Circor KF T Series Instruction manual

Installation, Operation and Maintenance Manual
SERIES T/TE/TW/TWE
ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE
Page: 1of 12
Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
INSTALLATION, OPERATION & MAINTENANCE MANUAL
KF SERIES T
ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual
SERIES T/TE/TW/TWE
ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE
Page: 2of 12
Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
CONTENTS
1) SCOPE------------------------------------------------------------------------------------------------------------------------------------------------------------4
2) INSTALLATION ------------------------------------------------------------------------------------------------------------------------------------------------4
2.1) SERIES T -------------------------------------------------------------------------------------------------------------------------------------------------------4
2.2) SERIES TW ----------------------------------------------------------------------------------------------------------------------------------------------------4
3) OPERATION ----------------------------------------------------------------------------------------------------------------------------------------------------5
3.1) INITIAL START-UP/COMMISSIONING ----------------------------------------------------------------------------------------------------------------5
3.2) NORMAL OPERATING ACTIVITY -----------------------------------------------------------------------------------------------------------------------5
3.3) BLOCK AND BLEED OPERATION------------------------------------------------------------------------------------------------------------------------5
3.4) BODY CAVITY RELIEVING SYSTEMS -------------------------------------------------------------------------------------------------------------------5
4) MAINTENANCE -----------------------------------------------------------------------------------------------------------------------------------------------5
5) RECONDITIONING--------------------------------------------------------------------------------------------------------------------------------------------6
6) REASSEMBLY --------------------------------------------------------------------------------------------------------------------------------------------------7
7) VALVE SERVICING INTERVALS ----------------------------------------------------------------------------------------------------------------------------7
8) VALVE MAINTENANCE GUIDE LINES--------------------------------------------------------------------------------------------------------------------7
8.1) ROUTINE MAINTENANCE --------------------------------------------------------------------------------------------------------------------------------8
8.2) VALVE FLUSH ------------------------------------------------------------------------------------------------------------------------------------------------8
8.3) VALVE CLEANING-------------------------------------------------------------------------------------------------------------------------------------------8
8.4) EMERGENCY REPAIR --------------------------------------------------------------------------------------------------------------------------------------8
9) QUICK REFERENCE -------------------------------------------------------------------------------------------------------------------------------------------8
9.1) NEW INSTALLATION “START-UP” ---------------------------------------------------------------------------------------------------------------------8
9.2) PROPER VALVE TESTING ---------------------------------------------------------------------------------------------------------------------------------8
9.3) SHELL TESTING ----------------------------------------------------------------------------------------------------------------------------------------------9
9.4) HYDROSTATIC SEAT TESTING ---------------------------------------------------------------------------------------------------------------------------9
9.5) SUPPLEMENTAL AIR SEAT TEST ------------------------------------------------------------------------------------------------------------------------9
9.6) DOUBLE BLOCK AND BLEED (DBB) VALVES ---------------------------------------------------------------------------------------------------------9
10) GEAR OPERATOR FIELD ADJUSTMENT--------------------------------------------------------------------------------------------------------------- 10
11) VALVE MAINTENANCE OVERVIEW-------------------------------------------------------------------------------------------------------------------- 10
12) LUBRICATION EQUIPMENT------------------------------------------------------------------------------------------------------------------------------ 10
13) PROPER VALVE STORAGE-------------------------------------------------------------------------------------------------------------------------------- 10
14) TROUBLESHOOTING--------------------------------------------------------------------------------------------------------------------------------------- 10

Installation, Operation and Maintenance Manual
SERIES T/TE/TW/TWE
ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE
Page: 3of 12
Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
BILL OF MATERIALS
PARTS LIST
No.
Description
1
Body
2
Bonnet
3
Ball/Stem
4
Trunnion Bearing
5
Stem Seal
6
Stem Back-up Ring
7
Seat
8
Seat O-Ring
9
Seat Back-up Ring
10
Seat Sub Seal
11
Wave Spring
12
Bonnet Cap Screw
13*
Stop Screw
14
Bonnet Seal
15*
Stem Bearing
16*
Stop Plate
17*
Retainer
18
Retract. Port Screw
19
Retract. Port Seal
20
Injection Fitting
21
Bleed Valve
22
Bonnet Align. Pin
23*
Grounding Plunger
24
Grounding Spring
29
Key
30
Thrust Plate
31
Thrust Adjust. Screw
32
Jam Nut
33
Thrust Plate Bolt
34
Lock washer
35
Bonnet Primary Seal
40
Internal Ball Check
41
Trunnion Cover O-Ring
* Not used in 8”FP & larger assemblies.

