APV BV100 Series Instruction manual

www.australianpipelinevalve.com.au
INSTALLATION, OPERATION & MAINTENANCE MANUAL
FLOATING BALL VALVES
BV100 SERIES

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AUSTRALIAN PIPELINE VALVE BRAND RANGE -CATALOGUES
APV FAMILY OF BRANDS RANGE - CATALOGUES
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“Australian Pipeline Valve
produces isolation,
control and flow reversal
protection products for
severe and critical service
media in utility, steam,
pipelines, oil & gas
and process industries.
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products form the most
competitive portfolio
in the market.”
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& Sight Glasses
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& Trunnion Mounted
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Special Service
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FLOATING BALL VALVES - BV100 SERIES
INDEX
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 1
Introduction 2
Safety Information 4-5
1.0 Scope 5-6
1.1 Environmental considerations 5
1.2 Storage 5
1.3 Preparation 6
2.0 Installation 6-10
2.1 Installation positions 7
2.2 Preparation for installation 7
2.3 End connections 7-8
2.4 Valve installation by welding 8-10
3.0 Operation 10
3.1 Manual operation 10
3.2 Lock device 10
4.0 Maintenance 10-15
4.1 Gland packing 11-12
4.2 Body seal 12-13
4.3 Inspection and replacement of trim components 13-14
4.4 Disassembly procedure 14
4.5 Reassembly procedure 14-15
5.0 Construction - Typical bill of materials 16
Appendix A - Bolting torque’s 17-18
Appendix B - Exploded B.O.M. 19

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INTRODUCTION
The majority of this information is common knowledge to experienced valve users. When properly
installed in applications for which they were designed, Australian Pipeline Valve (APV) valves will give
long reliable service. This instruction is only a guide for installation and operation on standard service and
covers general maintenance and minor repairs. A professional APV approved valve engineering facility
should be utilised for reconditioning or major repairs. Check the part number on the label to ensure the
valve is configured to firesafe specifications if firesafe is required.
Note
We recommend that this entire document be read prior to proceeding with any
installation or repair. Australian Pipeline Valve and it’s parent company take no
responsibility for damage or injury to people, property or equipment. It is the sole
responsibility of the user to ensure only specially trained valve repair experts
perform repairs under the supervision of a qualified supervisor.
RESPONSIBILITY FOR VALVE APPLICATION
The User is responsible for ordering the correct valves. The user is responsible for ensuring APV Valves are
selected and installed in conformance with the current pressure rating and design temperature
requirements. Prior to installation, the valves and nameplates should be checked for proper identification
to ensure the valve is of the proper type, material and is of a suitable pressure class and temperature
rating to satisfy the requirements of the service application.
Do not use valves in applications where either the pressure or temperature is higher
than the allowable working values. Also valves should not be used in service media
if not compatible with the valve material of construction, as this will cause
chemical attacks, leakage, valve failure.
RECEIVING INSPECTION AND HANDLING
Valves should be inspected upon receipt to ensure:
- Conformance with all purchase order requirements.
- Correct type, pressure class, size, body and trim materials and end connections.
- Any damage caused during shipping and handling to end connections, hand wheel or stem.
The User is advised that specifying an incorrect valve for the application may result
in injuries or property damage. Selecting the correct valve type, rating, material
and connections, in conformance with the required performance requirements is
important for proper application and is the sole responsibility of the user.

