INSTALLATION, OPBRATION AND MAINTENANCE MANUAL FOR AIL TRUNNION MOUNTED BALL VALVES

1.

STORAGE AND HANDLING OF VALVES On receipt check that the valve is in fully assembled and in tact, The valve should be in open position to protect the ball surfacefrom any inadvertenthandling damage. Prior to shipment from the factory end protectorsare attachedto the inlet and outlet of each valve, for protection from mechanicaldamageand forprevention of the intrusion of dust and any other foreign objects into the valve bore, during transit. These valve end protectors should be kept intact and be removed only at the time of installation. Valve shouldbe storedin a coveredarea,which is dustfree,leasthumidandwell ventilatedplace. Always care portion shall be exercised to damagethe extended not of stem housing, gear units/actuators,which are very vulnerable to damage due to wrong or careless handling.Placing valvesdirectly on the groundor on the concrete floor is not recommended.Under no circumstances shouldthe valve be storedoutdoors.The valve should be kept on a wooden pallet at least 6 above the ground level. Always AIL Ball Valvesare shipped with balls in fully open position for protection of ball and seat ring surfaces.Valve should always be left open during the storageperiod.

Do not apply tar, paint, greaseor any other material insidethe valve, as this could impair the performance of the valrre. While transportingthe valve from storagearea to on installation site,it shouldnot be dragged the ground. For moving r,r'itha crane,valves shouldbe positively slinged u,ith a ll'ire around the valve body and end flangesor throughthe lifting lugsprovided.The crane r',.ire shouldnot be in direct contactwith valve operating gear units / actuators.Do not rope or chain through the valve port. ball / seat Negligence the abovecautionsmay cause of of seat or stem, rvhich will damageor deformation affect sealingand operationaltorque performanceof the valves.

2.

VALVE INSTALLATION removeall foreignmatterfrom the Beforeinstallation, pipelineby flushingthe line with rvateror compressed air. As normally any site are dusty and full of loose not ensure to removevalveendprotectors components, before valves are ready for mounting. inlets thoroughlyclean Afterremovalof endprotectors, pipes and valves so that flange and outlets of bc.th gasket faces are free from dust, which may affect sealingperformance. Any scratchor defecton gasketcontactfacesofvalve flangesand pipe flangesshouldbe carefully detected and corrective actions like applying sand paper or grinding stoneto make the surfacesmoother,shall be done.

Do not rope or chain tluough the valve port Before couplingthe flanges,first align bolt holes of w.iththoseofpipe flanges(ie companion valve flanges flanges),then insert gasketsand tighten bolts. Rnfu, lot'que and the necessar)' bolt tighteningsequence (clnrts attaclrcd).Theseshall be strictly follou'ed to pipe and valve. If the ensurea leak tight joint betrveen unbalanced valve andpipesarenot alignedaccurately, stresson bolts and tighteningu,ill causeexcessive hence the alignment should be ensured. For largerflangedvalves,rvhichareprovidedrvith foot support,first the flangesare to be alignedand bolted rvith the pipe flanges.Then only the ground/ pedestal supportto be broughtup to the foot supportofthe valve. The foot support need not be bolted on the floor. In general,installation of a flanged valve does not beyondthosenormally usedfor the requireprocedures installation of flanged fittings. The valve may be installed in any position and either end of the valve The most ideal orientation may be installedupstream. for a ball valve. For a rveldendvalve,it shouldbe installedin theFULL OPEN POSITION. If the valr.emust remain closed during installation, extra care shall be exercisedto ar.oid weld spatters falling on the ball surface. Alignment of the valve with the pipe must be as accurateas possible so as to get a most favorable condition for weld deposition.

CAUTION : temperotures in excessof 100 deg C in the seat ring area will result in sest ring damage Temperoture indicatirtg crayons shotrld be used to monitor and control temperature in this area during welding.

3.

