COMEVAL, S.L. www.comeval.es Technical Dept. Ref. MEP-BV-01/04 Comeval, S.L.

reserves the right to alter any technical data contained in this leaet without prior notice.

INSTALLATION, START-UP AND MAINTENANCE HANDBOOK

BALL VALVES

BALL VALVES

BALL VALVES

1. GENERAL INFORMATION. WORKING PRINCIPLE AND DOCUMENTATION. BV Ball Valves are devised to stop the ow. The valves close by turning the handle 90 clockwise. The valves are engineered to match standard operational duties, in the event of special duties such as aggressive or abrasive media, high pressures or temperatures, etc., it is the plant engineer and / or purchaser responsibility to check that the selected valve be suitable to the application as well as the dimensional, pressure, temperature and material compatibility parameters. BV Ball valves are designed, manufactured and tested in conformity to the most strict quality standards that the DIN EN ISO 9001 standard dictates. All valves are subject to individual hydro and leakage tests at our QC Dept in conformity with EN 10.204 / 2.2. The testing medium is water at room temperature. Each manufacturing lot is strictly controlled by our Quality Section at the plant before dispatch. Extensive reports as per EN-10.204/3.1B are lled out and are submitted to the Purchase if required before dispatch. Moreover, witness testing carried out by Notify Bodies are arranged upon request at our modern Testing Facilities. Valves conform to PED 97/23/CE. Please consult our Data Sheets for specic information about the valve performance details. Factory reserves the right to alter or implement new product modications at any time. Our Data Sheets can be freely down loaded via Internet www.comeval.es/esp or calling our sales department +34 96 147 90 11. 2. GUARANTEE. BV are guaranteed against any manufacturing default in accordance to the Sound Engineering Practice and provided the application, installation and maintenance operations have been properly followed. No claims derived from a wrong handling and / or lack of observation of Technical Rules will be accepted. The guarantee coverage does not apply to eventual damages caused by operation under duties other than stated at our Data Sheets. Our guarantee Coverage does not cover for any commissioning or in site maintenance jobs or either products proved to have been tampered or faulted by material wear down. The buyer is responsible to check that the in-coming product is received in good condition and in conformity to the ordered specications, otherwise an immediate complain must be issued to the carrier or our Company at +34 961479011.

COMEVAL, S.L. www.comeval.es Technical Dept. Ref. MEP-BV-01/04 Comeval, S.L. reserves the right to alter any technical data contained in this leaet without prior notice.

BALL VALVES

3. ESSENTIAL SAFETY GUIDELINES. - Do not install the valves before having carefully read this Operating Manual in order to avoid prospective damages to people and property. Always use the valves within the scope of intended service and operating duties as per described in our data sheets, essential safety working regulations are to be strictly kept. - Only qualied personnel should start up and regularly follow maintenance jobs at the plant. Any deviation from the usual installation guidelines should be notied to us for recommendation and approval. 4. PRESERVATION, STORAGE & TRANSPORTATION. Avoid extreme temperatures, high environmental humidity or corrosive environment. Keep the valves away from dust, ames or rain to avoid rust of the valves surface. All valves are primed coated by a paint layer against corrosion during transport and storage, do not harm this layer. Exception: stainless steel ball valves. Avoid hitting or external vibrations, specially on the weak components such as handles or worm gears. Do not pile up excessive weight. Do not use fragile parts such as handles to lift up or pull valves. Always use right handling equipment, weights are stated in the Data Sheets. 5. INSTALLATION.
COMEVAL, S.L. www.comeval.es Technical Dept. Ref. MEP-BV-01/04 Comeval, S.L. reserves the right to alter any technical data contained in this leaet without prior notice.

