AVCO 9100 Series Instruction manual

BALL VALVES
9100 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 9100 series ball valves as
described in the current AVCO catalog. Custom made or customer modied versions of the 9100 series may
use this manual as a general guide only.

BALL VALVES
9100 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
2.1 Do not dismantle these valves when installing as they should be treated as a complete unit.
2.2 Ensure plastic end covers have been removed.
2.3 Flanged valves should be bolted and gasketed in accordance with relevant standards.
2.4 Connecting anges must already be welded in place before mating with the valve.
3 Operation
3.1 These valves provide tight shut-o󰀨 when used under normal operating conditions in accordance with the
relevant AVCO pressure/temperature charts.
3.2 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.
3.3 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.
Fig. 1
Typical Valve Installations

BALL VALVES
9100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
4 Manual Operation
4.1 All AVCO 9100 series ball valves are supplied with basic quarter turn lever handles as standard unless
otherwise stated and no other lever should be used as a substitute or to create greater leverage.
4.2 For all valve sizes there is a lock plate for valve lock-o󰀨 which is achieved by inserting a padlock or
other suitable locking device through the aligned holes. The valve can only be locked open or closed,
it cannot be locked in intermediate positions.
4.3 The handle is simply rotated provided no locking device is in place. There is a positive stop to achieve
full open or full closed positions. The lever can be set to rotate clockwise to open and counter-clockwise
to close or counter-clockwise to open and clockwise to close by simply removing the lever and ipping
the locking plate over.
4.4 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.
5 Automated Operation
5.1 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.
5.2 The handle/lever, and travel stop plate should be removed for automated actuation if not already
specied in the purchase order.
5.3 The stem has milled ats which are machined to exacting tolerances to ensure positive location. The
ats (1/2” thru 4”) or indicator line cut into the top of the stem (6” thru 12”) also indicate valve ball
position. When the ats or indicator line are parallel to the pipeline, the valve is open and when the ats
or indicator line are perpendicular to the pipeline, the valve is closed.
5.4 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.
AVCO
AVCO
Fig. 2
Valve Open/Closed Indication
Open Closed

BALL VALVES
9100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
Fig. 3 - Valve Stem & Mount Pad Set-Up
Table 1 - Valve Stem & Mount Pad Dimensions in Inches
SIZE ANS
Class
F
(in.) GH1
(in.)
H2
(in.)
J
(in.)
K
(in.)
ISO
5211
Weight
(lbs)
TORQUE
(in-lbs) CV
1/2”
150# M10 0.297 0.69 0.39 1.654 M5 F04 4.6 84 23
300# M10 0.297 0.69 0.37 1.654 M5 F04 7.1 84 23
3/4”
150# M10 0.297 0.73 0.39 1.654 M5 F04 5.3 96 53
300# M10 0.297 0.69 0.37 1.654 M5 F04 9.5 96 53
1”
150# M14 0.342 1.16 0.72 1.969 M6 F05 5.7 120 94
300# M14 0.342 1.06 0.63 1.969 M6 F05 10.6 120 94
1 1/4”
150# M14 0.342 1.06 0.63 1.969 M6 F05 11.5 178 118
300# M14 0.342 1.06 0.63 1.969 M6 F05 13.9 178 118
1 1/2”
150# M20 0.551 1.46 0.69 2.756 M8 F07 15.0 216 213
300# M20 0.551 1.46 0.69 2.756 M8 F07 15.9 216 213
2”
150# M20 0.551 1.50 0.69 2.756 M8 F07 19.8 300 378
300# M20 0.551 1.50 0.69 2.756 M8 F07 27.6 300 378
2 1/2”
150# M20 0.551 1.50 0.69 2.756 M8 F07 32.0 531 660
300# M20 0.551 1.50 0.69 2.756 M8 F07 40.4 531 660
3”
150# 0.984 0.669 2.42 1.14 4.016 M10 F10 43.0 781 951
300# 0.984 0.669 2.42 1.14 4.016 M10 F10 70.6 781 951
4”
150# 0.984 0.669 2.42 1.14 4.016 M10 F10 72.8 1444 1691
300# 0.984 0.669 2.42 1.14 4.016 M10 F10 101 1444 1691
6”
150# 1.063 1.063 2.43 1.34 4.921 M12 F12 137 3356 3806
300# 1.063 1.063 2.44 1.34 4.921 M12 F12 194 3356 3806
8”
150# 1.260 1.260 3.11 1.59 4.921 M12 F12 243 12744 7812
300# 1.260 1.260 3.11 1.59 4.921 M12 F12 359 12744 7812
10”
150# 1.417 1.417 3.37 1.83 5.512 M16 F14 366 15930 13371
300# 1.417 1.417 3.37 1.83 5.512 M16 F14 525 15930 13371
12”
150# 1.811 1.811 4.98 2.66 6.496 M20 F16 523 21240 19255
300# 1.811 1.811 4.98 2.66 6.496 M20 F16 783 21240 19255
H1
H2
F
G
PCD ØJ
4 HOLES
TAPPED K
THRU
MOUNT PAD - 1/2" THRU 2 1/2" MOUNT PAD - 3" THRU 4"
H1
H2
PCD ØJ
4 HOLES
TAPPED K
THRU
F
G
MOUNT PAD - 6" THRU 12"
H1
H2
4 HOLES
TAPPED K
THRU
F
G
PCD ØJ

