AOP D Series User manual

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CONTENTS
1. Parts list……………………... 2
2. Description……..…………… 10
3. Safety information’s…….……… 10
4. Installation and storing… 10
5. Operation …….……… 12
6. Maintenance…………………. 12
7. D valve Reconditioning……… 14
7.1 D valve disassembly………. 14
7.2.a. Lever valve assembly …… 16
7.2.b. Gear valve assembly …… 19
8. Troubleshooting.......................... 21
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
AOP SERIES D TRUNNION BALL VALVE, 2”FP – 6”RP

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Figure 1 – D Series-Standard Seat (class 150-900) – BARE STEM
(see parts list below)

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Parts list – D Series Standard Seat 150-900 class– BARE STEM (reference
Figure 1):
Item Qty Description
1 1 BODY
2 1 ADAPTER- CLOSURE
3 1 BALL
4 1 STEM
5
1
LOWER T
RUNNION
6 2 SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT)
7 1 BONNET (GLAND PLATE)
8 1 ADAPTER PLATE- GEAR
9 * ADAPTER STUDS
10 * ADAPTER NUTS
11 * CAP SCREW SOCKET HEAD- BONNET
12 * CAP SCREW SOCKET HEAD- LOWER TRUNNION
13 * CAP SCREW SOCKET HEAD- ADAPTER PLATE
14 1 O-RING, ADAPTER
15 1 O-RING, STEM
16 2 O-RING – SEAT MAIN SEAL
17 1 O-RING, BONNET
18 1 O-RING, LOWER TRUNNION
19 1 BACK-UP RING, BONNET (NOT SHOWN- 900/1500 CLASS
ONLY)
20 1 BACK-UP RING, STEM (NOT SHOWN- 900/1500 CLASS ONLY)
21 1 BACK-UP RING, TRUNNION (NOT SHOWN- 900/1500 CLASS
ONLY)
22 1 BACK-UP RING, ADAPTER (NOT SHOWN- 900/1500 CLASS
ONLY)
23 1 FIRE SAFE SEAL, TRUNNION
24 1 FIRE SAFE SEAL, ADAPTER
25 1 FIRE SAFE SEAL, BONNET
26 1 FIRE SAFE SEAL, STEM
27 1 GLAND BUSHING
28
1
BEARING RADIAL
–
DU
-
STEM
29 1 BEARING RADIAL – DU - TRUNNION
30 1 BEARING THRUST – DU - STEM
31 2 SPRINGS- SEAT
32 2 DRIVE PINS - STEM
33
34 2 TORQUE PIN
35
1
STEM KEY
36 1 FITTING- STEM
37 1 VENT/ DRAIN FITTING
38 1 BODY GREASE INJECTION FITTING
* QUANTITIES DEPENDING ON SIZE AND CLASS

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Figure 2 – D Series-Standard Seat (class 150-900) – LEVER OPERATED
(see parts list below)

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Parts list – D Series Standard Seat 150-900 class– LEVER OPERATED
(reference Figure 2):
Item Qty Description
1 1 BODY
2
1
ADAPTER
-
CLOSURE
3 1 BALL
4 1 STEM
5 1 LOWER TRUNNION
6 2 SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT)
7
1
BONNET (GLAND PLATE)
8 1 LOCKING BEARING HOUSING FOR 2FP UP 4RP VALVES —OR
ADAPTER PLATE- GEAR FOR 4FP AND 6RP VALVES
9 * ADAPTER STUDS
10
*
ADAPTER NUTS
11 * CAP SCREW SOCKET HEAD- BONNET
12 * CAP SCREW SOCKET HEAD- LOWER TRUNNION
13 * CAP SCREW SOCKET HEAD- BEARING HOUSING OR
ADAPTER PLATE (SEE ITEM 8)
14 1 O-RING, ADAPTER
15 1 O-RING, STEM
16 2 O-RING – SEAT MAIN SEAL
17 1 O-RING, BONNET
18 1 O-RING, LOWER TRUNNION
19 1 BACK-UP RING, BONNET (NOT SHOWN- 900/1500 CLASS
ONLY)
20 1 BACK-UP RING, STEM (NOT SHOWN- 900/1500 CLASS ONLY)
21 1 BACK-UP RING, TRUNNION (NOT SHOWN- 900/1500 CLASS
ONLY)
22 1 BACK-UP RING, ADAPTER (NOT SHOWN- 900/1500 CLASS
ONLY)
23 1 FIRE SAFE SEAL, TRUNNION
24 1 FIRE SAFE SEAL, ADAPTER
25 1 FIRE SAFE SEAL, BONNET
26 1 FIRE SAFE SEAL, STEM
27 1 GLAND BUSHING
28 1 BEARING RADIAL – DU - STEM
29
1
BEARING R
ADIAL
–
DU
-
TRUNNION
30 1 BEARING THRUST – DU - STEM
31 2 SPRINGS- SEAT
32 2 DRIVE PINS - STEM
33 1 STOP PLATE
34 2 TORQUE PIN
35
36
1
FITTING
-
STEM
37 1 VENT/ DRAIN FITTING
38 1 BODY GREASE INJECTION FITTING
39 1 SNAP RING
40 1 STOP PLATE CAP SCREW- ONLY ON 4FP AND 6RP VALVE
41 1 LEVER SUBASSEMBLY- NOT SHOWN
* QUANTITIES DEPENDING ON SIZE AND CLASS