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CONSIDERATIONS OF TECHNICAL RISK/ LIMIT
OF LIABILITY TO CLIENT FOR BALL VALVES
Australian Pipeline Valve don’t consider in our design the following factors of risk:
1. Australian Pipeline Valve ‘Standard’ ball valves can be used in a temperature range between -28.8 to +200°C. (Note,
pressure limitations apply above 38°C refer to Pressure/Temperature charts.) For service temperatures below -28.8°C
ball valve construction materials shall be submitted to an impact test at the minimum service temperature. For
temperatures outside of the range of -28.8°C to +200°C ball valves have to be provided with seats, seals and body
material able to withstand the temperature degree required.
2. The onus is on the customer to specify all materials of construction and service conditions. Australian Pipeline Valve shall
assume standard materials and conditions if not otherwise specified.
3. Australian Pipeline Valve ‘Standard’ ball valves are not equipped with devices suitable to avoid internal over-pressures
caused by incorrect operations of process or by-fluids & liquids subjected to an increase of volume and/or pressure
(these devices, such as the over-pressure hole in the ball or safety seats are available upon request).
4. Australian Pipeline Valve ‘Standard’ ball valves are not designed with special devices to withstand a sudden thermal
jump (thermal shock).
5. In general Australian Pipeline Valve ‘Standard’ ball valves are not mechanically designed to bear overloads due to
exceptional atmospheric or natural phenomenon’s (such as earthquakes).
6. In general Australian Pipeline Valve ‘Standard’ ball valves are not designed to bear loads on flanges, on pipe connections
or pipeline.
7. In general Australian Pipeline Valve ‘Standard’ ball valves can’t withstand ice inside their bodies (in this case user must
specify the optional stem extension for insulating, avoiding the presence of residual product inside the valve).
8. Australian Pipeline Valve ‘Standard’ ball valves are not suitable for low temperature service below -29°C (-20°F) unless
provided with cryogenic stem extension and other modifications (available on request).
9. Australian Pipeline Valve ‘Standard’ ball valves are suitable for ‘industrial’ oxygen (not medical) service when supplied
degreased and packed in polyethylene bags only.
10. The compatibility between ball valves construction materials and medium is selected by the user. The user is ultimately
responsible for verifying the compatibility between medium and materials.
11. Abrasive or dirty service, high temperature service, low temperature service, vacuum service, near zero pressure service
and other special applications should be clearly stated when requesting quotation.
BALL VALVE START-UP
Before installing the ball valve onto the pipe-line it is mandatory for the user to verify the compatibility of the ball valve with
service conditions (medium, temperature and pressure). With reference to standard ball valves held in stock the reseller and
end user will have to assure themselves of the compatibility with the use of conditions required by the customer. Australian
Pipeline Valve ball valves must be only used for on-off (fully open/fully closed) service.
Before using the ball valve in a potential explosive atmosphere it’s necessary: -
• To verify the compatibility between the ball valve and the zone in which the ball valve should be installed.
• To foresee the pipe-line ground condition on which the ball valve should be installed.
• To check that the temperature of the ball valve surface is not higher than the flammable point of the atmosphere in which
the ball valve is installed (in this case specify an insulating cover device for the valve and an extension for the wrench)
• Before installing ball valves with welding ends to make sure that the process of welding is carried out in accordance with
all the safety requirements of the classified zone.
• To avoid mechanical knocks during the installation that may cause sparks.
Australian Pipeline Valve cannot be held responsible for damage caused by use of the product especially if it is improper use or
modified.

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FLOATING BALL VALVES - BV100 SERIES
SAFETY INFORMATION
The following general safety information should be taken in account in addition to the specific warnings
and cautions specified in this manual. They are recommended precautions that must be understood and
applied during operation and maintenance of the equipment covered in this I.O.M.
Never attempt to disassemble a valve while there is pressure in the line. Ensure both
upstream and downstream pressures are removed. Disassemble with caution in case
all pressures are not relieved. Even when replacing stem packing, caution is
necessary to avoid possible injury.
To prevent valve bending, damage, inefficient operation, or early maintenance
problems, support piping on each side of the valve. When handling gases/fluids that
could cause damage to human health, the environment or property, the necessary
precautions to prevent risk must be taken.
• A valve is a pressurised mechanism containing energised fluids under pressure and
consequently should be handled with appropriate care.
• Valve surface temperature may be dangerously too hot or too cold for skin contact.
• Upon disassembly, attention should be paid to the possibility of releasing
dangerous and or ignitable accumulated fluids.
• Ensure adequate ventilation is available for service.
This manual provides instructions for storing, general servicing, installation and removal of ball valves.
APV and it’s resellers refuse any liability for damage to people, property or plant as well as loss of
production and loss of income under any circumstances but especially if caused by: Incorrect installation
or utilisation of the valve or if the valve installed is not fit for the intended purpose. It is the sole
responsibility of the user to ensure the valve type and materials are correctly specified.
SCOPE OF INSTALLATION ACCORDING TO THE TYPE OF FLUID
(DANGEROUS FOR THE ENVIRONMENT OR HUMAN HEALTH)
Group 1 Classification
- The incorporation of additional safety elements “Double Packing” (utilising a stem extension) is
recommended for the range of products included in Group 1.
- The use of valves without additional safety devices in Group 1 will be the responsibility of the user or
the purchaser, as well as the advisability of installing leakage detection systems.
Group 2 Classification
- Carbon steel valves will not be used in corrosive fluid lines.

