APV TWIN Series Instruction manual

www.australianpipelinevalve.com.au
INSTALLATION, OPERATION & MAINTENANCE MANUAL
EXPANDING SEAL PLUG VALVE
DOUBLE BLOCK & BLEED
API6D
TWIN
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 2-5
Safety Information 6-7
1.0 Preservation And Storage 8
1.1 Storage 8
1.2 Periodic maintenance during storage 8
1.3 Environmental considerations 8
2.0 Installation 9-13
2.1 Valve preparation 9
2.2 Valve installation 9-10
2.3 Maintenance prior to flushing 10
2.4 Flushing the pipeline 10-11
2.5 Maintenance post flushing 12
2.6 Commissioning 13
3.0 Operation 13-15
3.1 Pressure Test 14
3.2 Optional - “Differential Thermal Relief” - Bleed System 14-15
4.0 Removal From Line 16
5.0 Gearbox Removal 16
6.0 Valve Disassembly 17
7.0 Maintenance 18-19
EXPANDING SEAL PLUG VALVE DOUBLE BLOCK & BLEED API6D - TWIN SERIES
INDEX
Australian Pipeline Valve - Installation, Operation and Maintenance Manual 1
© Copyright Australian Pipeline Valve 1990 - 2018 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.

Australian Pipeline Valve - Installation, Operation and Maintenance Manual2
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.
EXPANDING SEAL PLUG VALVE DOUBLE BLOCK & BLEED API6D - TWIN SERIES

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EXPANDING SEAL PLUG VALVE DOUBLE BLOCK & BLEED API6D - TWIN SERIES
MODEL TWIN EXPANDING SEAL PLUG VALVE NON LUBRICATED DOUBLE BLOCK AND BLEED
DOUBLE BLOCK AND BLEED SOLUTIONS
• Permanent integral thermal relief and bleed function
• In-line mainternance in case of seal replacement
• Very short installation space required
• Double isolation function, according API-6D/ISO14313
• Only 1 actuator required to operate the valve
Unlike other valve types, the APV TWIN Twinseal style Dual Expanding
Twinseal style plug valve creates an optimum seal without causing any
abrasion and wear, providing a ‘zero-leakage’ solution, upstream and
downstream ensuring a long life-time of the seals and valve, as well as a
low opening and closing torque. This unique design is combined with a
bleed function, all in one valve, saving space as well as providing a
reliable, safe and economical solution.
PRODUCT STRUCTURAL FEATURES
Used in various industries such as petroleum, chemical industry, chemical
fertiliser, power industry etc. Class 150 - 1500LBS and working
temperature of -29~180°C.
MAIN STRUCTURAL FEATURES
• The Twinseal style double expanding plug valve has a rugged structure, reliable sealing, excellent
performance and exact tolerances.
• Sealing rings around the valve plug provide the seal. It has a unique design incorporating machined and
pressed sealing rings.
• Bi-directional, double block and bleed.
OPERATION PRINCIPLE
When the hand wheel is turned, the plug will rotate toward the closing direction for 90 degree turn
closing, the plug will then be firmly seated after moving downward into its closing position.
When the hand wheel is turned inversely, first of all the plug will move upward and the valve plug and
valve seat will be separated till the valve plug is turned 90 degree driven by the plug and finally the bore
of the plug will be in alignment with the channel of valve body.
The advantage of this type of valve is during the opening and closing of the valve, the plug and valve seat
are separated and there is no friction, thus the sealing face experiences no abrasion in the process, at the
same time the soft seal is applied for sealing so that there will be no leakage in the process of closing.

