Operation Manual Pipeline Ball Valve
Zhejiang Linuo Flow Control Technology Co., Ltd.Lupu, Pandai, Ruian, Zhejiang, P.R.China 325200
Tel:86-577-65099777 Fax:86-577-65386988
E-mail: [email protected]: www.linuovalve.cn
Operation Manual
CONTENTSI、 Overview ------------------------------------------------------------------------------- 3
1. Floating Ball Valve ----------------------------------------------------------------------- 32. Trunnion Mounted Ball Valve ------------------------------------------------------------ 33. Soft Seated Ball Valve -------------------------------------------------------------------- 34. Metal Seated Ball Valve ------------------------------------------------------------------- 3
II、 Applicable Range ------------------------------------------------------------------------- 5III、 Chief Parameter --------------------------------------------------------------------------- 7
1. Curve of Pressure and Temperature ------------------------------------------------------ 72. General Material Assortment --------------------------------------------------------------- 8
IV、 Product Diagram, Decomposition, Assembly and Testing Approach--------------------- 121. Product Diagram ----------------------------------------------------------------------- 122. Decomposition -------------------------------------------------------------------------- 143. Assembly ---------------------------------------------------------------------------------- 16
4. Testing Approach ------------------------------------------------------------------------- 18V、 How to Use ---------------------------------------------------------------------------------- 19VI、 Maintenance --------------------------------------------------------------------------------- 20
VII、 Delivery and Storage ------------------------------------------------------------------------- 21VIII、 Installation ----------------------------------------------------------------------------------- 22
IX、 Adjustment of Manual Ball Valve after maintenance-------------------------------------- 23X、 Precautions ------------------------------------------------------------------------------- 24
XI、 Probable Malfunction and Exclusion Methods ---------------------------------------------- 25
I、 Overview
1. Floating Ball ValveBall without back shaft will present floating condition between two separate seats, so called as Floating Ball Valve, which are especially welcomed for cutting off, allocation and changing flowing direction of medium in pipelines. It contains structures including back sealing shaft, anti fire and static, automatic pressure release and locking device. Floating ball valve is of simple structure design and good sealing performance. For the seat of outlet end sealing ring bears whole force of working pressure from the ball, so this structure will be only recommended applicable for middle and low pressure valves.
2. Trunnion Mounted Ball Valve
Trunnion Mounted Ball Valve, which is widely used for cutting application, is also called side mounted ball valve. There are two split and triple split types of body, respectively means the body is divided into unbalanced two separate pieces and triple pieces along the vertical section of flow line. Its pivot structure design assures accurate ball location. Besides, spring structure is selected as standard seat to push the seat to the ball to realize low pressure sealing performance. Valve cavity is capable of automatic emission with an installed drain valve.
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With a stationary ball, the valve will be largely supported by two pieces of stationary axis and sliding bearing, all of which are connected with ball. Therefore, the ball will not be offset under pressure of medium. Generally there are sliding bearing and rolling bearing on both sides of up and down shafts connected with the ball, this special design is much benefit for reducing the friction between shaft and bearing, and low operation torque. Therefore, this trunnion mounted ball valve is suitable for high pressure and large size valves.
3. Soft Seated Ball Valve
Valve of soft seated means the sealing ring is consisted of metal and non-metal material. High sealing performance can be guaranteed with resilient materials like PTFE, which is wildly used in most soft seated ball valves. Furthermore, this kind of soft seat presents low requirement on the machining precision and surface roughness of the sealing face. Due to good self-cleaning performance of PTFE and low friction wear, as well as the improvement of machining, valve roughness and life cycle can be largely improved.
4. Metal Seated Ball Valve
Metal seated ball valve is designed with elastic and automatic compensational seat structure. Sealing face coated with hard alloy will make the seat more reliable, temperature and corrosion resistant and long service life. Thus valve seat and ball perform good cutting, self-cleaning and suitable for regulating medium of solid and fiber. Besides, metal seated ball valve is especially applicable for mining and chemical industry with black liquid of high temperature and grey liquid, as long as the sealing face is fine coated to be high hardness as well as corrosion resistant performance. For current, surface treatment processes of metal seated ball valves in inland and oversea areas are overlaying, spray welding and spray coating.