Installation, Operation and Maintenance Manual
SERIES T/TE/TW/TWE
ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE
Page: 4of 12
Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
1) SCOPE
The following instructions are very important
for the maintenance, disassembling and
assembling of Series 35C Check Valve. The
instruction refers also to grease emergency seal
valves with back-up rings for high pressure
services.
NAME PLATE INFORMATION
2) INSTALLATION
2.1) SERIES T
Install valve in system using proper size and
type mating flanges and appropriate gaskets (for
RF) or seal rings (for RTJ). Valve design allows for
line flow in either direction. Series T Valves are
provided with a flatted diameter stem (6" bore
and smaller) or a keyed stem (8" bore and larger)
and four tapped holes in a machined bonnet
surface for convenient actuator or gear operator
mounting. Location and dimensions of these
holes and stem sizes are listed on the
appropriate KF Data Sheet (consult factory).
KF offers an optional gear operator with
handwheel which can be field mounted.
Installation requires that the gear operator
covers be removed for access to the mounting
holes. Attachment is accomplished by socket
head cap screws through the operator case and
into the mating threaded holes provided in the
bonnet. After attachment to valve, adjust the
threaded “Open” and “Closed” travel stops by
observing ball port and stem flats or key radial
position. Complete assembly by installing covers.
2.2) SERIES TW
Series TW has the same installation, operation,
and maintenance as Series T except the TW
valve is to be welded into the pipeline with the
following procedure.
I. Prior to welding it is imperative that all
welding surfaces be cleaned from
contamination such as dirt, rust, and grease
which may affect weld performance. Make
sure ball is in open position.
Caution: During the welding process, valve
body temperature should be monitored
around the circumference at a location in line
with the seat sealant injection fittings. The
temperature at this plane should be checked
with the tempilstik or other reliable
temperature indicator and not allowed to
exceed 300˚F. This precaution is necessary to
assure that non-metallic seat/seals do not
suffer heat damage.
II. Tack weld valve into position and check for
proper alignment.
III. Finish weld following proper weld procedure
for material grade and condition, and the
above caution.
IV. If weld procedure being used requires post
weld heat treatment one of the following is
applicable: (A is preferred)
A. Localized post weld heat treatment
limited to the heat affected zone does
not require disassembly of the valve, and
use of this method does not void the
valves pressure test certifications.
However, it is imperative that the valve
body temperature be monitored and
controlled as described in Note 1.
B. Post weld heat treatment of the entire
body require disassembly of the valve in
order to prevent damage to the valve
internals. Disassembly of the valve voids
warranty and test certifications.

Installation, Operation and Maintenance Manual
SERIES T/TE/TW/TWE
ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE
Page: 5of 12
Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
3) OPERATION
3.1) INITIAL START-UP/COMMISSIONING
Once the valve has been installed on the line it
shall be left either in fully open or fully closed
position depending on start-up/commissioning
operation
Important: Do not leave the valve in half/
partially open position for a long period of time.
Ensure that the pipeline is free of any debris such
as sand, tool, welding slag or weld splatter and
rod ends. This will damage the valve ball and
seat during start-up/commissioning operations.
3.2) NORMAL OPERATING ACTIVITY
KF Series T Ball Valves are recommended for
on-off service only. Throttling (partial opening)
during flow conditions may cause excessive non-
uniform wear on seats, preventing tight shut-off.
All Series T Ball Valves open by rotating handle
or gear operator handwheel in a counter
clockwise direction. Exact closed and open
position is determined by the radial location of
the stem flats or stem key with respect to the
fluid bore centerline of the body. When the flats
or key are perpendicular to the fluid bore, valve
is closed. Positive stops and arrow indication are
provided on handles and gear operators.