VALVE OPERATION Ball valves are 90 deg operationopen.ie quarterturn of the ball makesthe valve eitherfully openor close. Valves do not have any preferreddirection of or installation.Easiness proximity of handwheel rvhile fixing the consideration, operationis the only r.alve on to the pipeline. Refer general assentbly drawing of a geur operatecl ball valve for the understancling intental construction. Normally clock'*'iseoperation is for close and antithe for clockwiseoperation open.By observing position the indicatorprovided on the gearunit or the actuator, positionof the valve canbe ascertainedopenor close AIL trunnion mountedball valves are generallyfitted with a self locking gearunit, for a manually operated rvhich gives a multi-turn valve. Electric actuators, drives output,arefitted on the gearunit, so the actuator the input shaft of the gear unit, rvhich in tum drives with the ball- A hat the valve stem. Stem is engaged s t e m e n g a g e sw i t h a milled projection of the femalemilled slot on theball, andhence corresponding any rotary motion of the stem has to rotate the ball' Gear units have in-built mechanicalstopper screws, for settingthe exactopenandclosepositionof theball.

In the full;, openpositionof the valve, the ball bore shouldexactlyalign rvith valve bore, as otherwisethe pig can get stuck during the pigging operation. The stopperscre\vs factorysetto exactopenandclosed are positions. over are Pneumatic/gas/gas oil actuators fitted directly gear unit, as valve, u,ithout a separate on top of the these actuatorsthemselvesare quarter turn devices. Ball valves are NOT recommendedfor throttling free flow of fluid sen'ice.They arefor eitherallor.ving or to totallycut it off. If the ball is left half open/close it r.vill lead to hearrverosionof both the ball and seat rings and hence causeheavy leakage. Trunnion mountedball valves are generallyupstream Both the seats floating andcapable are sealingvalr.'es. in of axial movement the pipe axis.The seatrings are kept pressed the ball by meansof flat springs.This to that valves are capableof passingthe featureensures andbleedtestrequirements. Henceonline doubleblock whenthevalve bleedingofthe vent or drainis possible, is in FULL OPEN or FULL CLOSEposition.By this r.vay is possibleto periodicallyensurethat both the it valve seatsare sealinsor not. ON - LINE MAINTENANGE AIL TRUNNION MOUNTED ball valves are free.Horvevermaximum valve potential maintenance can be realized through the use of the maintenance procedures outlined in this section.

4.

4.1

BLOCK AND BLEED AIL ball valves are provided rvith vent and drain httings/ r,alves.It is reconmendedthat periodically the vent and drains are openedand flushed using a of compatible/ inert medium to preventaccumulation dirt/debris in the body cavity leading to the erosion designof ln of intemal sealingsurfaces. the standard of connections the valve pipelineball valves,threaded body for drain and vent lines are sealedby threaded plugs.Theseshouldnot be removedaslong asthevalve is under pressure. the valve body However u'ith line under pressure, and completely cavity can be vented to atmosphere Off drAiNCd W'iththc BALL IN CLOSED POSITION as follorvs Close the ball rralve. ventplug is provided, 2. Opentheventvalve.If special plug. fully remove the l. 3. Open the drain valve, at the bottom. 4. Allorv the flushing medium into the body cavity throughthe vent hole, allowing for drainagethrough the drain valve. 5. Continueflushing till all dirt/debrisare completely evacuatedfrom the cavitlr

4.2

PERIODIC MAINTENANCE to is Periodicmaintenance performedaccording a plant that is convenientaswell asto keepthe valve schedule in good working condition and realize full unit life. Longer seatlife and easieroperationcan be obtained abrasive This reduces is if sealant injectedperiodically.

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w'earby providing a this film of lubricantof mating sealingsurfaces.Dependingon the severityof the that sealant sen'ice environment,it is recommended inten'als.While month or lesser be injectedoncee\,'ery try charging rotatingtheball througha small angle(say 10 deg ) and return it back to the original position. due to operationin abrasiveor extreme Sealdamage, servicesenvironments,may eventually result in leakage Unlessthe valve is severelydamaged, leakage. in by canbe stopped injectingsealant the appropriate stem. areasof seat and

4.3

Seat leakage into the is Seatleakage controlledby injecting sealant injection system(seebelou' for seatsealant secondary description) the notethata leakacross seatcannotbe arrested Please turns of the ltand wheel (as in a gatevalve). by extra of Because high gearratio and mechanicaladvantage torquescan be appliedon of the gearunits, enorrnous the to the stem,and can damage stem or the gearunit is Only applicationof sealant the right stopperscrews. answerto arrest/haltthe seat leakagemomentarily.

