AVCO 1100 Series Instruction manual

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
This manual covers the installation, operation and maintenance of all AVCO standard 1100 series ball valves as
described in the current AVCO catalog. Custom made or customer modied versions of the 1100 series may
use this manual as a general guide only.

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
AVCO
1"
45° MAX.
45° MAX.
TOP DEAD
CENTER
1 General Design
1.1 AVCO Ball valves have been designed and engineered to provide long lasting and trouble free service
when used in accordance with the instructions and recommendations detailed in this manual.
1.2 The valves may be installed for ow or vacuum in either direction and may be installed in horizontal or
vertical applications. Although the valves will operate with the handle or operator on the underside of the
pipe it is not recommended and AVCO advises that, where possible, the valve handle be no more than
45o from top dead center when installed in a horizontal pipe run, particularly when an actuator other than
a manual handle is used.
2 Installation of Flanged and Threaded Valves
2.1 Do not dismantle these valves when installing as they should be treated as a unit.
2.2 Be sure not to overtighten taper threads.
2.3 Flanged valves should be bolted and gasketed in accordance with relevant standards.
2.4 If a threaded valve is ‘back welded’ after installation it should be treated as a weld end valve and
dismantled prior to welding in accordance with section 3.
3 Installation of Weld End Valves
3.1 Prepare a clean working area.
3.2 With the valve in the open position, remove the body bolts or screws.
3.3 Separate the end caps from the body and remove the retainer rings (integral with end cap on sizes up
to 3/4”), body seals (discard body seals) and seats whilst taking care not to damage the plastic parts.
The ball can be placed in a part open position to assist removal of the seats.
3.4 Whilst supporting the ball to prevent it dropping out and potentially damaging the ball surface, rotate the
valve to the closed position and remove the ball.
3.5 The ball, seats and retainer rings should be placed in a suitably remote clean area to minimize risk of
damage whilst welding is being undertaken.
Fig. 1
Typical Valve Installations

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
3.6 Reassemble the end caps onto the body with the appropriate body bolts or screws and position the
valve in its relevant location and secure appropriately in readiness for welding.
NOTE: AVCO Supplies butt weld end caps in sch 10, sch 40 & sch 80 as standard and recommends that the
adjoining pipe be the same schedule as that of the end cap to ensure an e󰀨ective and even weld.
3.7 With the valve in its relevant position TACK WELD with minimum weld su󰀩cient to hold its location
unaided.
3.8 After the tack weld has suitably cooled, remove the body bolts or screws and ease the body from
between the two end caps whilst taking care not to damage the mating surfaces.
3.9 Protect the end cap faces and nish weld the end caps to the pipe.
3.10 When cooled, clean the end cap faces and remove any weld spatter from inside the welded joint.
3.11 Replace the ball into the valve body (whilst in closed position) and carefully rotate to the open position.
Replace the seats and retainer rings and insert new body seals (supplied).
3.12 Ease the completed body assembly (as shown below for sizes up to 2” inclusive) between the end caps
ensuring that the faces and body seals are not trapped or damaged.
3.13 Insert body bolts or screws and tighten to the required torque using the suggested bolt tightening
sequence (see the bolting information section).
4 Operation
4.1 These valves provide tight shut-o󰀨 when used under normal operating conditions in accordance with the
relevant AVCO pressure/temperature charts.
4.2 If these valves are used in a partially open (throttling) condition, the seat life may be reduced as it will
be exposed to owing media in a localized area.
4.3 Any media which can solidify, crystallize or polymerize should not be allowed to stand in the ball valve
cavities unless regular maintenance is carried out as it could lead to damage of the seats and ball
thereby dramatically reducing the life. AVCO o󰀨ers cavity lled and/or steam jacketed options on this
series to minimize maintenance cycles.
Fig. 2
Valve Body Installation Procedure