3.3) BLOCK AND BLEED OPERATION
KF Series T Ball Valves are well suited for
sealing fluids, concurrently, at both ends. The
included bleed valve (21) provides a safe and
convenient method for checking closed valves
seat sealing effectiveness, as required, for Block
and Bleed valves.
Caution! Before opening the bleed valve note
orientation of the exhaust hole in the bleed valve
body. Stand clear of this direction when opening
the bleed valve. Never remove bleed valve (21)
while valve is exposed to line pressure.
3.4) BODY CAVITY RELIEVING SYSTEMS
Trunnion mounted ball valves do have a body
cavity where pressure can be trapped into a
closed volume. Under this circumstance any
increase of the contained fluid temperature or
any degradation of the contained fluid can result
in an uncontrolled pressure increase of the
trapped fluid to figures that are above the
design pressures of the pressure equipment.
To avoid the above scenario, all of the KF
trunnion mounted ball valves are provided with
the following body cavity relieving systems
(depending on the design of the seats):
Self-Relieving Seats: The design of self-
relieving seat is such that when the pressure in
the body cavity exceeds the maximum cavity
pressure, the seat will automatically disconnect
from the ball and allow pressure equalization
between the body cavity and the pipeline.
When one or both the seats are of the Self
Relieving type there is no need of any other type
of body cavity relieving systems.
4) MAINTENANCE
Routine maintenance on KF Series T Ball Valves
consists of periodic grease injections through
the two body lube fittings (20). See exploded
view on pg. 3. General purpose grease, such as
Mystic JT-6, is recommended for this service.
The use of thick, very viscous grease may
hamper designed sealing action and make seat
removal during any required disassembly more
difficult. The suggested strokes required, per
seat, for general maintenance is as follows:
Valve sizes up thru 6", 4-6 strokes;
8"-10", 10-12 strokes; 12"-14", 14-16 strokes;
16", 20 strokes. The stem journals are
permanently lubricated at the factory and
require no routine maintenance.
Note: The two stem journal fittings are for
sealant injection to provide temporary sealing in

Installation, Operation and Maintenance Manual
SERIES T/TE/TW/TWE
ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE
Page: 6of 12
Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
the event of a stem seal failure (Sealweld “Ball
Valve Sealant” No. 5050, available from
Sealweld Corp., Houston, TX or Calgary, Alberta-
Canada). Also, in the event of internal seat/ball
interface leakage, sealant may be injected
through the two body lube fittings to provide
temporary sealing.
5) RECONDITIONING
KF Series T Ball Valves may be rebuilt to new
condition without removing the valve from the
pipeline.
Caution! Prior to disassembly, valve must first
be isolated from system pressure and flow. Also,
with the valve seat at approximately half open,
internal pressure must be bled to 0 psi. Finally, as
a safety precaution open ball cavity bleed valve
(21).
After observing the above caution, remove
retainer (17), stop plate (16) and stem bearing
(15). These items are not included on 8" bore
and larger valves or gear operated assemblies.
On gear operated valves, remove the covers for
access to mounting screws (2 each on 2" bore
valves, 4 each on all others). Use an Allen
wrench to loosen and remove mounting screws.
Segment gear position will have to be adjusted
by rotating the handwheel in order to have
access to all of the mounting screws. When
screws are removed lift gear operator case from
valve.
Rotate ball to full open position and remove
cap screws (12). Using a large flat blade
screwdriver, pry up and remove bonnet (2) and
bonnet seal (14). Next, remove the four seat
retractor screws (18) and seals (19). Screw the
four retraction tools into retraction ports until
contacting seats (7).
Note: 1) It is very important not to overstress
the seats by threading the seat retraction tools
in too deep. 2) If thick, very viscous grease or
sealant has been injected to effect a temporary
seal, body lube injection fittings (20) and internal
ball checks (40) (if included) should be removed
to allow sealant to extrude during seat retraction.