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II. Application range
Related Standard(General)Design and Manufacturing Standard API 608,API 6D,BS 5351Flange Standard ASME B16.5,ASME B16.47,EN 1092Face to Face Dimension Standard ASME B16.10,API 6DTesting and Inspection Standard API 598,API 6DRated Value Standard of Pressure and Temperature ASME B16.34
Comply with the requirement of ATEX 94/9/EC: Group II category 2 GD, protection concept of non-electrical components:CT6
General Specifications (Nominal Size and Pressure)Nominal Size Nominal Pressure
Q41 Floating Ball Series DN15-DN20、 1/2”- 8“ PN10-PN40, Class 150-300Q47 Trunnion Mounted Ball Series DN100-DN800、2”- 32“ PN10-PN100,Class 150-2500
General Specifications (Format of Connection and Sealing Face)Connection Format Sealing Face FormatFemale Thread Entire Flat Face FFMale Thread Male Face RFFlange Male and Female Face MFButt Welding Tongue and Groove Face TGSocket Welding Ring Grooved Face RJWafer
Optional Material(General)Main Material Shaft Seat ( Soft
Seated)Sealing Seat ( Trunnion Mounted)
Packing O Ring
A216 WCB A182 F6a PTFE Hard Chrome Plating
Ductile Graphite PFA
A352 LC1 A182 F304 RPTFEOverlay Welding or Spray Welding Stellite
PTFE FEP
A105 A182 F316 NYLON Tungsten Carbide Spray Welding PPL NBR
A351 CF8 A705 630 ( 17-4PH) PPL Spray Welding
Ni60 SR
A351 CF8M 4140 PEK Ceramic Lining EPDM
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A351 CF3 VITONA351 CF3MA351 CF8CA351 CN7MA890 4A
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III,Chief Parameter
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1. 2.General Material AssortmentQ41F Floating type soft seated
Item Spare Parts Standard configuration (Casting)
Standard configuration (Forged Steel)
Acid Environment Low-Temperature Environment
1 Body/Bonnet
ASTM A216 WCB ASTM A105 ASTM A351 CF8M ASTM A352 LC1
2 Ball ASTM A105+ENP ASTM A105+ENP ASTM A182 F316 ASTM A182 F3043 Seat PTFE PTFE PTFE PTFE4 Shaft ASTM A182 F6a ASTM A182 F6a ASTM A182 F316 ASTM A182 F3045 Gasket Ductile
Graphite +Stainless Steel Band
Ductile Graphite +Stainless Steel Band
Ductile Graphite +Stainless Steel Band
Ductile Graphite +Stainless Steel Band
6 Bolt/Screw ASTM A193 B7 ASTM A193 B7 ASTM A193 B8M ASTM A320 L77 Nut ASTM A194 2H ASTM A194 2H ASTM A194 8M ASTM A194 48 Packing Ductile
GraphiteDuctile Graphite Ductile Graphite Ductile
Graphite9 Thrust
WasherRPTFE RPTFE RPTFE RPTFE
10 Packing Gland
ASTM A276 410 ASTM A276 410 ASTM A182 316 ASTM A182 304
11 Elastic Collar
ASTM A29 1566 ASTM A29 1566 ASTM A276 316 ASTM A276 304
12 Locating Washer
ASTM A216 WCB ASTM A216 WCB ASTM A351 CF8M ASTM A351 LC1
13 Anti-static Module
ASTM A276 304 ASTM A276 304 ASTM A276 304 ASTM A276 304
14 Handle Lever
ASTM A216 WCB ASTM A216 WCB ASTM A216 WCB ASTM A216 WCB
The valve is completed with actuator operator with spare parts as follow:15 Bracket ASTM A216 WCB ASTM A216 WCB ASTM A216 WCB ASTM A216 LC117 Connection
PadASTM A29 1025 ASTM A29 1025 ASTM A182 316 ASTM A350 LF2
Q41Y Floating metal seated type Item
Spare Parts Standard Configuration (Casting)
Standard configuration (Forged Steel)
Acid Environment Low-Temperature Environment