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Figure 3:D Series Bare Stem Valve – Lubricated Seat - 1500 Class

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Parts list: D Series Lubricated Seat 1500 class– BARE STEM
(reference Figure 3):
Item Qty Description
1 1 BODY
2
1
ADAPTER
-
CLOSURE
3 1 BALL
4 1 STEM
5 1 TRUNNION
6 2 SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT)
7 1 BONNET (GLAND PLATE)
8 1 TRUNNION COVER
9
1
GEAR PLATE
10 * ADAPTER STUDS
11 * ADAPTER NUTS
12 * CAP SCREW SOCKET HEAD- BONNET
13 * CAP SCREW SOCKET HEAD- TRUNNION COVER
14 * CAP SCREW SOCKET HEAD- ADAPTER PLATE
15 1 O-RING, ADAPTER
16
1
O
-
RING, STEM
17 2 O-RING – SEAT MAIN SEAL
18 2 O-RING – SEAT SECONDARY SEAL
19 1 O-RING, BONNET
20 1 O-RING, TRUNNION
21 1 BACK-UP RING, BONNET
22 2 BACK-UP RING, SEAT MAIN SEAL
23
1
BACK
-
UP RING, STEM
24 1 BACK-UP RING, TRUNNION
25 1 BACK-UP RING, ADAPTER
26 1 FIRE SAFE SEAL, TRUNNION COVER
27 1 FIRE SAFE SEAL, ADAPTER
28 1 FIRE SAFE SEAL, BONNET
29 1 FIRE SAFE SEAL, STEM
30 1 GLAND BUSHING
31 1 BEARING RADIAL – DU - STEM
32 1 BEARING RADIAL – DU - TRUNNION
33 1 BEARING THRUST – DU - STEM
34 2 SPRINGS WAVE - SEAT
35 2 DRIVE PINS - STEM
36
37 2 TORQUE PIN
38 1 STEM KEY
39 1 FITTING- STEM
40 1 BODY VENT/ DRAIN FITTING
41 2 SEAT GREASE INJECTION FITTING
42
2
INTERNAL CHECK VALVE (BELOW GREASE FITTING)
43 1 BODY VENT PLUG
* QUANTITIES DEPENDING ON SIZE AND CLASS

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Figure 4 – D Series Lever Operated Valve – Lubricated Seats – 1500 Class