BALL VALVES
9100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
5.5 The mount pad for each valve conforms to ISO 5211 and the stem dimensions are as shown in g. 3
and table 1 below. Standard ISO brackets and couplers are available from AVCO to suit a wide range
of actuator styles.
5.6 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.
5.7 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.
6 Maintenance
6.1 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 in this
section:
6.2 Stem Leakage - 1/2” thru 2 1/2”
6.2.1 Remove the handle/lever retaining nut or screw, handle/lever, travel stop (1 1/2” thru 2 1/2”) and
lock washer.
6.2.2 Examine the Belleville washers and check the outer edges are touching and concentric. If all
appears to be OK, continue to 6.2.4.
6.2.3 Remove stem nut, replace Belleville washers (if necessary) and ensure that the outside edges are
touching concentrically. Replace the stem nut.
6.2.4 Tighten the stem nut until the required torque is achieved (see table 2) or until the Belleville washers
are attened and then back o󰀨 by the minimum amount required until the lock washer can be
located onto the stem nut.
6.2.5 Replace the handle/lever and handle/lever nut or screw.
6.2.6 If stem leakage still occurs the valve will require refurbishment, full instructions are listed in section
7.
6.3 Stem Leakage - 3” thru 12”
6.3.1 If possible place valve in open position or if not remove the handle/lever retaining screw and handle/
lever.
6.3.2 Examine the packing ange Belleville washers and check the outer edges are touching and
concentric. If all appears to be OK, continue to 6.3.4.
6.3.3 Remove/loosen the packing gland screws, replace Belleville washers (if necessary) and ensure
that the outside edges are touching concentrically. Replace the packing gland screws and hand
tighten.
6.3.4 Tighten the packing gland screws until the required torque is achieved (see table 2) or until the
Belleville washers are attened.
6.3.5 Replace the handle/lever and handle/lever nut or screw if it was removed in 6.3.1.
6.3.6 If stem leakage still occurs the valve will require refurbishment, full instructions are listed in section
7.

BALL VALVES
9100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
6.4 Leakage at Body Joint
6.4.1 Check the body bolt torque settings and tighten to the required torque (see table 2) using the
suggested bolt tightening sequence (see the bolting information section).
6.4.2 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 7.
6.5 In-Line Leakage
6.5.1 Check that the valve is fully closing and that there are no restrictions preventing the full rotation to
the closed position.
6.5.2 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 7 for details on how to carry out a complete refurbishment.
6.6 Leakage at Pipeline Joint
6.6.1 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 Refurbishing
7.1 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 ring, thrust seal,
packing, Belleville 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
must 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, the valve has
been removed from the pipeline and are purely aimed at valve refurbishment.
7.2 Prepare a clean working area.
7.3 If tted, remove any actuators and associated brackets per manufacturers’ instructions.
7.4 With the valve in the open position, remove the body bolt nuts.
7.5 Separate the end cap from the main body whilst taking care not to damage the mating faces.
7.6 Remove the seat from the end cap.
7.7 Carefully rotate the ball in the main body of the valve to the closed position, remove the ball, second
seat and body seal.
7.8 Inspect the stem assembly and if it is considered to be in good condition skip to paragraph 7.11.
7.9 Dismantling & reassembling stem assembly - 1/2” thru 2 1/2”
7.9.1 If tted, unscrew the handle retaining nut/screw and remove the handle/lever. The travel stop (1
1/2” thru 2 1/2”) and stop pin can also be removed. Please note that these items are not installed if
the valve has been set up for powered actuation.

