instructions manual for storage, - staitech · 04 1 seat tfm 1600 05 ... instructions manual for...

INSTRUCTIONS MANUAL FOR STORAGE, INSTALLATION, OPERATION AND MAINTENANCE

OF CLEAN SERVICE BALL VALVES TYPE:

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A. Antunes INSTRUCTION MANUAL Nº 001/05

INSTRUCTIONS MANUAL Nº 001/05 2/8

c. Always operate the valve to the open position to ensure that no trapped pressure exists within the cavity.

d. Pipe should be cleaned in the interior using pressurized water to remove residues, barb, welding scum, etc. The presence of residues inside the pipe could damage the sphere and the seats.

e. A valve subjected to harmful substances can never be handled without being completely decontaminated and declared safe to handle.

f. Assure that the suitable pressure/temperature rating indicated on the valve body is larger or equal to the service conditions.

g. Any modification of a valve can never be performed without a prior consultation or recommendation by the manufacturer.

h. The valves handles can only be used during their operation and must not be used to carry them; otherwise the operator may be injured if this warning is not taken into consideration.

i. The handling and installation of the valve should be executed by personnel properly qualified and in agreement with the appropriate manual/mechanic techniques. Always use correct lifting methods and equipment when installing, removing and maintaining the product, and insure that it is correctly supported in its final operating location.

j. This product can be employed in several applications. Therefore it is the responsibility of the end user the usage of construction materials with the most suitable media and for each specific application.

k. In the case of products used in processes or environments that can cause limit temperatures (high or low) and consequently harm or injure the personnel in any way, the infra-structures must have proper protection and/or insulation.

l. Devices have to be installed to protect this equipment from over-pressurization (caused by external fire, etc).

m. Excessive forces acting on the flanges and connections must be avoided and prevented by the installation of this equipment on a system specially designed for that purpose.

7. INSTALLATION OF WELDED END BALL VALVES a. All welding should be done by qualified personnel. b. Use a high-purity purge gas to maintain cleanliness and reduce welding discolouration. c. Disassemble both end caps from the rest of the valve before proceeding. d. Perform the welding procedure on the cap according to standard industrial practices. e. Reassemble the valve. f. Test the valve for proper operation. 8. INSTALLATION OF CLAMP END BALL VALVES a. Place the gasket either in the end cap or pipe fitting and press them together. b. Attach both clamps with the appropriate ring. c. Test the valve for proper operation.



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9. OPERATION The long life of valves can be maintained under normal working conditions and in

accordance with the pressure/temperature rating. During operation, ball valves must be in either the complete OPEN or CLOSED position in

order to ensure their smooth and efficient working and a long duration of the seats. Leaving the ball in the half open position could eventually cause damage to the soft seats.

It is the responsibility of the end-user to install the necessary monitoring and safety devices, in order to assure that the of pressure and temperature limits use are not exceeded.

10. MANUAL OPERATION Manual operation of the valve is achieved by turning the handle a quarter turn (90º). The

valve is fully open when the handle is in line with the valve and pipeline or fully closed when the handle is across the pipeline.

11. REMOTE OPERATION Vinco Válvulas, S.A. is able to, whenever necessary, supply pneumatic and electric

actuators that cover a wide range of torque. The operation depends on the installation, operation and maintenance instructions of each

actuator. 12. MAINTENANCE a. Every 6 months check for any signs of leakage and that all fasteners (including the

gland nut) and joints are tightened to their correct torque value. b. One month is the maximum a valve can be left without operation. After this period the

valve should be operated through three full cycles. c. If leakage is evident on the stem packing area, it can be eliminated by increasing the

tightness of the lock nut. In the case of the leakage still persisting, the replacement of the stem packing is recommended.

d. Leakage can also occur due to damage to the body, end cap, body seals, seats or ball sealing surfaces. In this case, the valve must be dismantled for repair.

13. REPAIR KITS Vinco Válvulas, S.A supplies repair kits for all its valves. Although single piece parts are

available, (the repair of the valve is highly recommended utilizing all of the parts that are included in the repair kit).