Bear in mind the following guidelines along with general installation practices: Allow for enough space to ease maintenance operations. Remove the protective caps if they were still t in. Ensure that the valve inner side is dust free and no foreign matter had come in. Protect the valve seats from heating caused by welding works at the plant during commissioning. - These valves are generally bi-directional , otherwise, please check the ow arrow and valve marking. Avoid gradients, excessive rotation and pipe misalignment that could cause pipe stress once installed in the pipe work; in this sense weight of the valve should not be supported by the pipe except for small diameters. For anged valves, counter-anges should t smoothly. The same applies to screwed and welding end connections. Stem can be installed in any position, better vertical with handle upwards, specially for dangerous or corrosive uids. Same as with preservation and storage do not use fragile parts such as handles to lift up or pull valves. - All steam systems in the plant should be designed to prevent condensate depots which could lead to water hammers. Should valves are to be operated by actuators, follow the instructions given in the specic actuator manual. Should the stem position was horizontal, anchoring should be required depending on the complete valve and actuator assembly weight. - For 2 and 3 pieces ball valves, valves should be installed with ball in open position, -

BALL VALVES

making sure that the parts are perfectly aligned. Tighten bolts in an uniform and crosswise manner. A minimal eccentricity between valves makes the ball turn asymmetric and results in irreversible damage of the seats by effect of the ball push at closing thus causing seat leakage. For Weld end valves, clean carefully valve and pipe connections, tack-weld the valve on the pipe in four points on both end caps, putting trim away to prevent heat exposure. Once the welding process be over, wait till system cools down before inserting the trim back. Welding works should be carried out by qualied personnel and following Safety Regulations. For Screwed end valves, make sure the pipe screw has the correct nish and compatible cone with the valve, as per DIN259, NPT, etc. Use conventional sealant, such as hemp core, Teon, etc. Use wrench and apply force on the hexagon end of the valve only. Apply force to other area of valve may seriously damage the valve. Valve should be threaded smoothly. If not, do not try to force the thread in order to avoid valve broken.. For Flanged end valves, make sure that counter-anges are compatible with the standard of the valve anges. Select the proper gaskets according to the duty. Tighten in a crosswise, moderate and uniform manner. During start up tighten again if leakage is noticed. Do not force the counter-anges and not try to tighten the bolts when a gap exists between valve and pipe, or if misalignment is observed, to avoid tensions that may broken the parts. For wafer connections, make sure of proper centring of the valve between counteranges. Properly hold the valve to keep the centring and avoid its falling during tightening. Follow rest of precautions as above mentioned for Flanged end valves. - Once the valve installed, make an initial opening and closure manoeuvre to check its proper performance.
COMEVAL, S.L. www.comeval.es Technical Dept. Ref. MEP-BV-01/04 Comeval, S.L. reserves the right to alter any technical data contained in this leaet without prior notice.

Project engineers and contractors are responsible for the proper placement and commissioning of the valve.

BALL VALVES

6. START-UP. Before start-up, ensure that the material, pressure design, temperature design, ow direction and other essential parameters are correct in conformity to the process. Ensure that the valve is placed in its correct position before tightening the nal assembly. Observe all local regulations concerning the labour risks and essential safety protection at the plant. - Temperatures above 50C or below 0C may cause personnel injures if valves are touched. Ensure that the corresponding warning signs are displayed in the valve or surrounding site. During the rst lling and heating, check for signs of process leakage, including the potential leak paths at both end connections, at the split body connection, and on the shaft. If process leakage is found tighten gradually and in crosswise manner till leakage disappear. Avoid remains of welding and dirties ushing through the system as it would damage the valve seating if trapped between ball and seat. 7. MAINTENANCE AND REGULAR CHECKING. Maintenance and corresponding intervals should be dened and scheduled by the plant operation personnel according to service level. It is highly recommended to operate the valve at least once a month, and generally as often as possible, to avoid torque increase and prevent from deposits.
COMEVAL, S.L. www.comeval.es Technical Dept. Ref. MEP-BV-01/04 Comeval, S.L. reserves the right to alter any technical data contained in this leaet without prior notice.

