APV BVF100 Series Instruction manual

www.australianpipelinevalve.com.au
INSTALLATION, OPERATION & MAINTENANCE MANUAL
SIDE ENTRY 3 PIECE
TRUNNION BALL VALVES
API6D STANDARD
BVF100
SERIES

View our catalogues at www.australianpipelinevalve.com.au
AUSTRALIAN PIPELINE VALVE BRAND RANGE -CATALOGUES
APV FAMILY OF BRANDS RANGE - CATALOGUES
COMPLETE
PRODUCT LINE
“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.
APV valves and pipeline
products form the most
competitive portfolio
in the market.”
Oilfield Products
Valves & Wellheads
Gate, Globe & Check
Valves - Forged Steel
Plug Valves Lubricated,
Sleeved & Lined
Gate, Globe & Check
Valves - Cast Steel
Diamond Gear
Gearboxes
Flowturn Gate, Globe
& Check Valves
Flowturn
Instrument Valves
Flowturn Ball Valves
Multiway & Deadman
Flowturn Strainers
& Sight Glasses
Supercheck
Wafer Check Valves
Superseal
Butterfly Valves
Steamco
Steam Valves
Superseal
Industrial Ball Valves
TwinLok Tube Fittings Uniflo Check ValvesTorqturn Actuators
Ball Valves Floating
& Trunnion Mounted
Ball Valves
Floating Small Bore
Ball Valves
Special Service
Product Brochure
Contact us for your local stockist/distributor

Introduction 3
Safety Information 4-5
1.0 Preservation And Storage 5-6
1.1 Storage 5
1.2 Periodic maintenance during storage 5-6
1.3 Environmental consideration 6
2.0 Installation 6-11
2.1 Valve preparation 6
2.2 Valve installation 6-7
2.3 Maintenance prior to flushing 8
2.4 Flushing the pipeline 8-9
2.5 Maintenance post flushing 9-10
2.6 Commissioning 10-11
3.0 Valve Removal From Line 11
4.0 Gearbox Removal 12
5.0 Valve Disassembly 12-13
5.1 Body 12
5.2 Bonnet and stem removal 12-13
5.3 Ball removal 13
5.4 Seat and spring removal 13
6.0 Inspection And Repairs 13-15
6.1 Body and bonnet 13
6.2 Seat and seat housing 13
6.3 Soft seat insert (only for valve with soft seat insert) 14
SIDE ENTRY 3P TRUNNION BALL VALVES API6D STANDARD - BVF100 SERIES
INDEX
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 1

6.4 Seals 14
6.5 Spring 14
6.6 Bearings 14
6.7 Ball 14
6.8 Steam seal and stem 14
6.9 Bolts, nuts and threaded components 15
7.0 Valve Assembly 15-16
7.1 Valve lubrication 15
7.2 Seat and spring assembly 15
7.3 First adaptor assembly 15
7.4 Ball, support, bonnet and stem assembly 15
7.5 Second adaptor assembly 16
7.6 Gearbox mounting to valve 16
7.7 Pressure Test 16
8.0 Operation And Maintenance Instructions 16-20
8.1 Operation instruction 16
8.2 Lubrication 17
8.3 Valve operating 17
8.4 Maintenance schedule 17-18
8.5 Double block-and-bleed 19-20
9.0 Automatic Over Pressure Relief 20
10.0 Overview Design Features 22
Appendix 1 - Typical Bill of Materials 23-24
Appendix 2 - Bolting torques 25-26
Appendix 3 - Label details 26
Appendix 4 - Design features 27-28
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Australian Pipeline Valve - Installation, Operation and Maintenance Manual2