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
5 Manual Operation
5.1 All AVCO 1100 series ball valves are supplied with basic quarter turn lever handles as standard unless
otherwise stated.
5.2 For valve sizes up to 2” inclusive the lever has an integral stop for fully open and fully closed positions,
there is also a sliding lockable tab to prevent accidental or unauthorized opening or closing of the valve.
To operate, the lockable tab should be slid upwards and the lever rotated in the required direction. The
tab can then be released to slide down and locate in its slot. The lever can only be correctly installed in
one position. Rotating the lever clockwise closes the valve and counter-clockwise opens the valve.
5.3 For valve sizes 2 1/2” thru 4” there is a separate lock plate/indicator and valve lock-o󰀨 is achieved by
using a padlock or other suitable locking device. The handle is simply rotated provided no locking device
is in place. There are two stop pins per assembly which can be relocated along with the stop plate to
give opposite rotation (see g. 3) and di󰀨erent start positions. Thereby the valve is either clockwise to
open and counter-clockwise to close or counter-clockwise to open and clockwise to close.
TO CLOSE
TO OPEN
TO CLOSE
TO OPEN
5.4 The handle or lever on all valve sizes gives visual indication as to whether the valve is in the open or
closed position. If the handle/lever is in-line (parallel) with the pipeline, then the valve is open or if the
handle/lever is perpendicular to (across) the pipeline, then the valve is closed.
AVCO
AVCO
Fig. 3
Valve Handle Rotation Adjustment
Fig. 4
Valve Open/Closed Indication

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
6 Automated Operation
6.1 These valves can be set up for automated operation as part of a process control system. AVCO supplies
a large range of pneumatic and electric actuators with associated controls to accommodate most design
conditions.
6.2 The handle/lever, stem nut, stop pin and stop plate (2 1/2” thru 4” only) should be omitted for automated
actuation if not already specied in the purchase order.
6.3 The stem has milled ats which are machined to exacting tolerances to ensure positive location. The
ats also indicate valve ball position. When the ats are parallel to the pipeline, the valve is open and
when the ats are perpendicular to the pipeline, the valve is closed.
6.4 There is no positive stop on the valve for open and closed positions when set up for actuator usage as
it is intended that the actuator will control the valve travel.
6.5 The mount pad for each valve conforms to ISO 5211 and the stem dimensions are as shown in g. 5
and table 1 below.
H1
H2
F
G
PCD ØL
4 TAPPED
HOLES ØK
ØJ
SIZE F
(mm)
G
(mm)
H1
(mm)
H2
(mm)
J
(mm) KL
(mm)
ISO
5211
1/4”
(DN 8)
0.375
(9.5)
0.224
(5.7)
0.551
(14)
0.354
(9)
0.984
(25) M5 1.417 (36) F03
3/8”
(DN 10)
0.375
(9.5)
0.224
(5.7)
0.551
(14)
0.354
(9)
0.984
(25) M5 1.417 (36) F03
1/2”
(DN 15)
0.375
(9.5)
0.224
(5.7)
0.551
(14)
0.354
(9)
0.984
(25) M5 1.417 (36) F03
3/4”
(DN 20)
0.375
(9.5)
0.224
(5.7)
0.551
(14)
0.354
(9)
0.984
(25) M5 1.417 (36) F03
1”
(DN 25)
0.438
(11.2)
0.295
(7.5)
0.669
(17)
0.472
(12)
1.181
(30) M5 1.654 (42) F04
1 1/4”
(DN 32)
0.438
(11.2)
0.295
(7.5)
0.669
(17)
0.472
(12)
1.181
(30) M5 1.654 (42) F04
1 1/2”
(DN 40)
0.563
(14.3)
0.339
(8.6)
1.142
(29)
0.669
(17)
1.378
(35) M6 1.969 (50) F05
2”
(DN 50)
0.563
(14.3)
0.339
(8.6)
1.142
(29)
0.669
(17)
1.378
(35) M6 1.969 (50) F05
2 1/2”
(DN 65)
0.787
(20)
0.551
(14)
1.693
(43)
0.709
(18)
1.575
(40) M8 2.756 (70) F07
3”
(DN 80)
0.748
(19)
0.748
(19)
1.850
(47)
0.689
(17.5)
1.969
(50) M10 4.016 (102) F10
4”
(DN 100)
0.748
(19)
0.748
(19)
1.850
(47)
0.689
(17.5)
1.969
(50) M10 4.016 (102) F10
6.6 Standard ISO brackets and couplers are available from AVCO to suit a wide range of actuator styles.
6.7 AVCO advises, that where an actuator is used, the valve be installed as shown in g. 1 and as described
in paragraph 1.2 for optimal use and life span.
Fig. 5
Valve Stem & Mount Pad Set-Up
Table 1
Valve Stem & Mount Pad Dimensions in Inches

