APV FS900 Series Instruction manual

www.australianpipelinevalve.com.au
INSTALLATION, OPERATION & MAINTENANCE MANUAL
UNI BODY BALL VALVES
FS900 SERIES

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BALL VALVES - FS900 SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 1
INDEX
© Copyright Australian Pipeline Valve 1990 - 2021 Edition
Catalogues, photos, brochures and technical publications are the exclusive property of Australian Pipeline Valve.
Any unauthorised reproduction in total or in part, shall result in prosecution. Products and data sheets in this publication are subject
to change at anytime without notice. Australian Pipeline Valve reserves the right to carry out amendments to products and materials.
Introduction 2
Safety Information 3-4
1.0 Scope 4-5
1.1 Environmental considerations 4
1.2 Storage 4
1.3 Preparation 5
2.0 Installation 5-6
2.1 Preparation for installation 6
2.2 End connections 6
3.0 Operation 6-7
3.1 Manual operation 6
3.2 Lock device 7
4.0 Maintenance 7-11
4.1 Gland packing replacement 7-8
4.2 Body seal 8-9
4.3 Inspection and replacement of trim components 9
4.4 Disassembly procedure 9-10
4.5 Reassembly procedure 10-11
5.0 Construction - Typical bill of materials 12-13

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BALL VALVES - FS900 SERIES
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.

BALL VALVES - FS900 SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 3
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.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual
4
BALL VALVES - FS900 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. The ASME
class or cold working pressure shown indicates the maximum rating of the body however, seats & seals
down rate the pressure and temperature. See section 5 for pressure/temperature chart.
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.

BALL VALVES - FS900 SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 5
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 lever 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 name plate.
Ensure the valve is suitable for the service which it is being used.
b) Before installation check internal ball/seat retainer is tight.
c) Remove valve end protectors and ensure threads are free from damage. Check packing gland nut is
tight.
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.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual
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BALL VALVES - FS900 SERIES
2.1 PREPARATION FOR INSTALLATION
• Remove protective end caps or plugs and inspect valve ends for damage to threads.
• 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.
2.2 END CONNECTIONS
2.2.1 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 flow path. Use compatible grade of PTFE thread tape.
FS900 Series is not suitable for socket weld use.
3.0 OPERATION
3.1 MANUAL OPERATION
Valve adjustment is by clockwise turning of stem. Lever 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.

BALL VALVES - FS900 SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 7
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.
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. Do not over tighten or the valve could be damaged. If debris is
blocking the seat do not attempt to force the valve or the stem will be damaged.
A good program of inspection and maintenance cannot be over stressed. 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 nut 1/2 turn
at a time until leakage stops. Once leakage stops, continue tightening gland nut an additional 1/2 turn. If
leakage cannot be halted by adjusting packing, repacking of the valve is indicated. (Refer to field repair).

Australian Pipeline Valve - Installation, Operation and Maintenance Manual
8
BALL VALVES - FS900 SERIES
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 FS900
valve is firesafe only when fitted with graphite packing and graphite gasket. Check
the full part number on the label to ensure the valve is specified as firesafe. If the
port number indicates PTFE packing or body gasket the valve is not firesafe.
4.1 GLAND PACKING REPLACEMENT
In case of slight leakage from the gland, gland packing bolts can be lightly tightened up without
effecting torque. (Refer to Section 5.0 for Bill of materials).
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 locking tab. Remove
the gland nut.
2. Remove old packing, taking care not to scratch or damage the stem of stuffing box. Note, the stem
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 alternately in 1/2 turn increments until a reasonable
torque (Refer to Section 5.0 for Bill of materials) 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 nut 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 thrust washer however, this part can only be replaced during
complete disassembly of the valve. Should replacement of packing fail to prevent the leakage,
complete reconditioning of the valve may be required.

BALL VALVES - FS900 SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 9
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.
4.2 BODY SEAL
Sealing between three body segments is provided by a friction fit retainer and a gasket (Teflon or
graphite). Ensure thread is undamaged and body pocket around gasket is clean and free from scratches
or damage.
If a gasket seal is distrubed while removing or adjusting gasketed parts, APV
recommends installing a new gasket while reassembling. A proper seal is required
to ensure optimum operation.
4.3 INSPECTION AND REPLACEMENT OF TRIM COMPONENTS
Disassembly: -
1. Place the valve in the half open position, 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. Remove the nut fastening the lever. Remove the lever. Remove the retainer/lock nut/washer and the
stop plate.
3. Follow disassembly procedure 4.4 below.
4. Remove the ball from the body. Inspect the surface of the ball for any scrapes or damage.
a. The cause of the problem such as dirt, fluid, etc must be rectifed to avoid further damage.
b. If imperfections are found on the contacting area of the ball and ball seat the ball must be taken for
fine milling. If heavily damaged, then it will need to be welded and re-machined or the ball
replaced completely. If the scraped area damage is elsewhere, it too must be fine milled to avoid
the ball heavily damaging the soft seat during the open and close operation.
c. Remove the seat from the body. Inspect the seat for any scrapes, concaves, dust (including welding
dregs, iron bits, sands, etc) and abrasion damage. Typically the damage will occur at the same time
the ball is damaged and is the leading cause of leakage. If leakage occurs before repairing, replace
the seat (PTFE or RPTFE).
d. If marks from press or fine scrapes are found during abnormal operation pressure, consider the
right choice of valve.
5. Remove the stem and thrust washer from the body. Remove the thrust washer from the stem. Check
the stem for any damage.
6. Clean and inspect body and retainer gasket surfaces. Check for erosion, corrosion, or damage,