Now, using two box end wrenches, screw the
two seat retraction tools at one seat inward
simultaneously. This action will retract the seat
away from the ball. Watch for proper (even, not
cocked) seat movement. Continue retraction of
seat until approximately 1/16" clearance is
obtained between seat face and port face of the
ball. Now, using the two box end wrenches
simultaneously, repeat the process, screwing the
retraction tools in on the other seat until the 1
/16" clearance for ball removal is obtained.
Remove Ball/Stem (3) by pulling up on upper
stem. Be careful, observing that there is
adequate clearance between ball and seats for
ball/stem removal. After ball/stem is disengaged
from body, release the seats by simultaneously
unscrewing the seat retraction tools from each
set. Reach into bonnet port and remove each
seat, seat O-ring (8), seat back-up ring (9), seat
sub seal (10) and wave spring (11) as a unit, by
hand. Clean and inspect all parts for damage and
wear. Observe seat pocket bores, stem seal
bores and bonnet seal area for rust pits and
scale. If necessary, use fine emery for removal of
deposits on the machined surfaces. Fine emery
may also be used “very lightly” on the ball
sealing surfaces. Scratches or cuts on the
Nylon®/Teflon® seal surfaces of the seats are
cause for replacement. Flush lube and sealant
injection fittings and channels with two or three
pumps of general purpose grease while valve is
disassembled.
Inspect trunnion bearing (4) in both the body
and the bonnet. Do Not Attempt to Remove
These Bearings Unless Replacement is required!!
If bearing removal is necessary, use a durable
wide blade screwdriver or long chisel to split,
then drive out bearing. Be careful not to gouge
or score bearing journals.

Installation, Operation and Maintenance Manual
SERIES T/TE/TW/TWE
ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE
Page: 7of 12
Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
6) REASSEMBLY
Use new replacement parts, as required.
Install O-ring and back-up rings in their proper
locations and orient as follows:
Stem seal back-up rings (6) belong on the side
of the Stem O-ring (5) away from the ball and
with the concave face toward the O-ring. The
seat back-up ring (9) belongs on the side of the
seat O-ring (8) closest to the ball and with the
concave face toward the O-rings.
Use a liberal amount of general purpose
grease on seals and machined mating surfaces.
Fill the reliefs between stem O-rings with grease.
Install new trunnion bearings utilizing a
wooden block and hammer to drive them into
position.
Install seat assemblies and wave springs as far
as possible, by hand, into seat pockets of the
body. Take care to assure that O-ring seals are
not pinched during assembly. Seat assembly
must be placed deep enough into seat pocket so
that the conical point of the seat retraction
tools will contact the angled metal seat surface
when they are screwed into the threaded
retraction ports of the body. Using the box end
wrenches, screw the two seat retraction tools
inward, simultaneously.
Note: It is important not to overstress the seats
by threading the seat retraction tools in too deep.
Therefore, after both seats are installed and
mechanical retraction is begun, continue to
check ball clearance so that you do not exceed
approximately 1/16" space per side to provide
for ball/stem installation.
Install ball/stem between retracted seats and
pilot lower stem through trunnion bearing and
into stem journal. Remove seat retraction tools,
allowing seats to engage with the ball surface.
Next, place a new bonnet seal in the recessed
diameter on body face. Install bonnet, noting
proper orientation with bonnet alignment pin
(22). Tighten bonnet cap screws until bonnet is
made up “metal-to-metal” with face of body.
Complete assembly by reinstalling retraction
port screws and seals, stem bearing, stop plate
and retainer or gear operator assembly.
Clean the parts and inspect them for damage,
wear and corrosion. Observe seat pocket bores,
stem seal bore and bonnet seal area for rust pits
and scale. If necessary, use fine emery for
removal of deposits on machined surfaces. Fine
emery may also be used very lightly on the ball's
spherical sealing surfaces.
Scratches or cuts on the sealing insert surface
of the seats are cause for replacement. Flush
lube and sealant injection fittings and channels
with two or three pumps of grease while valve is
disassembled. Replace seals and other parts, as
required.
Reassemble in reverse order. Use a liberal
amount of general purpose grease (such as
Mystic JT-6) on all seals and machined mating
surfaces. Fill the relief area between the stem
and lower trunnion O-ring grooves with grease.
Finally, assemble the Bonnet to the body and
uniformly tighten the Bonnet nuts.