1 Body/Bonnet
ASTM A216 WCB ASTM A105 ASTM A351 CF8M ASTM A352 LC1
2 BallASTM A105+HCr ASTM A105+HCr
ASTM A182 316+HCr
ASTM A182 F304+HCr
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3 SeatASTM A182 F6a+STL ASTM A182 F6a+STL
ASTM A182 F316+STL
ASTM A182 F304+HCr
4 Seat Support Ring
ASTM A276 410 ASTM A276 410ASTM A182 F316 ASTM A182 F304
5 Seat Fire Safe Ring
Ductile Graphite Ductile Graphite Ductile Graphite Ductile Graphite
6 Dish Spring ASTM A705 631 ASTM A705 631 ASTM A705 631 ASTM A705 6317 Shaft ASTM A182 F6a ASTM A182 F6a ASTM A182 F316 ASTM A182 F3048 Gasket Ductile Graphite
+Stainless Steel Band
Ductile Graphite +Stainless Steel Band
Ductile Graphite +Stainless Steel Band
Ductile Graphite +Stainless Steel Band
9 Bolt/Screw ASTM A193 B7 ASTM A193 B7 ASTM A193 B8M ASTM A320 L710 Nut ASTM A194 2H ASTM A194 2H ASTM A194 8M ASTM A194 411 Packing Ductile Graphite Ductile Graphite Ductile Graphite Ductile Graphite12 Thrust
WasherSS316+Nitriding SS316+Nitriding SS316+Nitriding SS316+Nitriding
13 Packing Gland
ASTM A276 410 ASTM A276 410 ASTM A182 316 ASTM A182 304
14 Elastic Collar
ASTM A29 1566 ASTM A29 1566 ASTM A276 304 ASTM A276 304
15 Handle Lever
ASTM A216 WCB ASTM A216 WCB ASTM A216 WCB ASTM A216 WCB
The valve is completed with actuator operator with spare parts as follow:16 Bracket ASTM A216 WCB ASTM A216 WCB ASTM A216 WCB ASTM A216 LC117 Connection
Pad(Casting Steel)
ASTM A29 1025
Q47F Soft Seated Trunnion Mounted SeriesItem Spare Parts Standard
Configuration (Casting)
Standard configuration (Forged Steel)
Acid Environment
Low-Temperature Environment
1 Body/Bonnet/Down Bonnet
ASTM A216 WCB
ASTM A105 ASTM A351 CF8M
ASTM A352 LC1
2 Ball ASTM A105+ENP
ASTM A105+ENP ASTM A182 F316
ASTM A182 F304
3 Seat PTFE PTFE PTFE PTFE
4 Seat Support Ring ASTM A182 F6a ASTM A182 F6a ASTM A182
F316ASTM A182 F304
5 O Ring Viton Viton Viton PVMQ
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6 Spring ASTM A705 631
ASTM A705 631 ASTM A705 631
ASTM A705 631
7 Anti-static Module ASTM A276 304
ASTM A276 304 ASTM A276 304
ASTM A276 304
8 Up(Down)Shaft ASTM A182 F6a
ASTM A182 F6a ASTM A182 F316
ASTM A182 F304
9 Gasket Ductile Graphite +Stainless Steel Band
Ductile Graphite +Stainless Steel Band
Ductile Graphite +Stainless Steel Band
Ductile Graphite +Stainless Steel Band
10 Bolt/Screw ASTM A193 B7 ASTM A193 B7 ASTM A193 B8M
ASTM A320 L7
11 Nut ASTM A194 2H ASTM A194 2H ASTM A194 8M
ASTM A194 4
12 Adjusting Gasket ASTM A182 304
ASTM A182 304 ASTM A182 316
ASTM A182 304
13 Thrust Bearing RPTFE RPTFE RPTFE RPTFE
14 Sliding Bearing SS316+RPTFE SS316+RPTFE SS316+RPTFE SS316+RPTFE
15 Blowoff (Gas) Valve ASTM A29 1025
ASTM A29 1025 ASTM A182 316
ASTM A182 304
16 Injection Valve/Non-Return Valve
ASTM A29 1025
ASTM A29 1025 ASTM A182 316
ASTM A182 304
17 Up Shaft Seat ASTM A105+ENP
ASTM A105+ENP ASTM A182 F316
ASTM A182 F304
18 Packing Ductile Graphite
Ductile Graphite
Ductile Graphite
Ductile Graphite
19Bracket(with Actuator)
ASTM A216 WCB
ASTM A216 WCB ASTM A216 WCB
ASTM A216 LC1
20 Connection Pad(Forging Steel Valve)
ASTM A105
Q47Y Metal Seated Trunnion Mounted SeriesItem Spare Parts Standard