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Parts list – D Series Lubricated Seat 1500 class– LEVER OPERATED
(reference Figure 4):
Item Qty Description
1 1 BODY
2
1
ADAPTER
-
CLOSURE
3 1 BALL
4 1 STEM
5 1 TRUNNION
6 2 SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT)
7
1
BONNET (GLAND PLATE)
8 1 TRUNNION COVER
9 1 LOCKING BEARING HOUSING FOR 2FP UP 4RP VALVES —OR
ADAPTER PLATE- GEAR FOR 4FP AND 6RP VALVES
10
*
ADAPTER STUDS
11 * ADAPTER NUTS
12 * CAP SCREW SOCKET HEAD- BONNET
13 * CAP SCREW SOCKET HEAD- TRUNNION COVER
14 * CAP SCREW SOCKET HEAD- ADAPTER PLATE
15 1 O-RING, ADAPTER
16 1 O-RING, STEM
17
2
O
-
RING
–
SEAT MAIN SEAL
18 2 O-RING – SEAT SECONDARY SEAL
19 1 O-RING, BONNET
20 1 O-RING, TRUNNION
21 1 BACK-UP RING, BONNET
22 2 BACK-UP RING, SEAT MAIN SEAL
23 1 BACK-UP RING, STEM
24
1
BACK
-
UP RING, TRUNNION
25 1 BACK-UP RING, ADAPTER
26 1 FIRE SAFE SEAL, TRUNNION COVER
27 1 FIRE SAFE SEAL, ADAPTER
28 1 FIRE SAFE SEAL, BONNET
29 1 FIRE SAFE SEAL, STEM
30 1 GLAND BUSHING
31 1 BEARING RADIAL – DU - STEM
32 1 BEARING RADIAL – DU - TRUNNION
33 1 BEARING THRUST – DU - STEM
34 2 SPRINGS WAVE - SEAT
35 2 DRIVE PINS - STEM
36 1 LOCKING STOP PLATE
37 2 TORQUE PIN
38
39 1 FITTING- STEM
40 1 BODY VENT/ DRAIN FITTING
41 2 SEAT GREASE INJECTION FITTING
42 2 INTERNAL CHECK VALVE (BELOW GREASE FITTING)
43
1
BODY VENT PLUG
44 1 SNAP RING
45 1 STOP PLATE CAP SCREW- ONLY ON 4FP AND 6RP VALVE
46 1 LEVER SUBASSEMBLY- NOT SHOWN
* QUANTITIES DEPENDING ON SIZE AND CLASS

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2. Description
D series ball valves 2” FP to 6” RP are full bore, through conduit, bi-directional, anti-blowout stem,
double block and bleed with trunnion mounted ball for easy operation.
These valves are equipped with seats with plastic insert; self relieve type seats to eliminate cavity
pressure lock. The trunnion ball valve uses metal- backed self lubricating PTFE sleeve bearings and
thrust washers to reduce torque. The stem and lower trunnion is separated from the ball to eliminate
side loads.
The lever and wrench head can be easily removed/ reassembled by means of set screws.
The handwheel can be removed from the gear shaft by taking out the split pin.
3. Safety Information’s
Valves shall be operated and maintained strictly in accordance with these procedures. Operation or
maintenance outside of these procedures constitutes abuse of the product and voids all warranty and
claims.
When special operation is required, a formal written request to the company must be made for
approval to operate in this manner if warranty and product liability is to be maintained.
Before any work is performed on a valve, personnel working on the valve must obtain the proper work
permits required by his employer. Personnel shall always use safety precautions set forth by the law
and regulations required by his employer. Personnel shall also be aware that any venting or draining of
fluids from the valve shall be done in accordance with safety and environmental procedures in force at
the particular location.
The maintenance personnel doing the repairs should be well trained, and familiar with all of the
information contained in this manual.
The valves shall be appropriately used for the intended purpose. Any safety or protection devices on
the valve shall not be permanently removed or altered unless written approval is received from AOP
representative.
Transport, unpacking, lifting, connections to the different types of systems (electric, pneumatic,
hydraulic systems, etc.) shall be made by expert and qualified personnel
Should any difficulties or abnormalities arise which cannot be solved by the technician, contact AOP
representative.
Any servicing not covered by these instructions must be made by an authorized service center, after
preliminary approval has been given by AOP representative.
4. Installation and storing
Valves delivered by AOP
After the valves have been assembled and tested, the valves are drained and painted.
Sealing surfaces of connection flanges are greased and covered by protectors.
All valves are delivered in fully open position, unless is actuated with a normal close position actuator.
If the valve is lever operated, the lever may be separately packaged for easier handling and
transportation.
If the valve has a gear operator, the gear is installed on the valve and factory adjusted for open and
closed position. The gear handwheel may be separately packaged for easier handling and
transportation.