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FLOATING BALL VALVES - BV100 SERIES
DURING OPERATION TAKE INTO ACCOUNT THE FOLLOWING WARNINGS:
a- Graphite/Graphoil packing and body gasket is very brittle, any impacting, twisting or bending should
be avoided.
b- The valve’s internal parts such as ball, stem, seats, seals, gaskets shall be handled with care avoiding
scratches or surface damage.
c- All tools and equipment for handling internal critical sealing parts shall be soft coated.
d- Valves can be fitted with gaskets or seals in PTFE, Buna, Viton, etc., hence high temperatures will
damage sealing components.
e- Never part open valve, valve must be full open of full closed to avoid seal damage.
For all operations make reference to position number on part list of the applicable drawing listed.
1.0 SCOPE
This manual describes the methods of installation and maintenance for floating ball valves, which are
designed to fit between ANSI Class 150, Class 300 and Class 600 flanges or with buttweld ends.
1.1 ENVIRONMENTAL CONSIDERATIONS
According to ISO 14000 regulations and the environmental policy of APV the recyclability of the
components that form part of APV valves is as follows:
Recyclable components:
Metal parts, PTFE (hard), plastic plug (low-density polyethylene).
Non-recyclable components:
PTFE mixed with other compounds (glass-fiber, graphite, etc.), nylon, graphite and graphite mixed with
metal.
1.2 STORAGE
1.2.1 Temporary Storage
If valves are to be stored before installation, the following should be observed:
a) Keep the valves wrapped and protected as shipped from the manufacturer.
b) Do not remove the protective end covering until the valve is ready for installation. This will reduce the
possibility of foreign material damaging the internal valve components.
c) Valves stored outdoors should be positioned such that water does not accumulate in the valve body.
1.2.2 Long Term Storage
If valves are to be stored more than one year, they should be prepared in the following manner:
a) Remove the packing and apply a preservative to the packing chamber.
b) Do not remove the protective end covering.
c) Do not store the valves outdoors.

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FLOATING BALL VALVES - BV100 SERIES
1.3 PREPARATION
a) Remove the valve end protection.
b) Prior to shipment, a preservative/corrosion inhibitor may have been applied to the inner body of the
valve. This preservative/corrosion inhibitor can be removed with a solvent provided the solvent used
does not affect the seats/seals used in the valve.
c) The inside of the valve should be inspected and blown out with compressed air. Adjacent piping must
be clean and free from debris to prevent damage to the valve.
d) To prevent valve distortion, inefficient operation or early maintenance problems, support piping on
each side of the valve.
e) Make sure the valve is positioned such that there is sufficient space so that the hand wheel is easily
and safely reached and there is enough clearance for the stem when the valve is open.
f) Install the valve according to the flow indicator on the valve body where applicable.
2.0 INSTALLATION
Piping should be properly aligned and supported to reduce mechanical loading on
end connections. Never use the lever (wrench) to hold the valve during transport,
handling or assembly.
The following procedure is required to be followed for correct installation.
a) Before installation confirm the marking (rating, size and material) on the valve body and nameplate.
Ensure the valve is suitable for the service which it is being used.
b) Body bolts and nuts on valve shall be checked and retightened if necessary in case loosened during
installation.
c) Remove valve end protectors and ensure gasket faces are free from damage. Tighten all bolts between
mating flanges and valve equally paying careful attention to properly tighten bolts. Ensure you rotate
tightening procedure (opposing bolts sequentially) gradually increasing torque. Refer to Appendix Table
2 for bolt tightening sequence.
d) Prior to installation of valve, ensure the line is completely flushed to remove any debris as soft seated
ball valves are easily damaged. Filters or strainers should be installed upstream to protect soft seated
valves.
e) Valves will operate at any angle horizontally or vertically, although it is recommended you install
valves in a vertical position with stem pointing upwards for ease of operation, inspection and
accessibility.

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FLOATING BALL VALVES - BV100 SERIES
2.1 INSTALLATION POSITIONS
Ball valves are usually bi-directional, and therefore may be installed in either direction. In some cases,
ball valves such as ‘metal to metal’ seated and low temperature valves may be uni-directional, in which
case the direction of flow will be indicated on the valve body.
2.2 PREPARATION FOR INSTALLATION
• Remove protective end caps or plugs and inspect valve ends for damage to threads, weld ends or
flange faces.
• Thoroughly clean adjacent piping system to remove any foreign material that could cause damage to
seating surfaces during valve operation.
• Verify that the space available for installation is adequate to allow the valve to be installed and to be
operated.
Ensure sufficient clearance for the stem in the full open position. Inadequate
clearance for valves may add mechanical loading to the valve ends. Sufficient
clearance should be allowed for threaded end valves to be ‘swung’ during
installation.
2.3 END CONNECTIONS
2.3.1 Threaded Ends
Check condition of threads on mating pipe. Apply joint compound to the male end of joint only. This will
prevent compound from entering the valve flowpath.
2.3.2 Flanged Ends
Check to see that mating flanges are dimensionally compatible with the flanges on the valve body ensure
sealing surfaces are free of debris. Install the correct studs and nuts for the application and place the
gasket between the flange facings.
Stud nuts should be tightened in an opposing criss-cross pattern in equal increments
to ensure even gasket compression.
2.3.3 Socket weld Ends
Remove all debris, grease, oil, paint, etc., from the pipe that is to be welded into the valve and from the
valve end connections.