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EXPANDING SEAL PLUG VALVE DOUBLE BLOCK & BLEED API6D - TWIN SERIES
PERFORMANCE SPECIFICATION TECHNICAL SPECIFICATION
Class (MPa) Shell Test (MPa) Seating Test Suitable Suitable Operator Handwheel, bevel gear,electric-actuated
Temp. Medium
150 3.0 2.2
180°C* Water oil
and gas
Design Standard API599, API6D, ISO 14313
300 7.5 5.5 Face to Face ASME B16.10
600 15.0 11.0 Flange End ASME B16.5
900 22.5 16.5 Test and Inspection API598, API6D
* High/ low temperature available up to 2500 Class.
Non-slam
The operator is self locking so that line pressure
cannot force the plug to rotate. This prevents
slamming and risk of injury.
Tight shut off
When the valve is closed, the seating segments are
wedged tightly between the plug and body metal
to metal. The soft seat material is compressed into
the recessed groove. The design does not require
springs or pressure to effect a seal.
Double block and bleed and zero leakage
The Twinseal valve provides upstream and
downstream seal in both directions and a bleed
point is then provided between the two seats, to
prove no leakage.
Zero-leakage
The Twinseal meets the demands of frequent
cycling and verifiable, reliable zero leakage with
positive shut-off upstream and downstream.
Zero wear
Twinseal valves provide positive shut-off with
zero leakage.
The design of the valve ensures that during
opening and closing the seals are not in contact
with the body. Only at the last stage of closing
does the seal contact the body - and then the
force is compression only.
Every turn of the handwheel retracts the seals
from the body.
That means no wear to the seals and long life.
Large port
Twinseal valves have a nominal plug port of 60
- 70% thus effecting minimum pressure drop. True
circular full port also available.
Closing Operation

Australian Pipeline Valve - Installation, Operation and Maintenance Manual 5
EXPANDING SEAL PLUG VALVE DOUBLE BLOCK & BLEED API6D - TWIN SERIES
MAIN PARTS MATERIALS
No. Part Name Material
1 Body ASTM A216 - WCB, ASTM A351 - CF8, CF8M, CF3, CF3
2 Lower Bonnet ASTM A216 - WCB, ASTM A105, ASTM A351 - CF8, CF8M, CF3, CF3M
3 Bearing Assembly
4 Drain Valve Assembly
5 O-Rings NBR, PTFE, VITON
5A Gasket SW316 + Graphite
6 Gasket Spiral Wound
7 Bolt ASTM A193 - B7, A320 - B8, A193 - B8M
8 Nut ASTM A194 - 2H, A194 - 9, A194 - 8M
9 Plug ASTM A216 WCC+ENP, ASTM A182 - Gr. F6a, ASTM A182 - F22, ASTM A351 - CF8, CF8M, CF3, CF3M
10 Disc ASTM A182 - Gr. F6a, ASTM A182 - F22, ASTM A351 - CF8, CF8M, CF3, CF3M
11 Bonnet ASTM A216 - WCB, ASTM A351 - CF8, CF8M, CF3, CF3M
12 Bearing Assembly
13 Slip Sealing Ring Viton, PTFE
14 O-Rings NBR, PTFE, VITON
15 Packing Flexible graphite + stainless steel, PTFE
16 Gland ASTM A216 - WCB, ASTM A351 - CF8, CF8M, CF3, CF3M
17 Yoke ASTM A216 - WCB, ASTM A351 - CF8, CF8M, CF3, CF3M
18 Slide Bushing ASTM A216 - WCB, ASTM A105, ASTM A351 - CF8, CF8M, CF3, CF3M
19 Stem/Back Stem ASTM A182 - Gr. F6a, ASTM A182 - 316
20 Handwheel ASTM A436 Gr. 60 - 40 - 18, A216 - WCB
21 Yoke Nut ZQA 19 - 4
22 Guiding Stud ASTM A182 - Gr. F6a, ASTM A182 - F22, ASTM A351 - CF8, CF8M, CF3, CF3M
23 Pin ASTM A182 - Gr. F6a, ASTM A182 - F22, ASTM B637-718 Inconel, ASTM A351 - CF8, CF8M, CF3, CF3M
24 Sealant Nipple Assembly
BLOCK & BLEED:
DBB - Double Block and Bleed , method to test seat integrity with valve closed while under pressure.
DIB - Double Isolation and Bleed, Bi-Directional seating. API6D definition of redundant sealing surfaces
in both flow directions.
Side view End view

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EXPANDING SEAL PLUG VALVE DOUBLE BLOCK & BLEED API6D - TWIN SERIES
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 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
• Ensure that all fluid ports are connected or closed as necessary before applying
pressure to equipment.
• Use proper lifting and supporting equipment to protect personnel and equipment.
• DO NOT loosen any fasteners, connections or attempt removal until all pressure
and mechanical loads are isolated and/or removed from the system.
• For sour service containing H2S, ensure that valve installed complies with NACE
MR0175.
• For applications concerned with external fire hazards, use valve in compliance
with API6FA/ API607

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EXPANDING SEAL PLUG VALVE DOUBLE BLOCK & BLEED API6D - TWIN SERIES
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.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.
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.

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.
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EXPANDING SEAL PLUG VALVE DOUBLE BLOCK & BLEED API6D - TWIN SERIES