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All D valves should be stored in full open position as received, with the flange seal surfaces and the
bore greased, and the protectors installed on the flanges.
Before installation
Ensure that, during transportation and before installation, grease fittings and sealing surfaces of
connection flanges are not damaged.
Remove the connection flange protectors and ensure that no foreign materials are inside the valve bore.
If pressure tests are conducted before installation, drain the valve to remove testing water.
Installation
Clearly identify the valve through its data plate, check its weight with the packing list or relevant
documents and then place it on a horizontal surface, using suitable handling equipment.
Handling equipment must be provided which is appropriate for the total weight of the package.
For D valves small size, light valves, use the line flange holes if the valve has flanged ends. Do not use
lifting lugs or eyes provided on the gear or actuator, if present.
Pay particular attention that slings do not damage the gear or actuator.
Lift the valve and put it on a plane, horizontal surface, take care to avoid damaging the valve
connections by using wooden saddles or other suitable equipment.
To avoid the ingress of debris or sand into the ball and seat area the protective covers should not be
removed until the valve is ready to by installed in the line. When the valve needs to be installed in the
line take away the protective plastic or wooden flange protectors.
During installation the valve must be fully open and the line sections, between which the valve will be
installed, must be aligned, clean and correctly spaced. Should the valve be closed, the exposed face of
the ball must be protected with grease or other anti-adhesive product.
When the valve has butt welding ends, welding on the line must be performed using the proper
welding procedure. After welding, clean and check the weld bead and repair as required.
AOP D valves may be installed in any position with either end facing upstream. The valve should be
installed in such a way as to facilitate maintenance and actuating operations.
When installing the valve allow for possible deformations caused by the expansion of the line. The
valve must not support the line. Avoid any strain in the valve body.
CAUTION: Do not overload the valve beyond the design piping loads stated on the
requirements.
Use studs, nuts and raised face gaskets or ring joints, as per size and class conforming to ASME B16.5.
Tighten the studs alternately, cross pattern method, several times, using the torques recommended by
ANSI or gasket manufacturer specification.
Field testing: when field testing is required the following procedures are recommended:
-Ensure that the test fluids are compatible with the valve seat and seal material
-Flush the system to remove foreign material that may be in the line as a result from installation
procedures, to avoid damages to the ball and seats
-If performing line shell testing, the valve shall be in half open position. The maximum line
pressure can be 1-1/2 times the valve maximum cold working pressure.
-If performing seat testing, make sure the valve is fully closed. The maximum pressure for seat
testing is the maximum cold working pressure.
-After completion of testing, purge all test fluids from the valve.
CAUTION: if the seats are tested to a higher pressure than maximum cold working pressure,
the seats can be permanently damaged. If a higher test pressure is desired contact AOP
representative for details.

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5. Operation
D series ball valves only work in the fully closed or fully open position; these valves work for on/off
service only.
WARNING: These valves shall never be operated partially open or partially closed. Throttling
(partial opening) or “pinching” flow may cause non-uniform wear on seats and ball over the
sealing surfaces where it is exposed to the flow line, preventing tight shut-off.
To close the valve, turn the lever or gear handwheel clockwise until it stops; to open the valve turn the
lever or gear handwheel counter-clockwise until it stops.
All lever operated valves should have the lever in line with valve through bore when opened and
perpendicular (90 degrees) with the through bore when closed.
All gear operated valves have the gear indicator along with valve through bore when opened and
perpendicular with the through bore when closed. The gear has also “OPEN” and “SHUT” markings.
While opening or closing the ball must reseat, this reseating torque is higher than the run torque. If
lever operated turn the lever until the stop plate stops on the stop screw. If gear operated turn the
handwheel until the gear has a positive stop.
If the valve is motor actuated read carefully the actuator operation manual.
CAUTION: The end stops have been shop set to assure the correct 90 deg. rotation from fully
open to fully closed position. Do not change their adjustment.
If the valve is not correctly reseated at the end of opening or closing the ball and the seats can
quickly be damaged when exposed to flow pressure, preventing tight shut-off.
These valves can be operated by one person. It is recommended that no extensions be used for
operating the valve.
6. Maintenance - recommendations
The D series ball valves have a tight seat to ball seal insuring leak-free performance for a long period
of time. However all valves can be drained and lubed depend on application conditions or anytime if
desired. Also the gears are factory lubricated for long operation (on gear operated valves). If desired
the gear can be lubricated using the lube fitting located on the side of the gear operator.
6.1. Drainage Procedure
Valves may accumulate water, scale, deposits and other foreign matter, during their service. These
materials may damage the valve in the following ways:
-At low temperature, ice may form inside the valve hindering its normal operation.
-Foreign matters may prevent the valve from fully closing and the ensuing throttling may
damage the ball or the seat seals. Foreign matter may get caught between the ball and the seat and
damage their surfaces.
A drainage schedule is the best way to prevent damage caused by foreign matter. However, it is
recommended that drainage should be carried out in the following cases:
•Whenever the valve does not close
•Before the arrival of the cold season
•After washing the line
•After hydraulic test