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FLOATING BALL VALVES - BV100 SERIES
Insert the pipe into the valve end connection until it bottoms out in the socket weld bore. Withdraw the
pipe 1/16” so that a gap remains between the pipe and the bottom of the socket weld bore to prevent
cracks (ASME B16.11). Tack the pipe into the valve and complete the fillet weld.
WELDING INSTRUCTIONS
• Local welding regulations and specification must be complied with when carrying
out welding work.
• Remove any paint and rust around the weld area on the pipe and welded end of the
ball valve.
• Check that the ball valve is correctly positioned and aligned with the pipeline.
• Where weld connection is close to seat area, due to short length of the welded ends
there is a risk that the soft inserts may be destroyed during the welding work.
Hence the following procedure is advised: -
Use temperature measuring strips to check that the temperature does not rise beyond
the permissible limits (160°C). The strips must be fitted to the connection near the soft
inserts. These temperature measurements strips are designed so that, when a type-
dependent temperature is reached, the colour irreversibly changes from white to
black. The temperature measurement strip must be monitored constantly throughout
the welding work. If any change of colour is noticed, the welding work must be
interrupted immediately and the weld allowed to cool. For ‘swing out centre’ design,
the centre section containing soft parts can be removed during welding if preferred,
see 2.4.1.
2.3.4 Buttweld End Valves
Clean the weld ends as necessary and weld into the line using an approved weld procedure. Make sure
the pipe and valve body material given on the valve body or nameplate is compatible with the welding
procedure. (Refer our compatibility cross reference chart for equivalent pipe, valve & fittings grades at
the Technical section of our website). Soft seats can be damaged during welding, take steps to ensure
valve is not over heated, especially smaller size valves (see above caution note).
2.4 VALVE INSTALLATION BY WELDING
For all sizes of valves, leave valves in the full open position during installation, welding and post-weld
heat treatment. This will reduce temperature transmission to soft seats. After welding completion, open
the valve and flush line to clean out any foreign matter. Valves over 65 NB ( 2 1/2”) have minimal risk of
temperature damage to seats.
2.4.1 Disassembly Method
For valves up to 80 NB (3”) the welding temperature can adversely affect the PTFE and elastomer
components. Follow the welding instructions above but also use temperature measuring strips to monitor

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FLOATING BALL VALVES - BV100 SERIES
temperature. It will be the responsibility of the operator to ensure valves are kept cool during welding
and then post-weld testing of the valve should be performed. Larger size valves over 80 NB (3”) are less
likely to transmit heat to seat and stem packing during welding but still care should be taken. The ‘swing
out’ version of BV100 Series valve can be disassembled prior to welding to avoid damage to seats and
body seals (only 3 bolts need to be removed to ‘swing out’ the centre section of the remaining bolt).
Ensure the centre section of the valve is ‘swing out’, typically only 800 class up to 50 NB (2”) are ‘swing
out’ design. The seats and seals remain in the centre section hence no seat or seal removal is required. If
this option is recommended by APV then these valves have in-line removable sections hence no line
movement is necessary to insert the fully self contained centre section. There must be sufficient
movement in line to allow tightening of body bolts to compress the body gasket. In class 1500 and 2500
the disassembly method cannot be performed due to intersecting components.
1- Tack weld in 4 points on both end caps, leave the valve in the open position and do not move during
and at least 30 minutes after welding until the valve cools. For socket weld also see 2.3.3, for butt
weld also see 2.3.4.
2- Remove centre section and complete welding.
3- Replace centre section but first apply grease to the seat rings to aid the seat and torque (unless for
oxygen service).
The below procedures should also be followed:
a) Always ensure there is no pressure or product in the line. Ball valves will be supplied with socket weld
ends to ANSI B16.11 or butt weld ends to ANSI B16.25. Welding should be done using procedures and
welders qualified under section IX of the ASME boiler and pressure vessel code.
b) For 1500 & 2500 class valves, if the body seats are removed, put them back in the same side from
which they were removed and take care not to cut or scratch them. Smear some grease into the seat
pocket to help them fit into pockets. (Don’t apply grease if for oxygen service). If the valve leaks from
the stem after assembly, try adjusting the stem packing. Always clean all welding surfaces from
contamination, grease etc., prior to welding.
Note: For higher pressures and sizes, Delrin and PEEK seats may have graphite or PTFE backing rings.
c) Always do as a low temperature weld as necessary to obtain a reliable connection. Use whatever
measure necessary to localise heat at the joint, dissipating it before damage can occur to adaptor
gaskets and/or seats (the main risk is seats). Use a tempil stick or other temperature indicator on the
outside of the valve body (centre section) directly adjacent to adapter end piece) being welded to
assure the body temperature does not increase 160°C. Always leave valve in open position during
welding but also at least 60 minutes after welding unit valve cools.
d) Where required APV will supply spare body gaskets. Graphite body gaskets are brittle so great care
should be taken not to damage.
2.4.2 No Disassembly Method
Valves under 50 NB (2”) that are not disassembled should have pup ends fitted to avoid seat damage. If
not fitted ensure valve body temperature is kept cool. Temperatures over 180°C can damage seats &
seals. In 1500 and 2500 class, BV100 valves have encapsulated seats, hence you must have 3mm of
movement in your line in order to replace disassembled centre section, due to seats intersecting end cap