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Australian Pipeline Valve - Installation, Operation and Maintenance Manual 3
INTRODUCTION
The majority of this information is common knowledge to experienced steel valve users. When properly
installed in applications for which they were designed, APV valves will give long trouble free service. This
instruction is only a guide for installation, operation and minor maintenance. A professional APV approved
valve engineering facility should be utilised for reconditioning and minor repairs.
RESPONSIBILITY FOR VALVE APPLICATION
The User is responsible for ordering the correct valves. APV Valves are to be installed in the observance of
the pressure rating and design temperature. Prior to installation, the valves and nameplates should be
checked for proper identification to be sure the valve is of the proper type, material and is of a suitable
pressure class and temperature limit to satisfy the applications requirements.
RECEIVING INSPECTION AND HANDLING
Valves should be inspected upon receipt to determine:
- Compliance to purchase order requirements.
- Correct type, pressure class, size, body and trim materials and end connections (this information may
be found on the nameplate or may be stamped on the body of the valve).
- Any damaged caused during shipping and handling to end connections, hand wheel or stem.
Note
We do 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.
Do not use any valve 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.
The End User is advised that misapplication of the valve may result in injuries or
property damage. A selection consistent with the particular performance
requirements is important for proper application and is the sole responsibility of the
end user.

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SAFETY INFORMATION
The following general safety notices supplement the specific warnings and cautions appearing elsewhere
in this manual. They are recommended precautions that must be understood and applied during operation
and maintenance of the equipment covered herein. This manual provides instructions for storing, general
servicing, installation and removal of ball valves.
Do not use the ball valve in process conditions where the pressure, temperature,
media and other technical conditions exceed the limitations set by the valve’s
specifications. When handling fluids that could cause damage to human health, the
environment or property, the necessary safety precautions to prevent risk must be
taken.
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 client to ensure the valve type and materials are correctly specified.
Do not attempt to disassemble a valve while there is pressure in the line. Make sure
both upstream and downstream pressures are removed. Disassemble with caution in
the event all pressures are not relieved.
To prevent valve distortion, inefficient operation, or early maintenance problems,
support piping on each side of the valve.
• A valve is a pressurised device containing energised fluids and 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.
• Adequate ventilation should be available for service

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DURING OPERATION BEAR IN MIND THE FOLLOWING WARNINGS:
a- The graphoil packing and body gasket is very brittle: any twisting or bending shall be avoided.
b- The internal parts of valves (ball, stem, seats) shall be handled with care avoiding scratches or surface
damage.
c- All tools and equipment for handling and supporting internal critical sealing parts shall be coated with
soft materials.
d- Seats & seals usually include Viton, Devlon, Nylon & Teflon, hence high temperatures and some
chemicals will damage sealing components.
e- Never part open valve, valve must be fully open of fully closed or else the seats will be damaged.
For all operations make reference to position number on part list of the applicable drawing. The drawing
in the Appendix is a general drawing only, for more accuracy refer to the as-built drawings supplied with
the order.
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” 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.
1.0 PRESERVATION & STORAGE
1.1 STORAGE
a- If storage in the field for a long time before installation is necessary, it is suggested to put valves in a
dry and/or covered place. In this case the packaging and end covers integrity is especially important.
b- All the valves are supplied with special plastic ends to cover and protect the internal parts. We
recommend you do not remove them during storage period.
c- Valves should be left in the open position (unless actuated and set fail closed).
1.2 PERIODIC MAINTENANCE DURING STORAGE
In case of extended storage, the valves must be inspected and maintained as follows:-
• External surfaces must be inspected to ensure no damage to flange faces, paint finish etc. In case of
the presence of rust and/or damaged painting, the area must be cleaned by brushing, degreasing &
repainting.