Configuration (Casting)
Standard configuration (Forged Steel)
Acid Environment Low-Temperature Environment
1 Body/Bonnet/Down Bonnet
ASTM A216 WCB
ASTM A105 ASTM A351 CF8M ASTM A352 LC1
2 Ball ASTM A105+HCr ASTM A105+HCr ASTM A182 F316+HCr ASTM A182 F304+HCr3 Seat ASTM A182
F6a+STLASTM A182 F6a+STL
ASTM A182 F316+STL
ASTM A182 F304+STL
4 Seat Support ASTM A276 410 ASTM A276 410 ASTM A182 F316 ASTM A182 F304
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Ring5 Seat Fire Safe
RingTextile Graphite Textile Graphite Textile Graphite Textile Graphite
6 Spring ASTM A705 631 ASTM A705 631 ASTM A705 631 ASTM A705 6317 U
p(Down)Shaft
ASTM A705 630 ASTM A705 630 ASTM A705 630 ASTM A705 630
8 Gasket Ductile graphite+ stainless belt
Ductile graphite+ stainless belt
Ductile graphite+ stainless belt
Ductile graphite+ stainless belt
9 Bolt/Screw ASTM A193 B7 ASTM A193 B7 ASTM A193 B8M ASTM A320 L710 Nut ASTM A194 2H ASTM A194 2H ASTM A194 8M ASTM A194 411 Adjusting
GasketASTM A182 304 ASTM A182 304 ASTM A182 316 ASTM A182 304
12 Thrust Bearing
SS316+nitriding SS316+nitriding SS316+nitriding SS316+nitriding
13 Sliding Bearing
ASTM A182 316 ASTM A182 316 ASTM A182 316 ASTM A182 316
14 Blowoff (Gas) Valve
ASTM A29 1025 ASTM A29 1025 ASTM A182 316 ASTM A182 304
15 Injection Valve/Non-Return Valve
ASTM A29 1025 ASTM A29 1025 ASTM A182 316 ASTM A182 304
16 Up Shaft Seat ASTM A105+ENP
ASTM A105+ENP ASTM A182 F316 ASTM A182 F304
17 Packing Ductile Graphite Ductile Graphite Ductile Graphite Ductile Graphite18 Bracket(with
Actuator)ASTM A216 WCB
ASTM A216 WCB ASTM A216 WCB ASTM A216 LC1
19 Connection Pad(Forging Steel Valve)
ASTM A105
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1. Product Diagram, Decomposition, Assembly and Testing Approach
Product Diagram
Floating Type Forged Body Soft Seat
Floating Type Cast Steel Body Soft Seat Metal Seat
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Trunnion Mounted Type Forged Body Soft Seat
Trunnion Mounted Type Casting Steel Body Soft Seat Metal Seat
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2. Decomposition① Cautions when decomposing as below:1 To make sure that pressure of middle cavity is completely released; repeat
opening and closing must be actuated. If the medium is harmful or even explosive and flammable, the valve should be⑵
washed and cleaned with cautious to make sure there is no residual medium especially in the valve cavity,thus repeat opening and closing can be operated.
Decomposition approachA Floating Type (Uni-directional, bidirectional can be achieved by specific requirement)
Rotate Clockwise of Shaft, the ball will be at close position. ⑴ Demount handle lever, remove elastic collar and limited block.⑵ Loose connection nut, and separate body into left and right, meanwhile remove⑶ ball, seat gasket, outlet seat, spring, inlet seat(valve left is inlet, the valve body is outlet, the removed one from body are seat gasket and outlet seat, the removed one from left body are spring and inlet seat ), and conjunctional gasket from valve body. Be cautious when removing valve ball and seat, avoid collision, falling and damaging of surface.