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FLOATING BALL VALVES - BV100 SERIES
and centre pieces. You can still use disassembly method 2.4.1 above provided you have 3mm of line
movement. APV will supply spare body gaskets where required. If you do not disassemble the valve, do
not attempt to weld valves under 50 NB (2”) that do not have pup ends unless you are using water cooling
and monitoring the temperature.
For pup end valves and valves 50 NB (2”) and over with short ends there is no need for disassembly,
valves can be welded straight in line. There is no need to keep cool but if valve does not have extended
long ends it still pays to ensure that the valve body near seat and body seal area remain below 150°C
especially for valves 80 NB (3”) and smaller.
The responsibility for welding of the valves into piping systems is that of those performing the welding.
Refer to ASME B31.1, B31.3 etc. Written welding procedures covering all attributes of the process and
materials to be welded shall be in accordance with Section IX of the ASME Boiler and Pressure Vessel Code
and any additional requirements from the applicable piping code including any possible necessary
localised post weld heat treatment depending on material specifications.
3.0 OPERATION
3.1 MANUAL OPERATION
Valve adjustment is by clockwise turning of stem. Lever operated and gear operated valves have a
position indicator to indicate open or closed (see figure 1). Ball Valves must not be used for throttling. Do
not leave part open, or seats will be damaged. Valve must be full open or full closed or damage to seats
or body will occur.
FIG 1.
3.2 LOCK DEVICE
Where provided (optional) the valve has a locking lug that allows valve to be locked in full open or full
closed position.
4.0 MAINTENANCE
Valves should be periodically checked at least once every 3 months, but depending on service, criticality
and frequency of use, more regular checking may be required.

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FLOATING BALL VALVES - BV100 SERIES
Packing leakage could result in personal injury. Valve packing is tightened prior to
shipping but may require adjustment to meet specific service conditions.
If a valve does not fully close, damage to the seat and body will result due to the
venturi effect resulting in high pressure erosion. Flush or remove the valve at next
opportunity.
A good program of inspection and maintenance cannot be overstressed. It is recommended that the valve
be periodically and at least partially stroked/function tested to ensure the valve functions and prevent
seizure/sticking of any mating surfaces. Duration depends on service, criticality etc. However it also must
be factored in that if there are impurities or particulates in the line each operation could reduce seat life
proportionately. Periodic inspection of critical leak-path areas such as body/bonnet joint, end
connections, seating surfaces, and around the stem packing should be a requirement.
The most common area for leakage is around the stem packing, this is usually due to wear and can
normally be stopped by adjusting the packing. This procedure is performed by turning gland bolts or nut
(9) 1/2 turn at a time until leakage stops. Once leakage stops, continue tightening gland plate nuts an
additional 1/2 turn. If leakage cannot be halted by adjusting packing, repacking of the valve is indicated.
(Refer to field repair).
Do not attempt to replacing packing or replace stem while the valve is in service!
(The stem is blowout proof and can only be removed by disassembling the valve).
Only graphite packing is to be used for firesafe service, PTFE is not firesafe. A BV100
valve is firesafe only when fitted with graphite packing and graphite or spiral
wound graphite filled body gasket. Check the full part number on the label to
ensure the valve is specified as firesafe. If there is no firesafe logo on the label the
valve is not firesafe. If the port number indicates PTFE packing or body gasket the
valve is not firesafe.
4.1 GLAND PACKING
In case of slight leakage from the gland, gland packing bolts can be lightly tightened up without
effecting torque. (see 4.0) See Figure 2 and table 2 in the Appendix.
4.1.1 Stem Leakage – Stem Packing Replacement
The most common point for leakage is around the stem and packing this leakage can normally be stopped
by adjustment of the packing gland. If this does not stop the valve leakage, the valve will have to be
repacked.
The system and valve MUST be depressurised and removed from the line before attempting any repair
work. After removing all pressure from the valve and draining the system the following procedure should
be used to repack the valve.
1. Remove nuts or screw from the lever. Remove the lever and lock plate. Remove the gland nuts.
2. Remove old packing, taking care not to scratch or damage the stem of stuffing box. Note, the stem