• The protection must be restored following the instruction indicated from APV in accordance with the
painting cycle used.
• Without any ball movement, the internal surface of the valves must be inspected to check the complete
absence of dust, rust, foreign matters and the integrity of lubricant coat. If not satisfactory then clean
and lubricate the internal part using a nebulised lubricant. Do not leave any lubricant on the seat itself
or else the seat may attract debris which in turn could damage the seat.
• After cleaning and lubrication the ball must be operated (close/open complete stroke).
• The ball must be kept in the full open position during installation.
• The end of the valve must be protected using the same end covers.
• We recommend you tropicalise bore and ends of valves if stored in humid or salt air environment.
Grease bore with valve full open so no grease is applied to soft seat inserts.
1.3 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.
2.0 INSTALLATION
2.1 VALVE PREPARATION
a- Remove the ends protectors and check accurately the status of the valve as indicated in point 1.2.
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- Do not operate the valve until the following procedures have been fully applied:
• Clean internal conduits.
• After cleaning the ball must be operated (one complete stroke).
• During installation the ball must be kept in the fully open position.
2.2 VALVE INSTALLATION
a- To handle the valve use body lugs if applicable or suitable eyebolts. Never handle the valve by yoke or
using the lever or actuator or gear box eye bolts. Never lift from bore of valve.
Do not lift the valve
using only one lifting lug.
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b- The end protectors must be removed only immediately before installation. If one of end is not
connected to the line for a period of longer than half a day the opened end shall be securely sealed
with plastic or wooden cover.
c- For butt weld type valves take care for the following: If brushing or grinding, seal valve conduit (bore)
to prevent damage. At the end of such operation clean accurately the conduit. The welding procedure
and post-weld treatment shall be performed taking into account the allowable maximum temperature
for seats and seals. The welding sequence shall be pre-planned in order to give an acceptable piping
load to the valve. Leave valve in full open position to reduce temperature transmission to soft seats. For
valves up to 80 NB (3”) use temperature measuring strips. Ensure temperature of body does not go
above 180
° C.
d- At the end of installation lock the valve full open in order to avoid any movement of the ball before
flushing the pipeline.
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.
f- Ball valves are usually bi-directional, and therefore may be installed in either direction. In some cases,
ball valves such as ‘metal to metal’ and low temperature valves may be unidirectional, in which case
the direction of flow will be indicated on the valve body.
If the ball valve is equipped with a test connection port, make sure that it is fully
closed before pressurising the valve.
Local safety regulations must be complied with for transport to the place of
installation. Make sure that the valves cannot tilt or slip in any way (see figure
below).

2.3 MAINTENANCE PRIOR TO FLUSHING
a- If the period between installation and flushing of the of the pipeline is longer than six months a
preventative maintenance operation is suggested.
• Lubricate the stem with fluid protective oil through the stem injector (if applicable). Do not grease
lubricate seats as grease may attract debris and damage seats.
• Remove valve from line and remove any debris and reflush.
2.4 FLUSHING THE PIPELINE
Flushing washes away all welding slag, dirt, sand, solids and debris collected in the pipelines during
construction prior to turning the valve and potentially damaging the seat. Flushing where deemed
necessary is the most dangerous activity for the valve, and it happens before they are put into service.
Ball valves are normally not lubricated, however, should it be required to flush potential debris (or
lubricate sticky valves) a different practise to the lubrication of either a gate valve or plug valve should
be employed. We recommend the following: -
1. Find a good grease for natural gas or your service. The grease must be insoluble. It must be resistant to
breakdown or shearing of the gel structure under high pressure injection and under the pressure
between seating surfaces. It must be stable over a wide range of temperatures, and not freeze. It must
not react chemically with the fluid and become solid, or rubber like (i.e. polymerize). Depending on the
service, the best greases are fully synthetic; if you have any doubt or concern, consult a valve
maintenance expert. Field experience has shown that greases and sealants may cause severe problems
with the seat and seal arrangement if used regularly during preventative maintenance. If a non-leaking
ball valve is lubricated with an adhesive grease/sealant, the floating, spring loaded seats can become
stuck within their seat pockets. When the ball floats due to a pressure differential across the valve, the
seals cannot track the ball and leakage can occur. Grease manufacturers produce low viscosity
synthetic ball valve lubricants such as Clare UK “601-Fluid”. Such light greases offer the following
advantages to heavier emergency sealant greases and cheaper brands of light greases:
• Enhanced resistance to hydrocarbon fluids and gases.
• Will not dry out or form a gum like some other greases when used within its application temperature
range.
• Will not disrupt the operation of the seat and seal arrangement.
Of course, be warned any type of grease, especially synthetic grease can become hard or sticky causing
torque problems and seat spring jamming in which case a line flushing agent like Clare 601 Valve Cleaner
may be required. Of course, for leaking seats a heavier sealant like Clare 601 lubricant must be used for
temporary emergency sealing.
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Beware of greases made of synthetic oil with a mineral thickener. The natural gas
(or storage prior to use) washes away the oil, leaving the thickener behind. The
thickener is like a powder that caulks or bakes hard on the seats, increasing the
operating torque. Always wipe the seats clean as much as possible prior to
installation. The increased torque may effect pneumatic actuated valves.

