Trunnion Ball Valve Maintenance Manual
Trunnion Ball Valve Maintenance Manual
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.
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.
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
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
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
|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
|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|
|5||O-Ring||Viton AED||Vion AED||Vion AED|
|6||O-Ring||Viton AED||Vion AED||Vion AED|
|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|
|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|
|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|
|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|
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