Loose gland packing bolts and remove gland packing.⑷ Due to anti blow-out design, the valve shaft, shaft bearing, thrust bearing and⑸
packing have to be removed out at valve cavity instead of packing hole. Remove spring and inlet seat from valve left body.⑹
B Trunnion Mounted Ball Type (Bi-directional) Rotate Clockwise of Shaft, the ball will be at close position.⑴ Demount handle lever, remove elastic collar and limited block.⑵ Loose connection nut at bottom cap, remove bottom cap, gasket, adjusting gasket⑶
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and thrust bearing. Loose gland packing bolts and remove gland and packing.⑷ Loose connection plate screw, remove connection plate, gasket, adjusting gasket,⑸ thrust bearing, anti-statistic spring, finally remove valve shaft. Loose connection nut, separate right and left body, meanwhile remove valve ball,⑹ seat ring, spring, conjunctional gasket from body. Be cautious when removing valve ball and seat, avoid collision, falling and damaging of surface.
Remove valve seat, seat sealing ring and spring from left body. ⑺
C Trunnion Mounted Ball Type(Unidirectional, Single seat inlet end tightness) Rotate Clockwise of Shaft, the ball will be at close position.⑴ Demount handle lever, remove elastic collar and limited block.⑵ Loose connection nut into separate left and right body, meanwhile remove valve⑶ seat, seat sealing ring and spring from left body. Loose connection nut at bottom cap, remove bottom cap, gasket, thrust bearing. ⑷ Loose gland packing bolts and remove gland packing, packing ring and packing.⑸ Loose connection plate screw, remove connection plate, gasket, adjusting gasket,⑹ thrust bearing, anti-statistic spring, finally remove valve shaft. Remove conjunctional gasket from valve body, Be cautious when removing valve⑺ ball and seat, avoid collision, falling and damaging of surface.
Note: Be cautious when removing up and down shaft to make sure well protected ball, avoid falling and collision.
3. AssemblyValve parts are taken out to get wiped and cleaned. After removal of dust and stain, the ball, sealing portion of seat surface and stem rotating section are recognized without injuries, besides, apparent defect or wear parts should be replaced. Also there should be no scratch on left and right binding valve body surface and left and right body surface with valve seat loaded. Before assembling the ball and seat should be paired grinded, the sphere flow holes should be grinded with synthetic diamond sand bar and cleaned to achieve sealing performance. Assembling should be carried out in the following order:① Floating Ball Type(Unidirectional)
Screwing the bolts into valve body.⑴ Installing the valve shaft bearing and trust bearing on the shaft, and press the shaft⑵
bearing with trust bearing for easy assembly. ⑶ Insert stem into stem hole through cavity of valve body, the stem top end will be at closed position. Insert valve seat gasket and outlet seat into valve body, and put conjunction gasket⑷ into body positioning end; ⑸ Insert sphere into valve body and valve stem, rotate the stem 2 or 3 times, let it self-aligning; Insert spring and inlet seat into left body, fold left and right body together.⑹ Screwing up connection nut evenly. ⑺ ⑻ Finally mount packing, packing ring , gland packing, and screw in packing gland bolts tightly, and properly tighten by using tools, then mount limit block, spring ring, handle lever, etc. Be cautious, no matter trunnion mounted or floating ball type,
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instead of tightening one packing gland bolts and another, the correct way is slightly tighten one of the first one, then tighten another one, and so forth, until the clamping pressure of packing ring, packing, packing gland bolts, to ensure the seal, rotating the valve stem to confirm smooth rotation.
Trunnion mounted ball type (bi-directional)2 Screw connection bolts into valve body. 3 Insert respectively seat, seal ring, spring into valve body, left body, and insert
conjunction gasket into seat positioning end; Mount antistatic spring into valve stem, and insert ball into valve body.⑶ Mount stem bearing on the up ending of stem.⑷ Insert up stem through up stem hole, the valve stem will be close position. Rotate⑸
stem 2~3 times, and have it automatically aligning. ⑹ Close the left and right body and relatively evenly tighten the coupling nut. Mount stem bearing on down stem, then insert lower stem into lower stem hole. ⑺ Screwing in bottom cap bolts, put in thrust bearing, then adjust gasket(Be cautious,⑻
the function of adjusting gasket is maintaining the distance of lower stem and bottom cap at between-0.2mm ~ +0.2 mm), bottom gasket and bottom cap, relatively tight bottom cap coupling nut.
Subsequently amount thrust bearing, adjust gasket⑼ (Be cautious, here the function of adjusting gasket is maintaining the interval of up stem and bottom cap at between+0.5mm~1mm mm ) , coupling gasket, connection plate, coupling screw into up stem, then tighten them slightly with tools, finally mount limit block, elastic ring, handle lever, etc.
