Trunnion Ball Valve Maintenance Manual

 

1. RECEPTION

1a- While unpacking the Trunnion Ball Valve, confirm that the valves and any of the accessories were not damaged during transportation.

1b- Do not place the valve directly on the ground or concrete floor. Place the valve on wooden pallet for inspection.

1c- Do not remove the end caps or protective flange coverings until it is ready for inspection or installation. If the protective coverings are removed for inspection, immediately reinstall them after the inspection.

1d- It is strongly recommended that the valves are to be stored in indoor, in a dry, dust free atmosphere.

 

2. STORAGE

2a- Trunnion Ball Valves should be stored in a dry, weatherproof building (preferably climate controlled).

2b- The Trunnion Ball Valve and its actuator should have all fluid ports or connections plugged to prevent ingress of water or dust. Coupling parts must be protected with grease or protective oil.

2c- Install plastic or plywood flange protectors on each flange. Tape the edges of the protector with dust-tape to provide an air tight seal.

2d- The product should be operated monthly to ensure lubricated areas have lubricant distributed accordingly. The valve stem should be left in a different position each month.

2e- Spray the inside of the Trunnion Ball Valve to make it clean after installation.

 

3. INSTALLATION

3a- Before installation a new Trunnion Ball Valve, confirm that the specifications of the valve match those of the intended installation area. The nameplate will provide the necessary information.

3b- When removing the valve from storage inspects it for damage.

3c- Before installing the Trunnion Ball Valve, remove the protective covering and end-caps to ensure the serrations on flange face are not damaged and the bore is clean. Clean the valve with approved solutions if necessary.

Caution: Prior to installation, ensure the pipeline is clean. Pipeline debris, scaling, etc. will damage the soft seat inserts of the valve and cause seat leakage during commissioning.

 3d- During commissioning and pipeline flushing, the valve must remain in full-open position to prevent damage to internal parts.

3e- Trunnion Ball Valve can be mounted in a horizontal or vertical position depending on pipeline routing. PASCO does not recommend installing the valve with the actuator on the underneath side because dir in the pipeline may enter the body cavity and damage the gland packing.

3f- It may be necessary to firmly support ht pipeline in order to protect the valve from excess stress and to reduce the pipeline vibrations. To facilitate serving, it is recommended that the valve be supported by the body, using approved support devices.

 

Flanged End Trunnion Ball Valve

 3g- Do not use flange bolts to correct misalignments.

3h-During tightening operation, ensure that piping stresses are not transferred to the valve.

3i- Over-tightening flange studs can cause damage and/or leakage at the flange or body-to-body end joints.

Butt welded End Trunnion Ball Valve

Note: Welding operation must be performed by a qualified welder. The welding procedure should be performed according to standard.

Caution: To prevent seat/seal damage during welding installation, do not allow the temperature of the valve body seat area to exceed 200F

 

4. OPERATION

 4a- For lever operated valves; the hand lever is either assembled with the valve or shipped by fastener, depending on the size of the valve or hand lever.

4b- For gear operated valves, the gearbox open/closed adjustment has been made prior to dispatch and must not be disturbed. Rotation of hand wheel in clockwise direction closes the valve

 

5. MAINTENANCE

 5a- In order to avoid failure during operation, all valves in a process plant should be periodically inspected thoroughly for wear on the ball, seats, seals, or body. If wear is discovered, Relia recommends replacing seats, seals, and packing with genuine Relia parts.

5b-The type of process, fluids involved, working conditions, and location of valve in the process plant, will determine the frequency of the inspection/maintenance.

5c- Preventive maintenance is essential as the failure due to lack of maintenance may cause and emergency shutdown of the plant.

5d- Before removing the Trunnion Ball Valve from the pipe, it is important to mark the relative position of the valve flange with respect to pipeline flange and the flow of direction of the valve.

5e- Once a Trunnion Ball Valve is repaired, it should undergo a complete set of tests to make sure that the valve is adequate for the original working conditions. Hydrostatic/pneumatic shell/seat tests should be carried out as per  specifications relevant to the valve.

 

6. TROUBLES AND SOLUTIONS

TROUBLES Cause Solutions
Loose from the stem

1) Packing too loose

2) Packing ruined

1) Tighten the inferior nuts

2) Persisting, replace the packing

Loose from body and bonnet Bolting is not tight enough Tighten the bolting
Hard to open or close The seat insert is too dry Inject some lubricant via the injection valve
Gas-loose from packing The size of packing is wrong Replace
Loose from piping Defective connection Re-arrange

 

7. Assembly Drawings

Material Specifications

No. Name of Part A105/ENP LF2/F316 F316/F316
1 Nut A194 2H ASTM A194 7 ASTM A193 B8
2 Bolt A193 B7 ASTM A320 L7 ASTM A182 F316
3 Bonnet ASTM A105 ASTM A320 LF2 ASTM A182 F316
4 Gasket 304+Graphite 304+Graphite 304+Graphite
5 O-Ring Viton AED Vion AED Vion AED
6 O-Ring Viton AED Vion AED Vion AED
7 Graphite 304+Graphite 304+Graphite 304+Graphite
8 Spring Inconel X-750 Inconel X-750 Inconel X-750
9 Seat Ring ASTM A105 A182 F316 A182 F316
10 Pin Carbon Steel Stainless Steel Stainless Steel
11 Trunnion ASTM A105 A182 F316 A182 F316
12 Bearing Carbon Steel+Graphite Carbon Steel+Graphite Carbon Steel+Graphite
13 Gasket 304+Graphite 304+Graphite 304+Graphite
14 Ball ASTM A105+ENP A182 F316 A182 F316
15 Drain Plug Carbon Steel Stainless Steel Stainless Steel
16 Ring A105+ENP Stainless Steel Stainless Steel
17 Seal Ring Viton AED Stainless Steel Stainless Steel
18 Seat Ring PTFE, Nylon, PEEK PTFE, Nylon, PEEK PTFE, Nylon, PEEK
19 Feet Carbon Steel Carbon Steel Carbon Steel
20 Injection Valve Carbon Steel Stainless Steel Stainless Steel
21 Lifting Lug Carbon Steel Stainless Steel Stainless Steel
22 Body ASTM A105 A182 F316 A182 F316
23 Safety Valve Carbon Steel Carbon Steel Carbon Steel
24 Relief Valve Carbon Steel Stainless Steel Stainless Steel
25 Trunnion Bearing Carbon Steel+Graphite Carbon Steel+Graphite Carbon Steel+Graphite
26 Stem A182 F6A A182 F316 A182 F316
27 Key Carbon Steel Carbon Steel Carbon Steel
28 Thrust Washer PTFE PTFE PTFE
29 O-Ring Viton AED Vion AED Vion AED
30 Stuffing Box ASTM A105 ASTM A350 LF2 ASTM A193 B8
31 Bolt A193 B7 ASTM A320 L7 ASTM A193 B8
32 Packing 304+Graphite 304+Graphite 304+Graphite
33 Adapter ASTM A105 ASTM A105 A182 F316
34 Bolt A193 B7 ASTM A320 L7 ASTM A193 B8
35 Nut A194 2H ASTM A194 7 ASTM A194 8
36 Bolt A193 B7 ASTM A320 L7 ASTM A193 B8
37 Worm Gear Ductile Iron Ductile Iron Ductile Iron

© 2019 Relia Valve Co., Ltd. Trunnion ball valve manufacturer

Tel: + 86-577-86373155, E-mail: export@reliavalve.com