BALL VALVES
9100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
7.9.2 Remove the stem nut lock washer.
7.9.3 Use a wrench on the stem ats to prevent the stem from turning, unscrew the stem nut and remove.
The Belleville washers, gland ring, travel stop (1/2” thru 1 1/4”) and packing can now be removed.
The stem and thrust seal can be withdrawn via the body cavity.
7.9.4 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.
7.9.5 Fit the thrust seal onto the stem.
7.9.6 Insert the stem complete with thrust seal up into the valve body.
7.9.7 Ease the packing onto the stem whilst taking care not to damage it, followed by the gland ring.
7.9.8 Place the Belleville washers onto the stem whilst ensuring that the outside edges are touching
concentrically. The travel stop (if tted - 1/2” thru 1 1/4”) can also be located onto the stem at this
stage.
7.9.9 Replace the stem nut and Tighten the stem nut until the required torque is achieved (see table 2)
or until the Belleville washers are attened and then back o󰀨 by the minimum amount required until
the lock washer can be located onto the stem nut.
7.9.10 Operate the stem several times and re-tighten if required.
7.9.11 Screw in the stop pin(s), install the travel stop (1 1/2” thru 2 1/2”), replace the handle/lever and
handle/lever nut or screw. Please note that these items are not tted for powered actuation.
7.10 Dismantling & reassembling stem assembly - 3” thru 12”
7.10.1 Remove the handle retaining screw from the valve stem, remove the handle, handle washer and
stem washer (6” thru 12”).
7.10.2 Support the stem from inside the body and remove the stem retaining ring and locking plate. It
should now be possible to withdraw the stem from inside the body at which point the thrust seal can
be removed.
7.10.3 Unscrew the packing gland screws and remove Belleville washers. The packing gland ange,
gland ring (3” thru 4”), bushing (6” thru 12”) and packing can now be removed.
7.10.4 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.
7.10.5 Fit the thrust seal onto the stem.
7.10.6 Insert the stem complete with thrust seal up into the valve body. The stem will require supporting
from inside the valve body until the stem retaining ring has been installed at a later stage.
7.10.7 Ease the packing onto the stem and into the body cavity, followed by the gland ring.
7.10.8 Insert the bushing (6” thru 12”) into the gland ange and locate the gland ange onto the stem
followed by the locking plate. Place Belleville washers onto the gland screws and tighten to the

BALL VALVES
9100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
required torque (see table 2) or until the Belleville washers are attened. The Belleville washers
should have their outside edges touching concentrically. The stem retainer ring can be inserted as
soon as it is possible to do so.
7.10.9 Operate the stem several times and re-tighten the gland screws if required.
7.10.10 Place the stem washer (6” thru 12”) on the stem followed by the handle. For stems with square
drives, it is essential the handle is assembled so that when the valve is in the open position, the
handle is parallel to the pipeline. A quick check is to ensure that the handle is perpendicular to the
ats on the stem which locate with the ball.
7.11 Inspect the ball which must have no scratches or scoring, other than minor signs of rubbing, around its
seating periphery (g. 4). If the ball does not pass inspection it should be replaced.
7.12 Place a seat in the body cavity and another in the end cap. Ensure the seats are the right way round -
angled seating face should be visible.
7.13 Replace the ball into the valve body (whilst in closed position) and carefully rotate to the open position.
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 and body seals in place. DO NOT use grease with
abrasive additives.
7.14 Place the body seal onto the end cap and ease the completed end cap into the main body.
7.15 Replace the body nuts onto the body studs 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.
7.16 If possible the valve should be tested at design pressure for any leakage and relevant corrective action
taken as necessary.
PORT
SEATING ZONE
MUST BE CLEAR
FROM SCRATCHES
SOME SCORING/SCRATCHES
PERMISSIBLE OUTSIDE
SEATING ZONE
Fig. 4
Ball Inspection