Always wait the valve medium to cool down before starting any maintenance job at the plant, release the pressure from the system, drain the line and pipe system in the event of toxic, corrosive, ammable or caustic uids. Please review the valve seat surface and the ow passage as well as the stem packing. Seats, packing, gaskets, ball and stem can be easily dismounted by using common tools. When dismounting side entry split body valves, it is advisable to mark the parts to ensure a better alignment when mounting again. Firstly separate the halves by removing the body bolting. Then manual operator or actuator should be removed. Once the operator removed, the stop collar and associated washers can be removed from the top-works. Then relieve packing-box compression by removing packing bolting. Turn the valve to the closed position. Remove the seats and the ball should slide out through the body port with a gentle push. Push the stem downwards and stem packing and remove through the body port. Place all removed parts in a clean and secure place. Before mounting again bearing in mind chapter 5 (Installation) guidelines, be sure that seats and gaskets surfaces are free from dirty. Follow the above steps in the reverse order to reassemble the valve. Seats should perfectly t; if necessary slightly strike with a soft hammer. Once mounted, slowly operate the valve till a complete manoeuvre is covered, to allow perfect adjustment between ball and seats. Operate again the valve once tightened to check that operating torque is not excessive.

BALL VALVES

Recommended tightening torques for bolts depending on the metric are as follows: M8 28 Nm; M10 50 Nm; M12 70 Nm; M16 200 Nm; M20 250 Nm. PTFE seats are self-lubricating so no additional lubrication is required. Image below shows the view of a typical split body anged ball valve:

COMEVAL, S.L. www.comeval.es Technical Dept. Ref. MEP-BV-01/04 Comeval, S.L. reserves the right to alter any technical data contained in this leaet without prior notice.

If the stem (8) is leaking, gradually tighten the packing with packing bolts till leakage disappear. If not possible, dismount the handle, loose cover bolts, stem nut (14), disc (12) and o-rings and closely examine packing and surfaces for any scoring or process damage. Light damage may possibly be corrected by polishing the affected area. Extensive damaged will require new parts. Anyway packing should be changed. In case of leakage through the seats, rstly operate the valve to sweep dirty trapped between ball and seat. If the problem doesnt disappear, dismount two halves (1) and (2) to inspect ball (6), seats (5), and seat surfaces. Remove the ball and check for damage by erosion or other defect, replacing if necessary. For dangerous uids, test in a bench before installing again. If leakage is detected at end connections or between the halves of the valve, make sure of correct alignment and check for equal compression in all the contact surface and then gradually tighten. If leakage could not be stopped gaskets should be changed.

BALL VALVES

8. RECOMMENDED SPARE PARTS To be dened in view of plant size, duties, how critical the service is and their working peaks, etc. Not being costly valves, it is advisable to foresee complete valves as spare parts. It is convenient as well to foresee a set of gaskets per valve for proper maintenance works.

COMEVAL, S.L. www.comeval.es Technical Dept. Ref. MEP-BV-01/04 Comeval, S.L. reserves the right to alter any technical data contained in this leaet without prior notice.

BALL VALVES

TROUBLE SHOOTING CHART

SYMPTOM No ow Little ow LIKELY REASON Valve is closed End covers still placed Ball not open enough Upstream strainer basket clogged with dirties Clogged pipe lines Atmospheric Leakage Stem packing seals or sealing surfaces are damaged or worn down CORRECTIVE ACTION Open the valve Remove end covers Keep on turning the handle or actuator. Clean/replace the spare basket Check pipe lines Tighten the packing trying to eliminate leakage If necessary check surfaces and replace packing (10). Stem jamming, very high operation torque Working duties are beyond permissible parameters (medium, temperature, etc.) Stem (8)not lubricated enough Wrong turn direction (opposite) Remove the valve and consult factory or the nearest BV distributor Proceed to lubricate Turn in the correct direction (valve open being handle parallel to pipe, clockwise direction to close). Slightly loose packing slightly making sure there is no leakage Slightly loose bolts making sure there is no leakage Tight the lever rmly without using any wrench Open and close again to sweep dirty. Install a strainer upstream. Replace seats Check working conditions and actuator torque Install a new valve, making sure of proper alignment of pipe and halves as well as proper tighten.

Packing too tightened Body bolts too tightened Seat Leakage Valve is not properly closed Dirty trapped between ball and seat
COMEVAL, S.L. www.comeval.es Technical Dept. Ref. MEP-BV-01/04 Comeval, S.L. reserves the right to alter any technical data contained in this leaet without prior notice.

PTFE seats damaged Too high differential pressure End connections or halves connections broken Pipe and/or halves misalignment. Bolts not uniformly tighten or too tighten.