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
6.8 It is imperative that any bracket/coupler combination allows adequate clearance to ensure that the
coupler does not exert any compressive force directly on to the stem or stem nut, as this could lead to
premature stem leakage and possible damage. When assembled it should be possible for the coupler
to freely move up and down by a small amount.
7 Maintenance
7.1 AVCO valves will give a long and trouble free life provided they are operated within the specied design
parameters, but occasionally maintenance is required and should be addressed as set out below:
7.2 Stem Leakage
7.2.1 Remove the handle/lever retaining nut or screw, handle/lever and locking tab.
7.2.2 Examine the disc spring washers and check the outer edges are touching and concentric. If all
appears to be OK, continue to 7.2.4.
7.2.3 Remove the stem nut, recenter the disc spring washers while ensuring the outside edges are touching
concentrically. Replace the stem nut.
7.2.4 Tighten the stem nut until the required torque is achieved (see table 2) or until the disc springs are
attened and then further tighten by the minimum amount required until the lock pad can be located
onto the stem nut.
7.2.5 Replace the handle/lever and handle/lever nut or screw.
7.2.6 If stem leakage still occurs the valve will require refurbishment, full instructions are listed in section
8.
7.3 Leakage at Body Joint
7.3.1 Check the body bolt or body screw torque settings and tighten to the required torque using the
suggested bolt tightening sequence (see the bolting information section).
7.3.2 If leakage is still encountered the body seals will require replacement or the mating faces may be
damaged and should be inspected as detailed in section 8.
7.4 In-Line Leakage
7.4.1 Check that the valve is fully closing and that there are no restrictions preventing the full rotation to the
closed position.
7.4.2 If the full travel is being achieved then it is likely that the valve seats or ball is damaged or worn and
may require replacement. See section 8 for details on how to carry out a complete refurbishment.
7.5 Leakage at Pipeline Joint
7.5.1 For screwed valves ensure that the joint has been correctly tightened and adequate jointing material
used.
7.5.2 For anged valves ensure that mating faces and gasket are not damaged and verify that all bolts have
been tightened to the relevant torque giving adequate gasket compression. Gasket compression and
bolting torque for anged joints should be specied by the gasket supplier.
7.5.3 For weld end valves ensure that the weld has no leak points or ‘burn through’ and repair as required
using the instructions detailed in section 3 as appropriate.

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
8 Refurbishing
8.1 AVCO Valves can be refurbished if the need arises and complete maintenance kits are available or
individual components purchased as required. A maintenance kit consists of thrust washer, packing
washers, seats and body seals in quantities relevant to the specied valve size.
NOTE: If any of the seal, seat or washer materials di󰀨er to that of the originally supplied specication, then
the nameplate must be revised or the valve tagged to indicate the change as the temperature and pressure
range could be a󰀨ected.
WARNING: Ball valves are designed as pressure containing equipment and as such a risk assessment
should be carried out to ensure that no pressurized uid or gas is contained in the ball cavity and
relevant procedures followed for the handling of hazardous materials before any work commences.
NOTE: The following instructions assume that all relevant safety checks have been carried out and are purely
aimed at valve refurbishment.
8.2 Prepare a clean working area.
8.3 If tted, remove any actuators and associated brackets per manufacturers’ instructions.
8.4 With the valve in the open position, remove the body bolts or screws.
8.5 Gently slide the center body section from between the end caps whilst prizing the end caps apart to
clear the location ring. Take care not to damage the mating faces. The seat retainers may come lose
and should be restrained to prevent them from falling and becoming damaged.
8.6 Remove the body seals and seat retainers complete with seats.
NOTE: The seat retainers are integral to the end cap for valve sizes 3/4” and below.
8.7 Whilst supporting the ball to prevent it dropping out and potentially damaging the ball surface, rotate the
valve to the closed position and remove the ball.
8.8 Inspect the stem assembly and if it is considered to be in good condition skip to paragraph 8.18.
8.9 If tted, unscrew the handle retaining nut/screw and remove the handle/lever. The stop pins can also
be removed if desired.
8.10 Remove the stem nut locking tab.
8.11 Use a wrench on the stem ats to prevent the stem from turning, unscrew the stem nut and remove. The
disc spring washers, gland ring and packing can now be removed. The stem and thrust washer can be
withdrawn via the body cavity.
8.12 Thoroughly clean all components with a suitable cleaning uid. If there is any build-up of solids, use a
blunt tool (preferably not metal) and ensure machined surfaces are not scratched. If any component
shows signs of eroded or corroded leak paths or damage to machined areas, it should be replaced. The
ball must have no scratches or scoring, other than minor signs of rubbing, around its seating periphery
(g. 6). Any components that do not pass inspection should be replaced.
8.13 Fit the thrust washer onto the stem.
8.14 Insert the stem with thrust washer up into the valve body.