2. Use an appropriate high pressure grease-injection pump, capable of overcoming the pipe pressure and
the high pressure build-up caused by the grease itself, during it’s injection in the grease passages.
3. Inject a generous amount of grease in the seats before flushing. The object is to cover them all and to
fill the groove between seat carrier and ball with grease. The dirt will get stuck to the grease during
flushing, but it will not come inside. And before turning the valve for the first time, inject again a small
amount of grease into the seats. A little is enough (1/4 of the normal quantity per seat, see 8.4.1). The
dirty grease will be pushed into the pipe by the fresh grease, and the turning action of the ball will
drag fresh grease towards the seats, not dirty grease.
4. Do not turn the valve during flushing.
2.5 MAINTENANCE POST FLUSHING
a- At the end of flushing operation it may be possible to leave the line full of test fluid and in this case no
intervention is required. If the line must be drained proceed as follows:
• Make sure that the valve is in full open position.
• Open plugs and drain it completely. Observe safety plant procedures prior to opening any body plugs in
case any remaining fluid or gas is pressurised or trapped in body cavities.
• After draining flush the cavity of valve through the vent plug. Consult an expert on use of special
excavation procedures.
• Lubricate the stem with fluid protective oil or grease through the injector (if applicable). (Seat
lubrication is normally only required for emergency purposes not for ongoing maintenance).
• Completely tighten all drain and vent plugs. Consult your plant safety procedures and only perform
work under supervision of expert valve maintenance personnel.
b- Operate the valve at least 2 times (complete closing and opening operation).
c- Repeat the operation every 6 months if the pipeline is not used.
d- Always get authorisation to partially operate an in-service valve.
Personal injury may result from sudden release of any process pressure. APV
recommends the use of protective clothing, gloves and eyewear when performing
any installation or maintenance. Isolate the valve from the system and relieve
pressure prior to performing maintenance. Never unscrew sealant injection nipples
from body, seats or stem as these outlets are exposed to full line pressure and only
the in-built check valve in the sealant nipple itself isolates the pressure. Similarly,
the body drain and vent valve plugs are exposed to full line pressure if opened.
Disconnect any operating lines providing air pressure, control signals or electrical
power to actuators.
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Note
Do not operate the valve during flushing or entrained particulates could damage
soft seat or enter stem or seat pocket area.

2.6 COMMISSIONING
The first year of operation is crucial, because when the pipe is put into service, all debris is pushed
downstream, and contaminates the valves along it’s travels. With time, the pipe gets cleaner and initial
problems disappear. Strainers or filters should be installed upstream of all soft seated valves.
The same recommendations regarding grease injection for flushing (see 2.4) apply for commissioning. By
refilling the grease channels multiple times, the dirt is gradually pushed out of the seats. Provided that
the grease is properly chosen (see 2.4), it will not damage the valve, and to a certain extent will shield
the seats from contamination. Regular cycling is also important, for two reasons: to prevent the seats
from getting stuck, and to distribute fresh lubricant over the seating surfaces of the ball and seats. Once
the seat is greased, it is a good idea to pump fresh grease into the seat to expel any debris laden grease
(see 2.4.3) before cycling the valve to avoid damage to soft seat inserts. Many operators prefer not to
grease seats even during commissioning as the grease can attract debris which can damage the seats if
the valve is then turned. Also grease channels can become blocked if grease hardens. However, if the
service is dirty the seats will damage either way, hence many users find regular greasing delays the
damage. Should you need to apply grease to seats, ensure you then inject fresh grease to dispel any
grease which may have attracted contaminants and then partially stroke the valve multiple times to
remove as much grease as possible from the seats. After commissioning, once you believe the service is
clean you can inject a suitable grease line flushing agent and then partially stroke the valve again. You
should consult a valve maintenance specialist as different service, media, pressures, temperatures, etc.,
can require totally different practises. APV recommends the following programme for start up: -
1. For the first year, inject a small amount of grease into the seats before turning the valve, every time.
2. Cycle the valves periodically as follows:
• For the first month, every week.
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Note
Remember that ball valves in natural gas service are like the human body; they
need ‘exercise’. Keep moving them and lubricating them, and you will have fewer
problems. Do not let them have a sedentary life.
Natural gas is not usually clean. Natural gas may carry condensates and dirt that
gets trapped in the valves, and may damage the internal parts. Also, operation of
the valves becomes more difficult. It is true that plant sites do install filters in their
system, but experience has proven that no system is perfect. The internal parts of
the valve can be partially protected using judicious amounts of grease to fill the
cavities. However, other than when flushing (see 2.4.3) or if there is seat leakage,
or if valve cannot be opened, no grease should be applied via seat sealant injectors
to soft seats as it will attract debris and cause damage. A soft seated valve is
always at risk if service is not clean.