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14. DISASSEMBLY INSTRUCTIONS a. Before disassembly wear adequate protective equipment, be aware of the fluid, ensure

that no pressure is present in the valve, and observe all other security issues. b. Do not release the securing bolt before checking first if the valve is correctly supported. c. In the case of the weld end version, remove the body screws and take the valve body

section out of line without moving the end connectors from their place. d. For clamp versions, remove the clamp ring and take the entire valve out of line. e. The valves should be then taken to a clean, secure working place. f. For the clamp version, remove the end caps by unscrewing the bolts (the weld end

caps version is already disassembly at this time). g. Remove the body seal along with the respective seat or cavity filler from each side. h. Remove the ball. i. Unscrew the stopper from the body. j. Remove the upper stem nut, the lever, the stop plate (when applicable), the stop

washer, the lower stem nut, the disc springs and the gland packing. k. Withdraw the stem from inside the body. l. Now the packing can be removed from the bottom body (01) recess. m. With the valve completely disassembled, clean and examine all the following

components:

Ball surface: any surface defect, particularly in the seating area will be extremely detrimental to the performance of the valve and therefore the ball should be replaced if found defective.

Seats: seats replacement is recommended.

Stem seals and body seals: also to be discarded and replaced by new ones. n. Proceed to a careful examination of corrosion and mechanical damage particularly on

threaded components. If components are found to be defective they should be replaced.

15. ASSEMBLY INSTRUCTIONS a. Before rebuilding, ensure the suitability of the replaced components for the valve as

well as the cleanliness during the whole procedure. b. Fit the Stem thrust seal onto the Stem shoulder and insert this into the body stem bore

from inside the body cavity. c. Fit the Packing into the top body recess, over the top of the Stem, followed by the

Gland packing, the two Disc springs, and one of the Stem nuts. d. With the correct torque value (Tab. 2), line up the Stem nut, in order to lock it with the

Stop washer. e. Place the Stop plate (when applicable) and the Lever into position and tighten them with

the remaining Stem nut. f. Screw the stopper into the position on the body. g. Operate the stem several times before continuing the assembly. h. Insert the Ball by sliding it into the body onto the stem tang.



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i. Insert both Seats into the Body. j. Ensure that the ball is correctly ported (i.e. not partially open/closed), otherwise seat

damage will occur. k. Insert the Body seal into position. Locate the End cap onto the body and tight the Bolts

(Tab. 3). l. After having completed the re-assembly check for the maneuverability of the valve and

make sure that the ball rotates freely. If facilities are available, test the ball valve to the appropriate specification.

16. ENCLOSURES a. Sectional drawings. (fig. 1 and 2) b. Parts list. (Tab. 1) c. Gland nut torque values. (Tab. 2) d. Bolt torque values. ( Tab. 3)



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DN10 (3/8’’) to DN50 (2’’) DIN PORT DN15 (1/2’’) to DN50 (2’’) ASME BPE PORT

FIG. 1

DN65 (2 ½’’) to DN100 (4’’) DIN PORT DN65 (2 ½’’) to DN100 (4’’) ASME BPE PORT

FIG. 2



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PARTS LIST

PART QUANT. DESCRIPTION STAINLESS STEEL F316L

01 1 BODY ASTM A182 F316L

02 2 END CAP ASTM A182 F316L

03 1 BALL STAINLESS STEEL 316L

04 1 SEAT TFM 1600

05 2 BODY SEAL TFM 1600

06 3/5/6 PACKING REINFORCED PTFE

07 1 STEM THRUST SEAL REINFORCED PTFE

08 1 STEM STAINLESS STEEL 316

09 2 SEAT RING STAINLESS STEEL 316

10 1 STOP WASHER STAINLESS STEEL

11 1 GLAND PACKING STAINLESS STEEL 316

12 1 STOPPER STAINLESS STEEL

13 2/1 DISC SPRING STAINLESS STEEL

14 2 STEM NUT STAINLESS STEEL

15 1 LEVER STAINLESS STEEL

16 1 STOP INDICATOR STAINLESS STEEL

17 8/12/16 BOLT STAINLESS STEEL

Tab. 1



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GLAND NUT TORQUE VALUES

DIN ASME

- 15

15 20

20 25

25 -

32 40

40 -

50 50 / 65

65 -

80 80

100 100

M10X1

M12x1,25

M16x1,5

M24x2

10 ~ 13

18 ~ 22

28 ~ 32

38 ~ 42

Gland Nut Torque (N.m)Size

Tab. 2

BOLT TORQUE VALUES

DIN ASME

- 15

15 20

20 25

25 -

32 40

40 -

50 50 - 65

65 -

80 80

100 100 M14 150 ~ 190

Bolt Torque (N.m)Size

M6

M8

12 ~ 15

30 ~ 35

M12 80 ~ 120

M10 49 ~ 69

Tab. 3

instructions manual for storage, - staitech · 04 1 seat tfm 1600 05 ... instructions manual for...

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