Australian Pipeline Valve - Installation, Operation and Maintenance Manual
10
BALL VALVES - FS900 SERIES
especially near point where leakage occurred. If damage is found, those surfaces must be repaired
before continuing.
7. Replace or repair all damaged parts.
Reassembly: -
1. Installation of new seats, packing and thrust washer is recommended, then follow reassembly
procedure 4.5 below.
2. Install stop plate.
3a. Install retainer/thrust washer.
3b. Install lever.
3c. Install belleville washer and tighten the gland nut.
3. To complete the reassembly, operate the valve 10 times through open and close cycles to ensure all the
parts are assembled correctly and the torques are the same value during the open/close operations. If
torques are not the same during operation this could indicate that some parts have not been correctly
positioned during installation causing interference. Allowing the vale to operate in this state on a
pipeline under higher pressure would only cause more damage. The unit must be dismantled and
re-assembled, then cycled & tested with perfect result.
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 (unscrew) retainer nut.
3. Remove body gasket.
4. Carefully remove ball. Avoid scratching ball surface.
5. Remove seats.
6. Remove stem nut, lever, gland nut, stopper, spring washer, and gland retainer.
7. Remove stem by pulling from inside body cavity.
8. Remove thrust washer.
9. Remove gland packing.
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.

BALL VALVES - FS900 SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 11
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.
4. The gland packing and gasket should be replaced preferably each time the valve is disassembled.
5. Ensure the valve is in the closed position whilst reassembling the body and cap, the stopper must be
located in the right place, otherwise, the open and close operation will be opposite. Each bolt and nut
shall be pre greased and then tightened in accordance with applicable Torque as per Table 1 (see the
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 REDIAL ACTION
Valve does not rotate or operate 1. Packing is tensioned too tightly
2. The stem is torn or there is dirt
3. The times or on-off operation are too many or dirt
exists on the surface of the ball
1. Loosen and adjust again
2. Pull apart the valve and clean the dirt
Ball/Seat Leaking 1. Valve not fully 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 nut
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 retainer
2. Replace the gasket

Australian Pipeline Valve - Installation, Operation and Maintenance Manual
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BALL VALVES - FS900 SERIES
5.0 CONSTRUCTION
BILL OF MATERIALS
MATERIALS LIST
NO. PART NAME MATERIAL NOTES
1Body ASTM A216 WCB/CF8M
2Retainer ASTM A216 WCB/316
3Body gasket Graphite/PTFE
4Ball ASTM A351 CF8M/316 Solid
5Seat RPTFE Glass reinforced
6Thrust washer Graphite/PTFE
7Stem packing Graphite/PTFE
8Gland AISI 304/316
9Stem ASTM A276 316
10 Belleville washers AISI 304/316
11 Gland nut AISI 304/316
12 Handle Zinc plated steel/316
13 Handle nut AISI 304/316
14 Sleeve Vinyl plastisol
15 Locking tab AISI 304/316
16 Anti-static device AISI 316
17 Lock device AISI 304/316
L
Pressure
equalisation
hole
ØD
H
1
4
5
6
8
9
10
11 15 13
17
3212 14
16
7
W
M
B
A
EXPLODED VIEW OF PARTS PRESSURE/TEMPERATURE RATING
The above is indicative only. Design varies according to size, class, trim, etc. Refer as-built drawing.

BALL VALVES - FS900 SERIES
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 13
BREAK TORQUE VALUES (NM) - PTFE/REINFORCED PTFE SEATS
Valve
Size mm
Line Pressure - Mpa Maximum
Stem Torque
(NM)
1 2 3 4 5 7 9 10.3 13.8
8, 10, 15 4 4 5 5 6 6 6 7 7 13
20 10 10 11 12 13 13 14 14 15 28
25 12 13 14 15 16 17 19 19 20 31
32 14 15 16 17 18 20 24 24 25 40
40 20 20 21 22 23 24 26 26 27 50
50 23 24 24 25 25 26 28 28 29 52
ETC = BTO X .75. BTC = BTO X 1.0. Theoretical time shown only.
No safety factor is included. Theoretical torque only, actual torque will vary. When conditions below apply, then
calculate torque using the following application factors:
PEEK SEATS up to +80% to all torques shown
FREQUENCY OF OPERATION Less than once per month +25%
Less than once per month +40%
Less than once per year +60%
SERVICE CONDITIONS Light slurry semi solids +40%
Heavy slurry and some solids +75%
Temp. -40ºC to -20ºC +75%
Temp. -20ºC to 0ºC +25%
Temp. Over 150ºC +40%
Cv/KV FULL PORT 2000 PSI
Size in. Cv Factor
GPM
KV Factor
M2/H
1/4” (8NB) 7 6.0
3/8” (10NB) 7 6.0
1/2” (15NB) 8 6.8
3/4” (20NB) 13 11
1” (25NB) 32 27.5
1 1/4” (32NB) 48 41.0
1 1/2” (40NB) 82 70.0
2” (50NB) 120 103.0
2 1/2” (65NB) 445 381
3” (80NB) 680 583

www.australianpipelinevalve.com.au
AUSTRALIAN PIPELINE VALVE® HEAD OFFICE
70-78 Stanbel Road Salisbury Plain South Australia 5109 Telephone [phone] Fax [phone]
email: [e-mail]
If you have any requirements in the field of valves, please contact us for a prompt response. Continuous development of Australian Pipeline Valve products
may necessitate changes in the design or manufacture process. Australian Pipeline Valve reserves the right to effect any such changes without prior notice.
© Australian Pipeline Valve 1990 - 2021 Edition
LOCAL DISTRIBUTOR/AGENT
IOM APV Ball 1P FS900
ADELAIDE • BRISBANE • PERTH
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