Stem seal body leakage can result in personal injury. BVF100 valves have a triple
barrier internal stem seal and cannot be ‘adjusted’ like a gland packed ball valve.
In an emergency, injecting grease into the grease sealant injection nipple fitted to
stem (where fitted) may temporarily cause the leakage to cease (refer 8.2) but the
valve should be removed from the line for repair as soon as possible.
• For the second month, every two weeks.
• For the third month, every month, for at least 6 months.
• Then every three months.
Depending on the type of seat inserts and type of particulates encountered in the media, after
commissioning it is best to only use the seat lubrication nipples for emergency use as it is possible that
grease on the seats will actually attract debris which can then damage the seats during closing or
opening. Nylon and Devlon are hard and resistant to scratching, PEEK is even harder. Teflon® (PTFE) is
softer and scratches easier, yet it can have more resilience and ‘memory’ in terms of resistance to
permanent indentations. However, all soft seated valves are only suitable for clean service. Also note,
PEEK seated valves have a higher operating torque. Teflon has the lowest operating torque, however it
has more ‘memory’ and if left closed for a long period of time the torque required to unseat it will
increase. Teflon is not suitable for larger sizes and higher pressures. Regardless of soft seat materials,
valves need to be regularly partially stroked to prevent sticking of seats and accumulation of entrapped
debris.
3.0 REMOVAL FROM LINE
It is desirable that the maintenance operations are carried out by skilled personnel who are experienced
and well trained in standard field techniques and procedures. Be sure that the personnel involved in such
operations are aware of fundamental safety rules indispensable for the protection of their own and other
people’s safety. Ball valves are field maintainable, hence to carry out normal maintenance (stem
lubrication, stem packing substitution, seat lubrication) it is not necessary to remove it from line (seat
lubrication is only for emergency purposes not for maintenance).
If it is required to remove the valve from the line proceed as follows:
a- Ensure the line is fully depressurised.
b- Partially open the ball in order to depressurise the valve.
c- Remove the drain plug and vent plug. First release vent to ensure no remaining pressurised gas or fluid
trapped in cavity. Take safety precautions to avoid personal injury during this procedure. Then carefully
remove drain plug once you are sure valve has no remaining fluid or gas in cavity.
d- Keep the ball in the fully open position.
e- Remove the valve from the line. The valve shall be handled by means of lifting lugs fitting on the valve
(if applicable). Standard field techniques and procedures are satisfactory to disconnect it from the line.
f- After removal of the valve from the line, clean the valve and seal the ends with plastic or wooden
covers.
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4.0 GEARBOX REMOVAL
a- Removal (refer to enclosed drawings)
• Unscrew the bolts/nuts.
• Lift the gear box to disengage the valve stem and remove it with the plate.
b- Put in position a removable cover to prevent the introduction of dust, sand, etc., in the actuator
bushing.
5.0 VALVE DISASSEMBLY
The following should only be performed by an APV approved reconditioner.
Note, The below parts refer to the general drawing in Appendix 1. This is a general overview drawing
only. Each size & class range does vary so refer to the actual as-built drawing.
5.1 BODY
a- The valve shall be supported adequately leaving the adaptor part no.03 free.
b- Unscrew adaptor flange nuts.
c- Remove both adaptors part no. 03 sliding parallel to the through conduit valve axis.
d- The above mentioned operation must be performed taking care of the O-ring and fire gasket integrity.
5.2 BONNET AND STEM REMOVAL
a- Remove the actuator or gearbox from it’s support part no. 09.
b- Remove the bonnet part no. 10 be careful to maintain the bonnet axis parallel to the stem axis.
c- Remove gasket/or O-ring part no. 14.
d- Remove the stem part no. 12 sliding parallel through the bonnet part no. 10.
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Check the stem sealing area for pressurised process fluids even after the valve has
been removed from the pipeline, particularly when removing packing hardware or
sealing rings.
Note
The actuator or gearbox position stops have been properly set in the shop. Do not
alter the setting.