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For a drainage procedure, follow the below instructions:
1. Close the valve completely.
2. Slowly open the drain fitting (37)on the lower trunnion for valves up to 900 class; the drain fitting
(40) located on the body for valves 1500 class.
CAUTION: Open the drain valve slowly until the pressure in the body cavity has been
discharged. Make sure the fitting body does not unscrewing when start untight the fitting stem.
If necessary use a backup wrench to prevent the fitting body from unscrewing.
6.2. Lubrication- Grease injection
The D series valves have been designed and tested in such a way that they do not require the use of
lubricating or sealing grease during their normal service operation.
However, should the need arise, the D series ball valve 150 to 900 class is equipped with a body
injection fitting through which lubrication/sealant can be injected directly into the body cavity of the
valve; the D series 1500 class has 2 grease injection fitting located on the body seat area – see table 1
for recommended lubricants.
This may be necessary in the event of slightly damage to the seats caused by debris in the line; before
operating the valve if the valve has been left in its position, either fully open or fully close, for long
period of time; as soon as an increase of stem torque is noticed.
CAUTION: Grease fittings should not be removed if there is pressure in line. Grease fittings should
never be painted.
TABLE 1
SERVICE
CONDITION
PRODUCT
CLEANER / SEALANT MANUFACTURER
VAL-TEX SEALWELD LUBCHEM
NATURAL
GAS
Flush
Valve flush Valve cleaner Valve saver
Standard valve
lubricant
2000 light lube EQ 80 Lubchem ’50-400”
Standard sealant
80 bulk/ 80-HS stick Total lube 911 Everlast No.1
Standard low. Temp.
50 bulk / stick Winterlub 7030 Everlast No.1 AG
Severe leak seala
nt
80+PTFE bulk / stick Sealweld #5050 Formasil RS
SOUR
GAS
Flush
Valve flush
Valve cleaner
Valve saver
Standard valve
lubricant
2065 light lube EQ 80 Lubchem ’50-400”
Standard sealant
65 bulk / stick Total lube 911 Lubchem ’50-400”
Standard low. Temp.
65 bulk / stick Winterlub 7030 Lubchem ’50-300”
Severe leak sealant
80+PTFE bulk / stick Sealweld #5050 Formasil RS
DRY CO2 Flush
Valve flush Valve cleaner Valve saver
Standard valve
lubricant
2300 light lube Sealweld Silicone
Lubricant
Everlast WR
Standard sealant
302 bulk / stick Sealweld Silicone
Lubricant
Everlast WR
Standard low. Temp.
65 bulk / stick Sealweld Silicone
Lubricant
Everlast WR
Severe leak sealant
80+PTFE bulk / stick
Sealweld Silicone
Sealant
Formasil CO2
CRUDE OIL Flush
Valve flush Valve cleaner Valve saver
Standard valve
lubricant
2000 light lube EQ 80 Lubchem ’50-400”
Standard sealant
80 bulk/ 80-HS stick Total lube 911 Lubchem ’50-400”
Standard low. Temp.
50 bulk / stick Winterlub 7030 Lubchem ’50-300”
Severe leak sealant
80+PTFE bulk / stick Sealweld #5050 Formasil WR

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VALVE CLEANER/ SEALANT MANUFACTURERS:
VAL-TEX: Valves Incorporated of Texas 10600 Fallstone Rd. Houston, TX 77099, 281/530-4848;
800/627-9771
SEALWELD: 7240 Brittmore Suite 120 Houston, TX 77041; 713/937-9222; 800/237-0564
LUBCHEM INC: P.O. BOX 2626, Spring, TX 77383; 281/350-9600
7. D series valve Reconditioning
The D series valves can be rebuilt if it is necessary. The disassembly and reassembly of the valve
require proper lifting equipment and normal maintenance tools.
Spare parts are determined by the individual customer specification; however, the following list is
suggested as a minimum for typical maintenance operations:
1 All bearings (stem and trunnion)
2 Stem thrust washer
3 All O-rings
4 All back-up rings – as applicable
6 All fire safe seals
7 Bushing Gland
8 Seat springs
9 Seat subassemblies (rings with inserts)
10 Drain fitting
CAUTION: Prior to disassembly, the valve must first be isolated from system pressure and flow.
Operate the valve at least two times and drain the valve to make sure there is no residual pressure left
into the body.
After observing the above precautions, remove the valve from the pipe line system. Set the valve in a
clean place free of dust and/or metallic chips.
7.1. Disassemble the D series valve
1. Operate the valve to the closed position.
2. Stand the valve on the body end flange. Care should be taken to avoid damage of the sealing
surface of the raised portion or ring groove (as applicable).
3. If lever operated valve - remove the lever, wrench head, snap ring and stop plate. Unscrew the
bearing housing cap screws, remove the bearing housing.
4. If the valve is gear operated - loosen the gear nuts, at the same time lift the gear until it comes
off of the stem. Remove stem key. Unscrew the adapter plate cap screws, remove the adapter
plate.
5. Unscrew the gland plate capscrews and pull the stem assembled with the gland plate out from
the valve body, paying attention not to damage the soft seals. Remove the stem drive pins from
their holes on the top of the ball.
6. Carefully push the stem out of the gland plate, paying attention not to damage the soft seals,
then remove the upper thrust washer from the stem.
7. Remove the gland-bushing with the stem fire safe seal, the stem O-rings and the gland plate O-
ring from the respective grooves on the gland plate.
8. Remove the gland plate fire safe seal from its housing on the body.
9. Unscrew the lower trunnion capscrews and pull the cover (1500 class) and lower trunnion out
of the valve body, paying attention not to damage the soft seals.