②Trunnion mounted ball type( unidirectional)The medium in trunnion mounted ball (unidirectional) is flowing from left to right, and the sealing seat is located on left body. Unless customer has special requirements of exceptional. Screwing connection bolts in valve body.⑴ Mount stem bearing and antistatic spring on valve stem.⑵ Mount stem bearing on lower stem.⑶
4 Fasten the ball on the center of valve bady.5 Mount valve seat, seal ring, spring into left body, and insert conjunction gasket
into body positioning end, hold two parts of body, screw connection bolts tightly; 6 Screw in lower head bolts, put in thrust bearing and adjust gasket(Be cautious,
these adjusting gaskets aim to maintain -0.2mm ~ +0.2 mm distance between upper stem and lower head), insert bonnet cap and gasket, screw connection bolts tightly.
7 Mount thrust bearing and adjusting gasket(Be cautious, these adjusting gaskets aim to maintain +0.5mm~1mm distance between upper stem and ball), flange gasket, gasket, connection blots on upper stem in sequence and screw tightly. Insert packing, packing ring, packing gland and gland packing gasket into platform, and tight with tool slightly, finally insert block, flexible ring and handle lever, etc.
3. Testing methodAll valve inspection should undergo related standard pressure testing and guarantee testing time as per standard. Following inspection methods are recommended:
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Tightness test: Seal two ends of valve, keep semi-opening and insert a certain pressure of medium, keep pressure for a certain period, check the conjunction parts and see if there is any leakage on packing and shelf;
① High hydraulic pressure test: seal two ends of valve, keep semi-opening and input a certain pressure of medium, then close valve, connect one face with air to check if there is any medium coming out.
② Air tightness test: seal two ends of valve, keep semi-opening and input a certain pressure of air, close the valve tightly, connect one face with air, after releasing the rest air, check if there is any bubble coming out.
The judge on valve’s qualification is based on referenced standard.
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V、 Application method1. You are recommended to read operation manual carefully before the valve assembly.2. If valve operation is handle lever or hand wheel, clock wise rotation is opening,
anticlockwise rotation is closing.3. The way to distinguish the opening and closing state of valve and opening degree is
largely depend on location of handle lever and orientation of flat end. When handle lever is parallel with pipeline, the valve will present to be opening state, and when the handle lever is vertical with pipeline, the valve will present to be closing state. For pneumatic actuated valve, there is clear signal of valve opening degree and indication.
4. Flow directionOperator is required to abide by the typecasting instructions with flow direction on valve and nameplate when doing assembling. Or the using and performance will be affected and leading potential safety hazard. No typecasting instruction with flow direction on valve means installation at random direction.
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VI、 MaintenanceThe valve is recommended to be checked and maintained at regular intervals to
achieve its inherent function. Below maintenance points are supposed to be adhered to:
1、packing sealIf there is a little leakage on packing part, properly tighten packing gland bolts under condition of non-affect of torque. If leakage is not halted by properly tightening of bolt, valve is requested to be disconnected and check whether packing is abnormal. Packing is required to be replaced if found destroyed, meanwhile, if the ball valve is mounted with manual equipment, the inspection and disassembly should be undergone after dismantling of manual equipment. After all the parts are replaced, check the valve is switching to place. If not, adjustment should be done immediately.(for detail please see “IX”, the adjustment after amendment of manual ball valve)
2、body sealing partThe conjunction part of body and left body is of RTFE gasket. Tighten conjunction bolts can reduce leakage. If leakage is not reduced after tightening, the valve is required to be separated and check whether gasket is abnormal, the conjunction gasket should be replaced if it is destroyed.
3、seat sealing partIf there is leakage on valve seat, ball valve is required to be dismantled and checked
whether the ball and seat are destroyed or deformed, related parts are required to be replaced, please note no extra particles are allowed to enter into valve body cavity.
4 、 the ball and seat are required to be facing up after replacement, so that sealing performance is not affected.
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VII、Delivery and StorageDelivery:
The valve is required to be mounted during assembly and delivery, valve bumping should be avoided to prevent damage.Storage:
The valve is required to be stored on opening state, with good sealing capping at venting channel hole, pile up relay is forbidden, neither in a wet and closed air inside.