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5.3 BALL REMOVAL
a- Remove the ball part no. 02 and the support.
part no. 23 through the lateral port.
5.4 SEAT AND SPRING REMOVAL
a- Seats are easily removable from lateral flanges.
b- Ensure the flanges are on a horizontal plane.
c- Lift the seat-ring part no. 04.
d- Remove and clean the springs part no. 08.
6.0 INSPECTION AND REPAIRS
The following inspection and maintenance procedures of valve components should be performed by a
professional valve repairer. Replace any parts that are damaged with genuine APV spare parts.
The sampled drawing in Appendix 1 is used as an example to reference parts. However, the Bill of Material
varies according to size, class & trim, hence refer to as-built drawing.
6.1 BODY AND BONNET
a- Clean accurately inside the body. The surfaces shall be free of rust, scale, dirt etc.
b- Clean accurately the body seats with kerosene removing any dirt.
c- Any local scratches shall be smoothed with emery cloth.
d- Inspect bonnet gasket status and replace is damaged.
e- Lubricate gasket area and matching surface with an appropriate thin film of grease.
6.2 SEAT AND SEAT HOUSING
a- Seat housing shall be free of rust, scale, dirt, etc.
b- After cleaning lubricate accurately the seat housing with a thin film of grease.
c- Repeat the operations a & b for the second seat-ring and gasket. Check in particular the status of the
seat surfaces in contact with the ball. Clean accurately and smooth eventual small damages using
emery cloth. Any deep scratch crossing the whole sealing area shall be cause for rejection.
Note
(only for ENP ball): - Keep in mind that if electroless nickel plating is damaged the
ball will require replacement or re-machining and re-plating.
Exploded view upper
stem and seat area

6.3 SOFT SEAT INSERT (ONLY FOR VALVE WITH SOFT INSERT)
a- The soft insert shall be free of damages otherwise the seat shall be replaced.
WARNING: due to the specialised manufacturing process, the performance of the seat insert is
guaranteed only if manufactured by APV. Do not attempt to press in a new after market seat insert.
b- A non genuine or client made refurbished part will void the warranty.
6.4 SEALS
a- Clean and check the gasket’s status and repair/replace them if damaged.
6.5 SPRING
a- Remove and clean the spring part no. 08 with kerosene or similar solvent.
b- Fill with grease the spring holes on the seats.
c- Check the springs function properly.
d- Assemble the springs on the seats, be careful to avoid any damages to the seat gasket.
6.6 BEARINGS
a- The surfaces of the bearing shall not exhibit any signs of scratches or deep abrasion.
b- If necessary the bearing can be removed acting with the proper tool (screwdriver or chisel) between
bearing wall and ball.
c- The new bearing can be forced into the housing.
6.7 BALL
a- Clean the ball, check accurately the surfaces in contact with the seats and bearings.
b- Any damages of the surface must be eliminated by polishing with emery dust. Any deep scratch
crossing the whole sealing area shall be cause for rejection.
c- Lubricate accurately all the surfaces with a film of grease.
6.8 STEM SEAL AND STEM
a- Clean the stem surfaces and check in particular the portion in contact with gaskets.
b- The stem shall be free of abrasion, scaling or scratches.
c- Lubricate accurately with the grease.
d- Check seals and replace them if necessary.
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If a gasket or seal is disturbed while removing or adjusting soft parts, APV
recommends installing a new gasket or seal. A proper seal is required to ensure
optimum operation.