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10. Remove the trunnion O-ring from the trunnion groove and the lower trunnion fire safe seal
from its housing in the body.
11. Remove the body stud nuts or, for the studded ends valve, the body capscrews.
12. Lift the closure off the body paying attention not to damage the soft seals.
13. Remove the closure O-ring from the groove on the closure and the closure fire safe seal from
its recess.
14. Pull the seat ring unit out of the closure, paying attention not to damage the soft seals.
15. Slip the seat O-ring off the seat ring.
CAUTION: The seal ring consists of an insert pressed into the seat ring by the manufacturer. Do
not attempt to remove the seat insert from holder.
16. Remove the seat springs from their housing in the closure.
17. Remove the ball from the body cavity.
18. Pull the trunnion bearing from the bottom of the ball.
19. Repeat steps 14-16 for removal of the body seat ring.
20. Remove the stem bearing (3) from the body stem bore.
21. Remove the drain fitting
CLEANING:
Remove any foreign and corrosive products within the body.
CAUTION: Abrasive cleaning could never be used, especially on sealing area. If water jetting is
used, dry with compressed air.
Clean all metallic parts with soft cloth saturated with a solvent. Observe all sealing surfaces.
Clean the grease fittings and if present the grease channels.
Clean the sealing rings and the gaskets with a soft cloth. If necessary, wash them with soap and rinse
them with clean water.
CHEMICAL RESISTANT VINYL OR RUBBER GLOVES SHOULD BE WORN DURING
CLEANING OPERATION
INSPECTION
After cleaning, all valve components should be inspected for damages, dents, scoring, wear or
corrosion. If any damage is found, proceed with the repair where possible, or with substitution of the
parts.
For a complete inspection procedure, the following operations shall be carried out:
1. Check the metallic parts for damage along the sealing surfaces and on moving surfaces.
Particular attention should be paid to surface nicks and corner damage.
2. Make sure that the sealing rings and gaskets are not slashed, extruded and/or otherwise
damaged.
3. Check for scratches, plating defects, the surfaces of the bearings, the thrust washers, the gland
bushing, the ball and the seat components.
4. Inspect all spares that are going to be used to ensure damage has not occurred in storage or
transportation.
MINOR REPAIRS
If any damage is found, the minor repairs should be carried out by trained persons, otherwise contact
TK representative.
The minor repairs that may be carried out on site by maintenance personnel shall be in accordance
with the following points:
1. Rectify by normal good engineering practice the damage on metallic surfaces.
2. Remove surface nicks on ball and stem by using a mild abrasive.
3. Remove all corner damages by using a mild abrasive or with a bearing scraper.
4. Replace all faulty parts and components.
Flush lube and sealant while the valve is disassembled.