7) VALVE SERVICING INTERVALS
Valve shall be inspected regularly during
operation and subjected to scheduled
maintenance. The operator is responsible for
servicing the valve at regular intervals. The
service intervals are determined by media in line,
temperature, pressure and number of cycles
during the operations. High pressure accelerates
the loss of lubricants.
8) VALVE MAINTENANCE GUIDE LINES
In order to guarantee efficient valve operation,
the valve shall be inspected on regular basis
during the operation and subject to scheduled
maintenance. All maintenance work shall be

Installation, Operation and Maintenance Manual
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TRUNNION BALL VALVE
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Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
done by qualified personnel. Follow the grease
gun or pump manufactures equipment’s
guidelines for proper use. Local regulations shall
be strictly followed for the safety and health of
persons involved.
8.1) ROUTINE MAINTENANCE
The valve lubricants are designed for routine
valve maintenance. It consists of injecting
lubricant/sealant though the groove or channel
inside the valve leading to seal points around the
ball thus topping off the lubricant/sealant. The
“Top Off” quantity can vary greatly due to
frequency of valve operation and service
conditions. The lubricant is available in stick or
liquid from and should be free from heavy agent
such as PTFE, clay and wax. The most widely
used lubricant by manufacturers and users is
“HYDROCARBON GREASE”.
8.2) VALVE FLUSH
Valve flush is a blend of synthetic oils. It works
through penetration by pressure and often
successful in softening hardened deposits of
lubricants and sealants. It forms protective
coating on the metal surface and impenetrable
barrier which will withstand high pressure and
friction in server service demands.
8.3) VALVE CLEANING
When the valve does not seal properly and
hard to turn, the valve cleaning is required.
Valve cleaners are the product that contains
detergent, sealant and oils. It clears
channel/passage where old grease may have
been hardened, inject cleaner through the
lubrication channels, leaves it for three-to-four
hours. If possible, cycle the valve to evenly
distribute the cleaner in the ball-seat contact
area. This procedure is often successful in
freeing seized or hard to turn valve.
Note: Always displace the valve cleaner with
equal quantities of Lubricant/Sealant after
cleaning.
8.4) EMERGENCY REPAIR
A severe seat or ball damage may cause the
valve to leak. The valve sealants are designed to
stop a leaking valve. The sealant contains
heavier agent such as PTFE and clay in a grease
base. The temporary seal can be achieved by
injecting a heavy sealant. Displace a heavy
sealant after use of a lighter lubricant/sealant to
avoid complications. The valve which requires
continuous heavy sealant injections shall be
either replaced or repaired immediately.
9) QUICK REFERENCE
9.1) NEW INSTALLATION “START-UP”
Valves are frequently damaged by debris
during hydro testing or start-up of a New
Installation.
It is very important that the valve be in full
open position during this process.
If the valve is closed or partially open,
debris can damage the ball and find its way
into seat pockets
This can cause the valve to leak soon after
start-up
9.2) PROPER VALVE TESTING
I. Each valve is to be operated before and
after testing for any unusual torque
requirements.
II. Test pressure measuring devices are to be
either currently calibrated pressure gages
or pressure transducers.
III. Tests are to be made with ball and seat
free of any sealant.
IV. Fluid for shell and seat tests is to be water
with a corrosion inhibitor.

Installation, Operation and Maintenance Manual
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ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE
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Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
V. Valves are to be substantially relieved of air
or gas when tested with liquid.
VI. Seat closure tests are to be conducted
after acceptable shell test.
9.3) SHELL TESTING
Prior to painting or other external coatings,
Valves is to be subjected to a hydrostatic shell
test. There is to be no leakage under the test
pressure when both ends are blanked and ball is
partially open. Testing pressure is 1.5 times MOP.
Test duration are 2 min for 4” and under valves,
5 min for 6” to 10” valves, 15 min for 12” to 18”
valves and 30 min for 20” and larger.
I. Fit the vent valve and set it in open
position.
II. Operate the valve to the half-open position.
III. Fill in the valve with the fluid (Venting the
air through the vent valve)
IV. Close the vent valve and apply pressure in
accordance with max operating pressure of
the pipeline.