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6.9 BOLTS, NUTS AND THREADED COMPONENTS
a- All bolts, nuts, and threaded particulars shall be cleaned with kerosene, dried and lubricated with
protective oil. The body bolts should have a copper based anti-seize grease applied. To ensure grease
does not dry or wash out and does prevent corrosion protective plastic nut caps with grease nipples
are available.
b- The threads should be visually inspected to verify the integrity of the components.
7.0 VALVE ASSEMBLY
The sample drawing in Appendix 1 is used as a reference, however, refer to actual as-built drawing as the
Bill of Material varies according to size, class and trim.
7.1 VALVE LUBRICATION
For components that need to be lubricated use grease IP Bimol Grease or similar.
7.2 SEAT AND SPRING ASSEMBLY
a- Put the spring part no. 08 into proper housing on the seats part no. 04.
b- Be sure that the flange/body seat area is properly lubricated and position it on a horizontal plane.
c- Insert the o-rings part no. 17 and the fire safe gasket into the grooves of the seat ring part no. 04.
d- Lower the seat ring into the body/flange cavity. Be careful to avoid damaging the gasket.
7.3 FIRST ADAPTOR ASSEMBLY
a- Assemble the adaptor part no. 03 with the body.
b- Screw studs part no. 19 and tighten the nuts part no. 19a (ensure they are pregreased as per 6.9).
c- Refer to Appendix 2 for bolting torques.
7.4 BALL, SUPPORT, BONNET AND STEM ASSEMBLY
a- Assemble the bearings part no. 20, the O-rings part no. 11 and 14 and the gasket with the bonnet part
no. 10.
b- Introduce the stem part no. 12 into the bonnet. Be careful to maintain the stem in the same axis of the
bonnet.
c- Assemble the ball part no. 02 with the bearings part no. 20a and support part no. 23 and insert the
ball in the lateral body cavity.
d- Insert the stem and the bonnet in the ball, through the upper port of the body. Make sure that the stem
groove of the key is along pipeline direction, with the ball in the fully open position. Screw and tighten
the stop screws part no. 18.

7.5 SECOND ADAPTOR ASSEMBLY
a- Assemble the second adaptor part no. 03 into the body lateral opening.
b- Screw studs part no. 19 and tighten the nuts part no. 19a (ensure they are pregreased as per 6.9).
7.6 GEARBOX MOUNTING TO VALVE
a- Assemble the gear support with the valve.
b- Insert the actuator/gear on the support with the valve.
c- Screw and tighten the studs/nuts actuator.
7.7 PRESSURE TEST
a- Move the ball in the half position.
b- Pressurise the valve body. The body hydrostatic test should be performed at a pressure 1.5 times the
maximum rating pressure in accordance with API6D.
c- With the ball in the fully open or closed position the maximum seat hydrostatic test pressure should be
be performed at a pressure 1.1 times the maximum pressure rating in accordance with API6D. In
addition a low pressure pneumatic test of 700KPA should be performed in accordance with API6D.
Seats should be tested bi-directionally.
8.0 OPERATION & MAINTENANCE
8.1 OPERATION INSTRUCTION
a- Hand wheel and gear operated ball valve have to be fully opened and closed to check the valve is
correctly operating.
b- In the case of automated valves, the instructions from the actuator’s manufacturer shall be supplied
separately. In this case, automated valves shall be operated with the required energy source (electric,
pneumatic, hydraulic) to check correct functioning.
c- Do not change any settings such as position stops or speed or torque governing devices.
d- Ball valves are provided with:
• Thrust and radial PTFE/steel bearing;
• Contact surface between ball and seats is anti-wearing and self lubricating. Hence no lubrication and
maintenance activity should be required. However, since the valves normally operate with industrial
fluids and gases which could have a range of impurities, a preventative maintenance program is
required as part of your plant management procedures.
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The valve is only intended to block or allow flow through the pipeline. The valve
should only be used in either fully open or fully closed position. Do not use this
valve to regulate flow by partially opening or partially closing the valve. The valve
should not stay in a semi-open or semi-closed state for more than two minutes.