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FLOATING BALL VALVES - BV100 SERIES
design is anti-blow out so the stem cannot be removed up through the top of the valve.
3. Clean and inspect stem, stuffing box, and gland. If any scratches, nicks, or corrosion is found, the parts
should be replaced.
4. Slide each packing ring over the stem and into packing chamber. Carefully tap each ring into place and
continue installing rings until the recommended number of rings have been installed. A thin smear of
molybdenum sulfide anti-seize grease may be used on the stem and packing chamber wall for packing
lubrication.
5. Replace gland, and gland nuts. Tighten gland nut(s) alternately in 1/2 turn increments until a
reasonable torque (refer table 2 in the Appendix) is applied to lightly compress packing. Lubricate stem
and cycle valve through a couple of complete cycles.
6. If slight stem leakage occurs after system is pressurised, continue tightening gland plate bolts in
alternating 1/2 turn increments until leakage stops. Once leakage stops, continue tightening gland
plate nuts and additional 1/2 turn. There is also a PTFE seal ring/bearing and larger sizes/higher classes
also have an elastomer o-ring. However, these parts can only be replaced during complete disassembly
of the valve. If a PTFE stem o-ring is fitted it can be replaced with an elastomer o-ring suitable for the
service medium and temperature. PTFE stem o-rings may require pre softening in hot water prior to
fitting. Should replacement of packing fail to prevent the leakage, complete reconditioning of the valve
may be required.
Personal injury may result from sudden release of any process pressure. APV
recommends the use of protective clothing, gloves and eye wear when performing
any installation or maintenance. Isolate the valve from the system and relieve
pressure prior to performing maintenance. Disconnect any operating lines providing
air pressure, control signals or electrical power to actuators.
NO. DESCRIPTION
8
11
1
10
2
3
4
5
9
6712
1Thrust Seal Washer
2Stem Packing
3Gland
4Belleville Spring Washers
5Stem
6Gland Nut
7Spring Washer
8Handle Nut
9Packing Nut Lock Clip
10 Stem O-ring
11 Anti-Static Device
12 Lock Device
FIG 2. CONSTRUCTION FOR GLAND PARTS
(example only, refer to as-built drawing)
4.2 BODY SEAL
Sealing between three body segments is provided by a gasket (Teflon, spiral wound or graphite) and both
valve segment surfaces also provide metal to metal sealing. In larger sizes or higher pressures an
elastomer O-ring may also be used. In case of slight leakage the body fastening bolts can be lightly
tightened up.

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FLOATING BALL VALVES - BV100 SERIES
If a gasket seal is disturbed while removing or adjusting gasketed parts, APV
recommends installing a new gasket while reassembling. A proper seal is required
to ensure optimum operation.
4.2.1 Body Gasket Tightening
Should leakage occur at the body joint, tighten bonnet bolts to the values shown in Table 1 (refer
Appendix). If after tightening body bolts, leakage continues, replacement of gaskets is recommended. A
new gasket is recommended anytime the valve is disassembled. The following procedure shown in 4.3 is
recommended for the replacement of the gasket and other trim components.
CAP BODY
Gaskets
FIG 3. STRUCTURE OF GASKETS IN BODY JOIN
(example only, refer to as-built drawing)
4.3 INSPECTION AND REPLACEMENT OF TRIM COMPONENTS
Disassembly: -
1. Place the valve in the half open position and remove all pressure and drain the system. Make sure that
leakage of any residual material is caught in an appropriate container and disposed of properly.
2. For gear operator or power actuator operated: - remove the bolt fastening the gearbox or power
actuator. Remove the gear operator or power actuator. Remove the bolt fastening the yoke or yoke nut
(depending on size/class).
3. For lever operated: - remove the nut fastening the lever. Remove the lever. Remove the retainer/lock
nut/washer and the stop plate.
4. Follow disassembly procedure 4.4 below.
5. Remove the ball from the body. Check the ball for any damage. Remove the seat from the body. Check
the seat for any damage.
6. Remove the stem and thrust plate from the body. Remove the thrust plate from the stem. Check the
stem for any damage.
7. Clean and inspect body and retainer gasket surfaces. Check for erosion, corrosion, or damage,
especially near point where leakage occurred. If damage is found, those surfaces must be repaired
before continuing.
8. Replace or repair all damaged parts.