4.4

Stem seal leakage can Stemsealleakage usuallybe controlledby inj ecting stem sealantinto the stem housing.refer sketch stent seal system provision of sertlant injection facility. for sectionif sealantdoes Refer to stem sealreplacement not control leakage.

STET,{ SEALANT PROVISION

Stem Seal System

4.5

STEM SEAL REPLACEMENT

It is desirable that the valve be relievetl of presstue prior to seal replacement If this is not possible, get in touch with AIL or their authorised service rep resent a t ive for addit i ona I info nn at i ort. After checking to ittsure that no pressure is trappecl in the valve, exercise thefollowing steps in replacing the stent seal. AIso refer the sketch ,'Stemseal svsteni, l. note the positiort of the gear unit in relation to the valve, and rernove it. preferablv the ntechanical stopper screws in the gear unit is not distttrbed. however if essentialll,such a clisturbance is neecledthe position shull be marked to facilitate exuct resetting wlrcn reinstalling the gear urit 2. Remove the kev and its retaining screu, antl washer. if provided.

BODY i CONNECTOR

SEAT SEALING SYSTEM 3. Loosen all the hexagonalcap screws,which hold

the gland. removethe gland from its place' 4. Takeout both the graphite seals (t*-o nuntbers)' J. Keep the new graPhite seals6. Place the gland back in its place and tighten all the cap screws. Diagonall-v opposite screws shall he tightened in sequenceIt is advisableto conducta stemseal leaktest (before fixing the gear unit), it shall be done as follows' Pressurisethe body cavity ( either through the clrain or vent) using 80 to t 00 psi air or nitrogen.As the valve is in fiilly open or dose condition, the cavity will getfully pressurisedupto the stemseals-Apply soapsolution on top of thegland to ensureno leak' backin itsposition, Nov'gear wit shall be rnounted orientatiortafter ensuring correct
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5.0

SECONDARY SEALING SYSTEM Following comprisesthe secondarysealing system

5.1

SECONDARY SEAT SEALING SYSTEM Refer sketch"seatsealingsystem".Both the seatsare providedwith sealant (specialgrease) chargingfacility (two button head injectors can be easily noticed, protruding out of the valve body, one for each seat). The sealant charged passes throughtheinjector, check a valve and through a small drilled hole into the seat ring and reachesthe seatingsurfaceofthe seat ring, which contactsthe ball. The charge gets uniformly distributedon the seatsurfhcethrougha circulargroove. A film formed on the seating surface provides for immediate emergency and sealing ofa leakingseatring. SECONDARY STEM SEALING SYSTEM The stem housing is provided with one packing fted injector,very closeto the valve cover flange. Special graphitebased stick sealant be screwed can insideafter removing the grub screw inside the injector. This sealantgoes directly on to a groove provided in the stemouterdiameterandhenceforms a packingaround t h e s t e m . O n c e t h i s p a c k i n g i s i n j e c t e d ,o n l i n e replacementof the top rin-eis possible. AIL trunnion mottnted ball valt'es(si:esB,,andlargerl are alway,s pt'ovided v'ith the abot'e referred sealant injectionfacili4'for both seatsos well as for stem. This is an extremeb,useful emergency facility. In the unlikely event of a leakage ecross the seat, charge sealant No. 735 or 1033. using a sealantgun.

5.2

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6.

REGULAR MAINTENANCE removal of Theseare major repairsu'hich necessitate of valve from the pipeline, such a replacement ball, that such repairs suggested seatrings, stem etc it is are undertaken only under the direct xtpentision of AIL ser,,ice engineer. Beforeremovalof valve from thepipeline'thepipeline DEPRESSURISED'Also vent/ is to be necessarily drain off the body cavity handling equipment as requiredfor the weights involved shall be ascertained from recordsidrawings.Valve shall be suitably and correctlyslinged,beforestartof flangebolt loosening' Onceall the flangebolts areremoved,move and place the valve safelyon to a rvoodenplatform and shall be to transported the repair shop.It is advisableto keep the valve in fully open position and rvith the end protectorsin place, while in storage,till serviceis undertaken. RECOMMENDED SPARES are that following minimum spares It is recommended availablewith the customer - one soft sealkit comprisingof rings, nylon insert, gland packing and gaskets - one set of bearings and thrust washers - suffrcientquantity of emergencysealant.

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