1.3.8 After completing all operations, flange bolts or screws must be tightened at the torque values specified in Table 2.

Bolt size Torque Nm Bolt size Torque

Nm

1/2 " 61 7/8" 324 5/8" 117 1" 489 3/4" 203

Table 3 Opposite flange bolt/washer tightening torque values

1.3.9 After line cleaning and chemical washing, the valves must be disassembled and cleaned manually.

1.3.10 Drain connections must generally be used at the beginning of start-up operation and at the process of first maintenance for the purpose of cleaning.

1.3.11 Before start-up, the tightness of flange (Table 3) and cap screws (Table 5) and the tightness of gasket (Table 4) must be checked and the loose ones must be tightened in accordance with the proper torque value.

1.3.12 The valves must be kept half-open during welding. In order to protect the washer and the gasket socket, it should be ensured that cap/body system is not over-heated.

1.3.13 Due to the reasons stated above, post-weld heat treatment for homogenization of the weld should only be applied to the welded spot.

1.3.14 In metal-seated valves, the valve body should not be heated more than 400 C in order to prevent any damages on disk seat. In case it exceeds 80 C in Globe valves, the seats will be damaged. The welding must be made by chilling.

1.3.15 Please check if the gasket and washer materials are suitable for the achieved temperature during operation.

1.4.0 START-UP and LINE TEST OPERATION

1.4.01 After completing all connections, allow the flow with pressure air or cleaning fluid by opening and closing the valve in order to prevent any foreign material residues. Opening and closing ensure the disposal of the residues accumulated in the valve and the line in the direction of the flow. At the end of this process, the residues that may be collected in the filter must be cleaned.

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1.4.02 Fill the line with fluid in order to perform line test. 1.4.03 Make sure there is no air trapped in the valve. 1.4.04 Check body/cap connection screws, check gasket connection or if any,

tighten adjustment screws to the appropriate values for test pressure. Over-tightening will shorten the life of gasket.

Gate Valves Globe Valves

150# 300# 600# 800# 1500# 150# 300# 600# 800# 1500# Stud Diam.

(lnches) Nm Nm Nm Nm Nm

Stud Diam.

(lnches) Nm Nm Nm Nm Nm 7/16'' 10 10 10 15 15 7/16'' 10 10 10 15 15 3/8'' 12 12 12 25 25 3/8'' 12 12 12 25 25 5/8'' 15 15 15 30 30 5/8'' 15 15 15 30 30

Table 4 Gasket bolt/screw tightening torque values

Stud Size BOLTNG MATERAL Civata malzemesi

Civata

ls B7M/L7M B7/B16 660 630 B8M CL.1 B8M CL.2

ft.lb (Nm) ft.lb (Nm) ft.lb (Nm) ft.lb (Nm) ft.lb (Nm) ft.lb (Nm)

3/8''-16 UNC 15 (20) 20 (27) 20 (27) 20 (27) 15 20 20 (27) 7/8''-14 UNC 25 (34) 30 (41) 25 (34) 35 (47) 25 (34) 25 (34) 1/2''-13 UNC 40 (54) 50 (68) 40 (54) 55 (75) 35 (47) 45 (61)

8/18''-12 UNC 55 (75) 70 (95) 60 (81) 80 (108) 55 (75) 65 (88) 5/8''-11 UNC 75 (102) 100 (136) 80 (108) 100 (136) 70 (95) 85 (115) 3/4''-10 UNC 135 (183) 170 (231) 150 (203) 200 (271) 125 (170) 150 (203) 1/8''-9 UNC 200 (271) 270 (366) 250 (339) 300 (407) 200 (271) 200 (271) 1-8'' UNC 350 (475) 400 (542) 350 (475) 450 (610) 300 (407) 300 (407)

1 1/8''-8 UN 500 (678) 600 (814) 500 (678) 650 (881) 450 (610) 450 (610) 1 1/4''-8 UN 675 (915) 850 (1153) 700 (949) 950 (1268) 650 (881) 650 (881) 1 3/8''-8 UN 900 (1220) 1200 (1627) 1000 (1356) 1300 (1763) 900 (1220) 900 (1220) 1 1/2''-8 UN 1200 (1627) 1500 (2034) 1300 (1763) 1700 (2305) 1200 (1627) 1200 (1627)

Table 5 Body cap bolt/screw tightening torque values

1.4.05 Fully open Gate and Globe valves, half open the ball valves. 1.4.06 Test pressure cannot exceed 50% of the nominal pressure of the valve. 1.4.07 After pressurizing the system, ensure full tightness. Test guarantees the

accuracy of all connections under pressure.

1.4.08 "Backseat" (5) in Gate and Globe Valve stems operates when the valve is fully open. The valve allows for additional gasket, when under pressure on the line. In order to prevent damage to Backseat tightness surface, you should avoid over-loading to flywheel when the valve is fully open.

1.4.09 If the valves remained at the same position for a long time, you may encounter difficulty of use. Stem gears have lost oil and gasket size has changed. Therefore, we recommend programmed on/off operations.

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1.5.0 OPERATION

1.5.1 Gate Valve In these valves, the flow is enabled by the movement of the slide (3)* between two seats(2). Bottom end of the stem (4) is connected to the top side of the slide (3); this enables the required resistance for maneuver. All movements of the slide (3) are directed to the channel on the valve body (1). The seats (2) are fixed to the body with an angled position. The gasket socket that contains gasket rings (6) is on the cap (1a). The gasket (6) is tightened in the gasket socket by gland (7) and gland flange (8), by providing the required pressure with four gland nuts (10) and two gland bolts (9). Cogged top of the stem (4) is fixed to its position with fork nut (12a) by connecting with stem nut (11). The valve is opened by turning the flywheel (17) counterclockwise. After the valve is fully opened, turn the valve a quarter round towards the closing direction, so that the valve does not stay in ring pressure "BACKSEAT" (5) position. Do not reduce with gate valve, it may damage the tightness surfaces.

(* : These numbers show the related part in figure 4.)

Never over-power the flywheel, (if there are any foreign substances) stem and tight surface may be damaged.

The following figure shows the normal mode of operation of Gate valve

8

4

13

3,3a

2,2a

1

9

10

1a

6

7

11

17a1817

14

19a

Figure 4 Open and closed positions of Gate valve

1.5.2 Globe Valve The structure and operation mode of globe valve are similar to gate valve. The difference is the flow control system and this is performed with a disk (3) in globe valves. It may be provided in parabolic form, as Teflon or with needle-disk upon request. The disk (3) is connected to the stem (4) with flexible connection. Since the fluid does not have a direct flow, significant load loss occurs in the globe valve. This means a perfect flow control, especially reducing and full transition control can be obtained. Similar to gate type, these valves are also opened by turning the flywheel (17) counterclockwise. After the valve is fully opened, turn the valve a quarter round towards the closing direction, so that the valve does not stay in ring pressure "Backseat" (5) position.

Close Open

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Never over-power the flywheel (17), (if there are any foreign substances) stem (4) and tight surface may be damaged.

The following figure shows the normal mode of operation of Globe valve

19a

4

14

17

13

3,3a

2,2a

1

6

10

1