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FLOATING BALL VALVES - BV100 SERIES
Reassembly: -
1. Installation of new seats, packing and seals is recommended, then follow reassembly procedure 4.5
below.
2. For gear operator or power actuator operated: - install the yoke and tighten the screws.
2a. Install key on the stem.
2b. Install gear operator on top flange and tighten the bolts.
3. For lever operated: - install stop plate.
3a. Install retainer/thrust washer.
3b. Install lever.
3c. Install washer and tighten the screw or fit circlip.
This completes the reassembly.
4.4 DISASSEMBLY PROCEDURE
Before removing valve from line ensure valve is in the closed position and line is fully closed off and
drained. Client should observe all industry & regulatory procedures in this process. To disassemble first
remove the operator (4.3.2) then the following steps should be followed with reassembly in reverse
order.
1. Drain & clean valve including contents in cavity.
2. Remove (2) BOLTS from (1) BODY and (4) CAPS.
3. Take off (4) CAPS from (1) BODY and remove (5) GASKET.
4. Carefully remove (15) BALL. Avoid scratching BALL surface.
5. Remove (3) SEATS from BODY and CAP.
6. Remove (11) STEM NUT, (10) LEVER, (9) GLAND NUT, (15) STOPPER, (17) STOP WASHER, (16) SPRING WASHER,
and (8) GLAND RETAINER (parts can vary according to size, class. Refer to as-built drawing).
7. Remove (12) STEM by pulling from inside BODY cavity.
8. Remove (6) THRUST WASHER.
9. Remove (7) GLAND PACKING and (20) STEM SEAL where fitted.
4.5 REASSEMBLY PROCEDURE
Check the packing box for pressurised process fluids even after the valve has been
removed from the pipeline, particularly when removing packing hardware or
packing rings, or removing packing box pipe plug.
1. For reassembly of the disassembled valves, follow the above disassembling procedure in the
reverse order.
2. After cleaning the disassembled parts, reset each part in the original position properly. The
threaded parts should be cleaned thoroughly and applied with lubricating paste.
3. The stuffing box and base of gasket should be thoroughly cleaned with care.

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FLOATING BALL VALVES - BV100 SERIES
4. The gland packing and gasket should be replaced preferably each time the valve is disassembled.
5. To reassemble body and cap, each bolt and nut shall be pre greased and then tightened in accordance
with applicable Torque as per Table 1 (see Appendix).
6. After installation of new parts:
Reassemble using reverse order of steps outlined above. Operate valve several times to be
assured of smooth operation before reinstalling.
TROUBLESHOOTING
MALFUNCTION POSSIBLE CAUSE REMEDIAL ACTION
Valve does not rotate
or operate
1. Packing is dropped too tightly.
2. The stem is torn or there is dirt.
3. The times of on-off operation are too
many or dirt exists on the surface of the
ball.
1. Loosen nuts and adjust again.
2. Pull apart the valve and clean the dirt.
Ball/Seat Leaking 1. Valve not full closed.
2. Seat or ball damaged
3. Debris trapped in valve.
1. Close the valve tightly
2. Replace seat or ball.
3. Clean the debris.
Stem Packing
Leaking
1. Gland bolts loose.
2. Packing damaged or missing.
3. Seal misaligned
1. Tighten gland bolts.
2. Replace packing (shut down rst).
3. Replace and align it correctly.
Body Gasket Leaking 1. Body bolts loose.
2. Body gasket damaged.
1. Tighten body bolts.
2. Replace the gasket.
Note
Nylon and Devlon are hard and more scratch resistant compared to Teflon®, and
PEEK is harder still. However, Teflon® is more resilient and has better ‘memory’ in
terms of resistance to permanent indentations. All soft seated valves are only suited
to clean service applications.