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8.2 LUBRICATION
a- Ball valves require no lubrication for normal operation. If required, it’s possible to lubricate the stem
and the seats through emergency sealant injection grease-check valve where required when these
nipples are provided. This is only in the event of leakage or if the valve is difficult to open. The stem
injection nipple can be optionally greased with molybdenum sulphide anti-seize grease to ensure ease
of operation especially for automated valves. If no leakage, it’s not required or advisable to lubricate
seat sealant injection nipples as the grease may attract debris which could damage the seats longer
term. See 8.2b below if seat lubrication is desired or required. Never unscrew complete sealant
injection nipples from body as they are under line pressure. Always replace protective caps where
fitted to sealant nipples after use.
b- Some end users prefer to lubricate/grease the valve seats at injection points on the seats of the valve
located on the valve body. Quantity of grease required can very greatly depending on the valve size,
cycle frequency and service condition. As a general guideline use 30 ml (1 ounce) of lubricant per inch
size of valve into each seat fitting. Use proper lubricant/grease for you line media application to ensure
resistant and compatibility to media and temperature flowing through the line. See 8.4.1 for emergency
seat sealant if seats leak.
c- Also see 8.4.1 for emergency seat sealant injection procedures.
Exploded view stem
and body sealant injection
8.3 VALVE OPERATING
a- It is advisable, where possible (especially if valve is an actuated ESDV), to move the ball periodically in
order to prevent any hard scale or memory lock between ball and seat.
b- Partial operating (at least about 5% of the total stroke) every 6-12 months will ensure a good life of
seats and ball. This will ensure the valve functions and will prevent seizure/galvanisation 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. However
immediately fully re-open or fully re-close the valve as partial opening for more than a few minutes
will damage the seat.
c- Before operating with the valve completely open or closed it is advisable to lubricate the internal
components as per point 2.4.3 and 2.6.

8.4 MAINTENANCE SCHEDULE
ESTABLISH INTERVALS ACCORDING TO PLANT REQUIREMENTS.
a- Stem packing or seal leakage. In case of leakage from stem seal or packing proceed first to inject
sealant through the sealant nipple where provided (see 8.4.1 below). If it does not stop the leak the
stem gland seal must be replaced.
b- Body-adaptor leakage. If leakage from body and adaptor join occurs, it is necessary to replace the
body gasket.
c- Seat leakage. In case of leakage from seat rings it is possible to inject special silicon grease into
emergency seal injection nipples (see 8.4.1 below). Be sure that the grease pump employed for this
intervention is able to give a pressure higher than the pipeline pressure.
8.4.1 Emergency Sealant Injection Procedure
A sealant is a heavy grease-like substance used to stop small leakages through sealing surfaces. A
slightly damaged or scratched sealing surface can still close if some sealant is injected. Sealant injection
is intended for temporary emergency situations, where a major valve overhaul to replace the seats is not
possible.
Sealant is injected through the grease fittings (25) located in the valve body, near the seat area. Grease
fittings are not fitted on all valves as some clients prefer not to have them to prevent the possibility of
applying grease unnecessarily which can then attract debris and damage the seat. In smaller size valves
there is only a body sealant injection. In this case the valves must be full open during injection, more
grease is required as the valve cavity must first fill, then stroke the valve in order to wipe the grease
onto the seats. Then repeat the procedure. For normal lubrication see 8.2.
Sealant injection is a temporary measure, remove the valve at first opportunity and
repair. Greasing the seats can then attract more debris onto the seats so only grease
in an emergency, unless flushing with light grease as shown in Section 2.4.
In most cases, sealant injection in the upstream seat will be enough to stop a small leakage. However, it
would probably be necessary to inject sealant each time the valve is operated to keep leakage under
control. If standard grease does not work there are many PTFE composite greases with advanced sealing
capabilities available.
The procedure for injection of sealant in the seats is as follows:
1. Before injection of sealant, ensure that the ball stops are not out of alignment. A small misalignment of
2 or 3 degrees may open the bore hole to the line pressure, causing continuous leakage.
2. Use an appropriate high pressure sealant-injection pump, capable of overcoming the pipe pressure and
the high pressure build-up caused by the sealant itself, during it’s injection in the sealant passages.
3. Confirm that the ball is in the closed position (unless, as is sometimes the case with valves 80 NB (3”)
and under, the valve has a single sealant nipple only on body cavity, then it must be in full open
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