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7.2. Assembly the D series valve
7.2.a. Assembling a Lever Operated Valve
After inspecting the parts and getting the new replacement parts as required, follow the next steps:
1Place the body on the flange on a clean, solid surface so it will hold the weight of the
assembled valve securely. Attention should be give to the sealing surfaces.
2If has been removed, install the studs in the body with the ID stamping up, and screw
them down completely by hand. Remove any particles which may have flaked off the
studs.
3Drive the stem radial bearing into body stem hole using a stem and a soft face hammer.
The bushing should be driven in so that it contacts the retaining lip in the bore. This
operation can be done safely on the smaller valves with the body lying on the trunnion
pad and using the stem as a driver.
4Place the stem thrust washer over the stem. The Teflon side of the washer should point
up.
5At this time the fire safe seals can be placed over the closure shoulder, the lower trunnion
(or lower trunnion cover) and gland plate (bonnet).
6The o-rings can now be added to all the parts.
Note: 900 and 1500 class valves require installation of back-up rings in all of the o-ring
grooves except for the seat o-ring groove in the 900, and the seat grease seal in the
1500. O-rings are positioned towards the pressure side of the groove, backup rings to
the outside of the body pressure. For seats the backup goes on the ball side of the
groove. See below fig.5 for details:
Fig.5

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7Wrap all the external fittings thread with Teflon tape. Note: The hole in the drain fitting
should not be covered with tape.
8Place the spring washers into the body and closure, so that the outside of the washer is
facing down and away from the assembler. Note: Lubricated seat valves use a wave
spring which is not directional.
9Insert the lower trunnion bearing into the ball at this time by using the trunnion or a small
arbor press.
10 Install the seats into the body and closure recess. Caution should be taken not to damage
the seat insert material.
11 Place the ball into the body cavity in the fully closed position. Using a caliper and a
marker, mark the center of the ball for close position. Check the marking measuring from
both sides of the ball hole.
12 Place the trunnion into the body, until it is fitted into the lower ball radial bearing. Install
the cover – 1500 class only. Loosely secure the trunnion with cap screws.
13 Lift the closure over the body and lower it onto the studs making sure that the API
connection flanges stud holes from the adapter are aligned in the proper two-hole position
with the body .
14 Install and tighten two body stud nuts on opposite sides of the body. The rest of the body
stud nuts can be installed at this time and the trunnion cap screws tightened. Torque all
fasteners as shown in table 2.
Table 2 Torque for B7, B7M, L7, L7M studs and cap screws
Thread Size
(mm)
Dry/Zinc Plated (ft-lbs) Cad/Teflon Coated (ft-lbs)
M6
x1
6
4
M8x1.25 16 10
M10x1.5 31 20
M12x1.75 38 26
M14x2 72 40
M16x2 113 70
M
20
x2.5
178
116
M
27
x3
440
287
15 Install the two drive pins into the ball. A little grease may be needed to keep the pins in
place.
16 Fit the stem into the body, aligning the drive pin slots in the stem with the drive pins in
the ball. The stem need to be installed with the key slot pointing to the right side of the
valve (3:00’o clock).
17 Install the gland plate over the stem; use a soft face hammer if necessary. Rotate the gland
plate to obtain alignment of the bolt holes and torque pin holes in the body and gland
plate. The following is a guideline for proper alignment of the 1/4” drilled hole in the OD
of the gland plate (bonnet):
-All 150 to 600 class valves and all 4FP-6RP including 900 and 1500 the 1/4” NPT
hole will be at the 7:30 o’ clock position
-2”900 & 1500 align at the 11:00 o’clock position
-3”900 & 1500 align at the 9:00 o’clock position.
For all the valves after 1/4 NPT threaded hole alignment the torque pin holes on bonnet
has to align with body pin holes.
See below Fig 6 and Fig.7 for details:

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Fig.6
Fig.7
18 Insert the gland plate (bonnet) cap screws into their threads on the body and tighten them
evenly. The cap screws will need to be torqued, please refer to the table 2 for the correct
torque. The gland plate and trunnion vent/drain and the body grease fitting should be
installed at this time. Note: Install the body/vent drain plug in the trunnion so that the
hole will point up when tight. Use installation torques noted in table 3 for fittings.
Table 3
Fitting Thread Size Torque Ft-lbs
1/4 NPT 25
3/8 NPT
39
1/2 NPT
75
3/4 NPT 135
1 NPT 288