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FLOATING BALL VALVES - BV100 SERIES
5.0 CONSTRUCTION
BILL OF MATERIALS
ITEM DESCRIPTION SPECIFICATION
1Body A351-CF8M/316 A216-WCB/A105 A351-CN7M/A20 A352-LCB/LF2
2Bolt A193 Gr. B8 A194 Gr. B7 A193 Gr. B8 A320 Gr. L7
3Seat RTFE/Nylon RTFE/Nylon RTFE/Nylon RTFE/Nylon
4End Cap A351-CF8M/316 A216-WCB/A105 A351-CN7M/A20 A352-LCB/LF2
5Gasket PTFE/Graphite PTFE/Graphite PTFE/Graphite PTFE/Graphite
6Thrust Washer PTFE PTFE PTFE PTFE
7Stem Packing PTFE/Graphite PTFE/Graphite PTFE/Graphite PTFE/Graphite
8Packing Gland 316 304 A20 A20
9Gland Nut SS304 SS304 SS304 SS304
10 Handle SS SS/Galv SS SS/Galv
11 Stem Nut SS304 SS304 A20 SS304
12 Stem A276-316 A276-316 B437-A20 B437-A20
13 Cover Plastic Plastic Plastic Plastic
14 Stop-Pin SS304 SS304 A20 SS304
15 Ball A276-316 A276-316 B437-A20 B437-A20
16 Spring Washer SS SS A20 SS
17 Stop Washer SS304 SS304 A20 SS304
18* Locking Device SS304 SS304 A20 SS304
19† Anti-Static Device SS316 SS316 A20 SS304
20† Stem O-Ring PTFE/Viton Viton PTFE Viton
* Optional
† Depends on size & class
The above is indicative only. Design varies according to size, class, trim, etc. Refer as-built drawing.
REFERENCED STANDARDS
ANSI/ASME B16.34 - Valve Flanged, Threaded and Welding End
API Spec 6D - Pipeline Valves
API608 - Refinery Ball Valves
BS 5351 - Specification for steel ball valves for the petroleum, petrochemical and allied industries.
API Std 598 - Valve Inspection and Testing
ANSI/ASME B16.5 - Pipe Flanges and Flanged Fittings

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FLOATING BALL VALVES - BV100 SERIES
APPENDIX A
Bolting Torques
TABLE 1
INDICATIVE* TORQUE VALUES FOR TIGHTENING FLANGE BOLTS Ft Lb (Nm)
Stud Size Bolting Material
B7M/L7M B7/B16/L7 B8/B8M CL.1 B8/B8M CL.2
3/8 - 16 UNC 15 (20) 20 (27) 15 (20) 20 (27)
7/16 - 14 UNC 25 (34) 30 (41) 22 (30) 25 (34)
1/2 - 13 UNC 40 (54) 50 (68) 35 (47) 45 (61)
9/16 - 12 UNC 55 (75) 70 (95) 55 (75) 65 (88)
5/8 - 11 UNC 75 (102) 100 (136) 70 (95) 85 (115)
3/4 - 10 UNC 135 (183) 170 (231) 125 (170) 150 (203)
7/8 - 9 UNC 200 (271) 270 (366) 170 (230) 200 (271)
1 - 8 UNC 350 (475) 400 (542) 219 (298) 350 (475)
Note:
(1) Torques shown are for A193 B7/B7M/B8/B8M and A320 L7/L7M/B8/B8M.
(2) Torque tolerance ±10%.
(3) For temperatures above 750°F (400°C) use 75% of the torque values.
(4) Above torque values are with the bolts lubricated.
(5) Values above are based on 30,000 psi (206.85 Mpa) bolting stress and lubricated with heavy graphite and oil mixture or a copper based
anti-seize grease.
(6) Do not exceed by more than 25% of values stated when emergency torquing is required.
(7) All bolts shall be torqued in the pattern as shown in Table 2 in Appendix to ensure uniform gasket loading.
(8) Optimum torque can vary depending on type of body gasket but do not increase torque more than 10% above those shown.
(9) Consult us for other bolt material.
(10) Most B8M and B8 bolts are class 1 so do not assume class 2 unless you are sure.
Bolt tensions shown in Table 1 must be decreased by 25% when other or no
lubrication used. Non lubricated bolts can have an efficiency of up to 50% less than
the torque of values stated.
Indicative torques shown only, different body gasket systems, different seating
styles, different sizes & classes, etc., will have different torque requirements.
Furthermore, other stud grades can have much lower torques depending if class 1 or
class 2 and or above variables.

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FLOATING BALL VALVES - BV100 SERIES
APPENDIX A - CONTD.
Stud Lubrication
• Re-tightening of body bolts (with system de-pressurised) and gland packing bolting is permissible, if
leakage occurs in these areas.
• Required Torque values are given in Table 1.
• The use of copper-based Anti-seize grease for body and packing stud lubrication and molybdenum
disulfide anti-seize grease for stem packing lubrication is recommended.
TABLE 2
BODY BOLT TIGHTENING SEQUENCE
1 4
23