BALL VALVES
9100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
8 Bolting Information
8.1 Stem nuts should be tightened nger tight and then torqued per table 2 or tightened with a wrench until
the Belleville washers are fully at. Once the required tightening has been achieved, the nut should be
backed o󰀨 no more than 1/8 turn until the lock pad can be assembled onto the stem.
8.2 Packing gland screws should be tightened nger tight and then torqued per table 2 or tightened with a
wrench until the Belleville washers are fully at.
8.3 Body stud nuts should be tightened until nger tight and then gradually fully tightened per the bolting
sequence shown in paragraphs 8.4 through 8.8 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.
8.4 Four bolt sequence.
8.4.1 First round to 30% torque - 1-2, 3-4
8.4.2 Second round to 60% torque - 1-2, 3-4
8.4.3 Third round to 100% torque - 1-2, 3-4
8.4.4 Final checking round - 1,3,2,4
8.5 Six bolt sequence
8.5.1 First round to 30% torque - 1-2, 3-4, 5-6
8.5.2 Second round to 60% torque - 1-2, 3-4, 5-6
8.5.3 Third round to 100% torque - 1-2, 3-4, 5-6
8.5.4 Final checking round - 1,6,4,2,5,3
8.6 Eight bolt sequence
8.6.1 First round to 30% torque - 1-2, 3-4, 5-6, 7-8
8.6.2 Second round to 60% torque - 1-2, 3-4, 5-6, 7-8
8.6.3 Third round to 100% torque - 1-2, 3-4, 5-6, 7-8
8.6.4 Final checking round - 1,5,3,7,2,6,4,8
8.7 Twelve bolt sequence
8.7.1 First round to 20% torque - 1-2, 3-4, 5-6, 7-8, 9-10, 11-12
8.7.2 Second round to 40% torque - 1-2, 3-4, 5-6, 7-8, 9-10, 11-12
8.7.3 Third round to 80% torque - 1-2, 3-4, 5-6, 7-8, 9-10, 11-12
8.7.4 Fourth round to 100% torque - 1-2, 3-4, 5-6, 7-8, 9-10, 11-12
8.7.5 Final checking round - 1,5,9,3,7,11,2,6,10,4,8,12
1
4 2
3
1
3
52
4
6
1
8
4
62
7
3
5
1
12
8
4
10
62
11
7
3
9
5

BALL VALVES
9100 SERIES
3210 S. Susan St, Santa Ana, CA 92704 Tel [phone] Fax [phone] Website: www.avcovalve.com
Valve
Size
ANSI
Class
Body Studs Packing Gland Screws Stem Nuts
Size Torque (ft.lbs) Size Torque (ft.lbs) Size Torque (ft.lbs)
1/2” 150 M8 26 - - M10 20
300 M10 38 - - M10 24
3/4” 150 M8 26 - - M10 20
300 M10 38 - - M10 24
1” 150 M10 38 - - M14 22
300 M12 50 - - M14 33
1 1/4” 150 M10 38 - - M14 22
300 M12 50 - - M14 33
1 1/2” 150 M12 50 - - M20 48
300 M16 100 - - M20 57
2” 150 M12 50 - - M20 48
300 M12 50 - - M20 57
2 1/2” 150 M12 50 - - M20 48
300 M12 50 - - M20 57
3” 150 M12 50 M14 22 - -
300 M14 75 M14 33 - -
4” 150 M12 50 M14 22 - -
300 M16 100 M14 33 - -
6” 150 M16 100 M16 33 - -
300 M20 170 M16 40 - -
8” 150 M20 170 M16 33 - -
300 M24 385 M16 40 - -
10” 150 M20 170 M20 48 - -
300 M24 385 M20 57 - -
12” 150 M20 170 M20 48 - -
300 M24 385 M20 57 - -
8.8 Sixteen bolt sequence
8.8.1 1st round to 20% torque - 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16
8.8.2 2nd round to 40% torque - 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16
8.8.3 3rd round to 80% torque - 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16
8.8.4 4th round to 100% torque - 1-2, 3-4, 5-6, 7-8, 9-10, 11-12, 13-14, 15-16
8.8.5 Final checking round - 1,9,5,13,3,11,7,15,2,10,6,14,4,12,8,16
Table 2
Valve Torque Settings
1
16
8
12
4
14
6
10 2
15
7
11
3
13
5
9