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19 Place the stem fire safe seal over the stem and into its recess of the gland plate.
20 Now fit the gland bushing over the stem until it fits against the fire safe seal.
21 If the valve is 2FP up to 4RP
-Bare stem, place the adapter plate over the stem with the internal stop at the 12
o’clock and 3 o’clock position. Insert the cap screws and torque as shown in table 2
for the correct torque. Install the torque pins now using a pneumatic pin driver.
-Gear operated, continue to 7.2.b for gear installation,
-Lever operated, place the locking bearing housing over the stem, secure it with the
cap screws, and install the torque pins using a pneumatic pin driver. Install the stop
collar and the snap ring. Note: the stop collar should be installed so that the valve
opens counter clockwise and closes clockwise.
22 If the valve is 4FP up to 6RP
-Bare stem, place the adapter plate over the stem with the internal stop at the 12
o’clock and 3 o’clock position. Insert the cap screws and torque as shown in table 2
for the correct torque. Install the torque pins now using a pneumatic pin driver.
-Gear operated, continue to 7.2.b for gear installation,
-Lever operated, over the bare stem valve install the stop collar cap screw, the stop
collar and the snap ring. Note: the stop collar should be installed so that the valve
opens counter clockwise and closes clockwise.
7.2.b. Assembling a Gear Operated Valve
Make sure to select the proper operator, contact AOP for part number and other relevant information’s.
23 With the operator positioned with the cover upside down, install the mounting studs
provided with the order. Measure the adapter plate and nut thickness to gage the proper
amount of stud to leave protruding from the gearbox.
24 Before sliding the operator completely against the plate adapter check the position of the
hand wheel shaft, on all D series valves the shaft will be to the top right (right handed gear)
when the valve is in horizontal position. The shaft will always be at 90 degrees from the
centerline of the valve toward the fitting side of the body. The operator can be rotated
around the stem into the proper position, without removing it from the stem.
25 After correctly positioning the hand wheel shaft, slide the operator toward the plate placing
the studs through the adapter flange until approximately 1/4" of the studs is exposed on the
back of the flange. Start all nuts onto the studs (flat side down) and tighten them with the
proper open end wrench.
26 Remove the indicator plate. Using the hand wheel, turn the hand wheel shaft so that the key
slot of the stem and operator are aligned with each other.
27 Tap the key gently into the key slot until it is below the surface of the operator hub. Do not
use excessive force to drive the key. If the key does not fit properly recheck the alignment
of the slots. (Another key or pin punch should be used to drive against the key, to prevent
damage to the operator key or key slot.)
28 To set the closed stop turn the hand wheel until the marking on the ball (created at pct 11) is
on the center comparing with the adapter flow bore. Check with a scissor type tool for the
ball marking to be on center. Loosen the jam nut on the stop screw position- see below
Fig.8. Turn the stop bolt clockwise until it stops. Retighten the jam nut. It may be necessary
to turn the stop screw counter clockwise in order to get additional travel and move the
operator further closed. The hand wheel should always be turned in the closed direction
to set the closed stop, so that all slack will be taken out of the gearing. This ensures a
more accurate stop setting.

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Fig.8
29 After setting the closed stop, a quick check should be made to ensure that it has been
correctly set. This is accomplished by turning the hand wheel shaft several turns towards the
open position, and then returning it until the closed stop is contacted. The keyway will be at
a 90 degree angle to the flow bore. Check with a scissor type tool for the ball marking to be
on center, ensure the ball did not close differently when operated.
If the marking on the ball is missing, a second way to check the correct closed position is to
mark the ball – after fully closing the gear- with a circle tangent to the adapter flow bore (or
body flow bore) in a plane 90 degree with the stem axis. Half way open the ball and measure
the minimum distance from the ball corner (ball flow bore to sphere corner) to the marking;
the distance shall be as L dimension from below table 4 and Fig.9.
Table 4
Valve size
Valve class
Dimension L
+/-.04”
2”FP and 3”RP
150
-
600
0.57”
2”FP and 3”RP
900
0.62”
2”FP and 3”RP 1500 0.57”
3”FP and 4”RP 150-900 0.72”
3”FP and 4”RP 1500 0.58”
4”FP and 6”RP 150-900 0.86”
4”FP and 6”RP 1500 0.79”
Fig.9
30 To set the open stop, turn the hand wheel shaft counter clockwise, moving the valve to the
open position. Look into the bore of the valve, and continue opening until the flow bore of
the ball is in alignment with the flow bore of the seat holders. There should not be more than
1/32" of the ball radius exposed into the flow bore once the final setting has been made.
31 Once the alignment is accomplished, loosen the jam nut on the open stop bolt and turn the
stop bolt clockwise until it stops. Retighten the jam nut. It may be necessary to turn the stop
screw counter clockwise in order to get additional travel and move the operator further open,
in order to align the ball flow bore with the flow bore of the seat holder. The hand wheel
should always be turned in the open direction to set the open stop, so that all slack will
be taken out of the gearing. This ensures a more accurate stop setting.