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VIII、 AssemblyPreparation before assembly
(1) Pipeline ends should be always ready for connection process, with front and back end concentric with line and two flanges parallel with sealing face. The pipeline should be completely sustainable of ball valve’s weight, or there should be appropriate supportive platform on the line. (2) Front and back pipeline should be swept clean, any grease dirt, welding spatter and
other particle should be swept off. (3) Ball valve and its mark should be checked and verified to make sure normal full opening and closing by repeat switch operations. (4) Dismantle protective parts on both ends of flanges. (5) Check all holes on the valve and clean probable stain. Because any tiny particle can
be damage to seat sealing face.Assembly (1) Pay attention to flow direction requirement when assembling valve on the pipeline. Manual operated ball valve can be mounted on any location of the line. However, ball valve with gearbox or pneumatic actuator operator must be mounted to stand on end (i.e. mounting the ball valve parallel with line and with actuator over the line. (2) The valve flange and pipeline flange should be mounted with sealing gaskets as per requirement.
(3) bolts on flanges should be symmetrical, subsequent and tightened equally.(4) Connect pneumatic connector (while pneumatic actuator is adopted).Checking after assembly(1) Operate actuator repeatedly to open and close valve, to make sure the valve is of
flexible and normal performance. (2) Check the sealing performance on the conjunctional face between pipeline and ball valve as per requirement.
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IX、 Adjustment of Manual Ball Valve after maintenanceAdjustment of Manual Ball Valve after maintenance places an important role in valve opening and closing location (may cause opening and closing not in place). Thus check on valve opening and closing location after maintenance and assembly should be carried out as per following debugging instructions: 1.Adjust opening location: Loose related adjusting bolts to full opening of valve, then tighten related adjusting bolts. 2.Adjust closing location: Loose adjusting bolts to full closing of valve, then tighten related adjusting bolts.
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X、 Precautions1, Customer is not allowed to set the valve at semi-opening state for a long period(t≥120 minutes). The valve should be opened in place to avoid damage to performance and affect flow function. 2, if the valve is used in a dangerous environment, user is recommended to use locking system to avoid mal-operation.3, accurate testing should be adopted as per related standard. 4, there shall be specific indication on special working condition while putting an order. 5, any particle should be wiped out when connecting the pipeline to avoid damage of sealing seat and guarantee valve performance.
6, all connector parts should be tightened equally while maintaining so that no extra force. 7, the pipeline should be assured of enough sustainability to valve weight, and extra supportive plate or bracket should be mounted when necessary.
8, pay attention to flow direction requirement on type casting and name plate when assembly, to make sure that medium flow direction is accordance with indicated direction.
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XI、 Trouble shooting
Malfunction Possible cause SolutionsShaft rotates rigidly and jammed
1. Over stress on packing2. Damage or accumulated
dirt between shaft and related parts
1. Loose bolts and re-adjust2. Disconnect to repair and
clean dirt3. Disconnect and clean
Leakage through seat or body
linkage flanges
1. Lack of pretightening force
2. Damage on sealing face or dirt
3. Deformation of seat or invalid
1. Increase pretightening force2. Repair and grind sealing face
and wipe dirt3. Replace seat
Leakage through packing
1. Lack of packing force2. Packing damage or
invalid
1. Tighten gland bolts2. Replace packing
Leakage on conjunction part
1. Flange bolts loose on conjunctional part
2. Conjunctional gasket damage or invalid
1. Tighten bolt 2. Replace conjunctional gasket
XII. Storage and Transportation
10.1. Products shall be stored in a dry and airy indoor where relative humidity is no more than 80%. Products shall not be exposed to ambient containing harmful substance which could lead valve corrosion.
10.2. Do not open packing until valve installation to prevent impurities entering inside valve with possible leakage.
10.3. Valve shall be secured firmly in transportation process with protective measures against rain and snow.
XIII. Quality Guarantee
Warranty period is executed as per relevant provisions in the firm contract. During warranty
period, all charges for maintenance and replacement resulted by the quality defects is
undertook by manufactures. If the malfunction is caused by improper operation of products
and not following the operation instruction stated in this document, all charges for
maintenance and replacement resulted from which shall be undertook by users.
IX. Service Commitment
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Linuo will keep tracking on performance satisfactory of product delivered and customer service to specific requirement is available upon request.
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