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
8.15 Ease the packing washers onto the stem whilst taking care not to damage them, followed by the gland
ring and stop plate (2 1/2” thru 4”). Place the disc spring washers onto the stem whilst ensuring that
the outside edges are touching concentrically. Replace the stem nut and Tighten the stem nut until the
required torque is achieved (see table 2) or until the disc springs are attened and then further tighten
by the minimum amount required until the lock pad can be located onto the stem nut.
8.16 Operate the stem several times and re-tighten if required.
8.17 Screw in the stop pin(s), replace the handle/lever and handle/lever nut or screw.
8.18 Replace the ball into the valve body (whilst in closed position) and carefully rotate to the open position.
Insert the seats, retainer rings and body seals.
NOTE: A trace of silicon based lubricant or clean grease (i.e. Petroleum jelly), if compatible with pipeline
media, will assist with rebuilding by holding the seats, retainers and body seals in place. DO NOT use grease
with abrasive additives.
8.19 Ease the completed body assembly (as shown in g. 2 for sizes up to 2” inclusive) between the end caps
ensuring that the faces and body seals are not trapped or damaged.
8.20 Insert body bolts or screws and tighten to the required torque using the suggested bolt tightening
sequence (see the bolting information section). It is suggested that periodic opening and closing be
performed during the tightening sequence to help with concentricity, as it is possible for the ball to be
trapped between the seats, especially in horizontal applications.
8.21 All of the above procedures can be carried out without the need to disturb anged or threaded end cap
connections to the pipeline, as the center section is designed to be removed alone to cater for welded
connections. It is at the owner/operators discretion as to whether these connections be renewed.
Fig. 7
Valve Re-Assembly Procedure
PORT
SEATING ZONE
MUST BE CLEAR
FROM SCRATCHES
SOME SCORING/SCRATCHES
PERMISSIBLE OUTSIDE
SEATING ZONE
Fig. 6
Ball Inspection

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
Valve
Size
Body Bolts Stem Nuts
Size Torque (in.lbs) Size Torque (in.lbs)
1/4” M6 70 3/8-24 UNF 29
3/8” M6 70 3/8-24 UNF 29
1/2” M6 70 3/8-24 UNF 29
3/4” M8 170 3/8-24 UNF 29
1” M8 170 7/16-20 UNF 29
1 1/4” M10 340 7/16-20 UNF 29
1 1/2” M10 340 9/16-18 UNF 63
2” M12 590 9/16-18 UNF 63
2 1/2” M10 340 M20 210
3” M12 590 1-14 UNF 482
4” 9/16-12 UNC 995 1-14 UNF 482
9 Bolting Information
9.1 The stem nut should be tightened nger tight and then torqued per table 2 or tightened with a wrench
until the disc spring washers are fully at. Once the required tightening has been achieved, the nut
should be further tightened no more than 1/4 turn until the lock pad can be assembled onto the stem.
9.2 The body bolts should tightened until nger tight and then gradually fully tightened per the bolting
sequence shown in gs. 8 & 9 to the torque shown in table 2. It is important that tightening be done
gradually so as not to trap or pinch any part of the seats or seals and to maintain concentricity.
9.3 Four bolt sequence.
9.3.1 First round to 30% torque - 1-2, 3-4
9.3.2 Second round to 60% torque - 1-2, 3-4
9.3.3 Third round to 100% torque - 1-2, 3-4
9.3.4 Final checking round - 1,3,2,4
9.4 Eight bolt sequence
9.4.1 First round to 30% torque - 1-2, 3-4, 5-6, 7-8
9.4.2 Second round to 60% torque - 1-2, 3-4, 5-6, 7-8
9.4.3 Third round to 100% torque - 1-2, 3-4, 5-6, 7-8
9.4.4 Final checking round - 1,5, 3, 7, 2, 6, 4, 8
13
4 2
8
4
62
7
3
5
1
Fig. 8
Fig. 9
Table 2
Valve Torque Settings

BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
9.5 If a bolt, screw or nut is damaged or lost, it should be replaced with one of exactly the same specication
as that originally supplied. AVCO holds spares in stock.
10 Valve Conformance
10.1 The valve shall be deemed to conform with its originally supplied specications provided that:
10.1.1 The maintenance kit material is identical to that of the originally specied valve or the name-plate be
revised to show the new conditions.
10.1.2 Any component that is replaced during maintenance or repair is an AVCO authorized spare part and
is specic to the originally specied valve. Any component of the valve can be replaced, but AVCO
recommends that if the body becomes damaged then the complete valve be replaced.
10.1.3 Parts from di󰀨erent AVCO valve series should not be inter-changed unless authorized by AVCO.
10.1.4 Parts from other valve manufacturers must not be used.
10.1.5 If the valve is altered in any way from that of the original specication or without consent from AVCO,
then no liability can be accepted by AVCO (Alloy Valves & Control).
11 Safety Precautions
11.1 Ascertain what media the pipeline carries before removing or working on any tted valve. The media
can be corrosive, toxic, ammable or a contaminant. Where there is evidence of harmful or hazardous
media ever owing through the valve, then utmost care must be taken. As a minimum AVCO suggests
the following precautions be taken, but it is the responsibility of the owner/operator to ensure that a risk
assessment is carried out and relevant safety procedures followed thereof.
11.2 Wear eye protectors.
11.3 Wear protective overalls and gloves.
11.4 Wear protective headgear.
11.5 Wear protective footwear.
11.6 Ensure running water is easily accessible.
11.7 Have a suitable re extinguisher nearby.
11.8 Check Upstream and downstream pressure gauges to ensure the pipeline contains no pressure.
11.9 Ensure any pressurized media in the ball or cavity is released by opening the valve half open.
11.10 Ideally the valve should be ushed or decontaminated with the valve in the half open position to clear
ball and body cavity.

1
6
7
4
6
7
2
2
15
14
18
13
5
8
16
12
10
9
13
11
17 18
13
5
8
16
12
10
9
13
11
17
72
15
6
3
1
4
6
3
7
2
14
1
2
2
7
3
6
4
6
3
7
5
8
16 9
10
17
21
19
12
13
11
21
14
14
Item Parts
1Body
2 End Cap
3 Retainer Ring
4 Ball
5 Stem
6 Ball Seat
7Body Seal
8 Thrust Washer
9 Packing Washer
10 Gland Ring
11 Disc Spring Washer
12 Lock Tab
13 Stem/Handle Nut
14 Body Bolt
15 Body Nut
16 Stop Pin
17 Handle/Lever
18 Handle Sleeve
19 Wrench Block
20 Handle Bolt
21 Lock Pad
BALL VALVES
1100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
Fig. 10
1/4” thru 3/4”
Fig. 11
1” thru 2”
Fig. 12
2 1/2” thru 4”
12 Exploded Views
12.1 The following gures show the typical exploded views for all valve sizes, but please consider that the
end caps (item 2) may di󰀨er to those actually shown in these gures.
Table 3
Copyright © 2009 Alloy Valves and Control Inc. All rights reserved. No part of this brochure may be used or reproduced in any manner whatsoever without written permission from AVCO
This brochure is general in nature and we reserve the right to alter dimensions, materials or make design improvements.
CD220621