V. Visually check the outside of the ball valve
for possible deformations or leakage.
VI. Depressurize the valve.
9.4) HYDROSTATIC SEAT TESTING
Valves are to be subjected to a hydrostatic
seat test. There is to be no leakage under test
pressure. Test pressure is to be applied
successively to both sides of closed valve with
other side open to atmosphere. Testing pressure
is 1.1 times MOP. Test durations are 2 min for 4”
and under valves, 5 min for 6” and larger valves.
I. Operate the valve to the fully close position
and open the vent valve.
II. Pressurize one side in accordance with max
operating pressure of the pipeline.
III. From the body vent, check for possible seat
leakage.
IV. Repeat same operations as per points 2 & 3
on opposite side of the valve.
V. Depressurize the valve.
Note: For valve without a body vent or drain
connection, it is necessary to install a control
system on the pipeline to measure the pressure in
upstream and downstream of the valve.
9.5) SUPPLEMENTAL AIR SEAT TEST
Valves subjected to an 80psi air seat test shall
show no signs of visible leakage.
9.6) DOUBLE BLOCK AND BLEED (DBB) VALVES
If the valve has DBB, the test shall be
performed as follows:
I. With the valve in half-open position, the
valve shall be completely filled.
II. The valve shall than be closed and the
valve vent opened to allow excess fluid to
overflow from the cavity connection.
III. Apply pressure on both the seats
simultaneously.
IV. Seat tightness shall be monitored from the
cavity connection.
V. Depressurize the valve.
Note: For valve without a body vent or drain
connection, the above test is not applicable

Installation, Operation and Maintenance Manual
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Document Name: IOM-T
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10) GEAR OPERATOR FIELD ADJUSTMENT
I. Locate “closed” stop adjustment screw on
gear operator. It is the screw on back of
gear case on same side of operator as the
hand wheel.
II. Operate ball valve to full closed, “feel” the
valve hit the stop.
III. With pressure on closed ball valve, loosen
the lock nut on “closed” stop adjustment
screw then back out screw [CCW] 3 or 4
turns.
IV. Open bleed fitting on side (center) of ball
valve.
V. Line media will escape from bleed fitting
while evacuating ball cavity. Allow a
minute or two for body cavity to bleed
down. If media continues to escape thru
bleed fitting, leakage is confirmed.
VI. If leakage continues to be observed at
bleed fitting, turn gear operator hand
wheel clockwise (right) to further close the
ball valve. As hand wheel is turned,
observe for change in amount of flow out
bleed fitting. The objective is to find a
position where flow no longer comes from
bleed fitting. At each check position, it is
necessary to allow some time to see if the
flow changes. If a position is not found to
stop leakage in the CW direction, turn hand
wheel CCW to see if the valve may have
been over-closing.
VII. If a position is found where leakage stops,
turn the stop-screw CW until it hits snugly
then tighten the lock nut.
VIII. If a position is not found where leakage
stops, it can be concluded that the seat
insert is damaged and repair is necessary.
11) VALVE MAINTENANCE OVERVIEW
Establish a valve Maintenance group
Have a set valve servicing schedule
Service schedule is dependent on the
media and the number of times the
valve is cycled
Valves should be lubricated at least one
time every six months.
12) LUBRICATION EQUIPMENT
Hydraulic hand guns are efficient for 4”
Bore and smaller
Hand guns require 50 Strokes to move
1oz of product
Air operated guns are the most efficient for
6” bore and larger
13) PROPER VALVE STORAGE
INSIDE STORAGE
Ball valves should be in the full open
position
End connection protectors should be tight
to prevent ingress of moisture and debris.
Valves should be left in original shipping
container (If possible).
14) TROUBLESHOOTING
Verify leakage (Block & Bleed)
Cycle the valve 3-6 Times
Wipes the ball and often allows trapped
debris to travel downstream
Can free-up a stubborn seat
Adjust Gear Operator/Actuator Stops
Occasionally, a stop set on a gear
operator may loosen causing the valve to
over or under level.

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Document Name: IOM-T
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FAULT
FINDING
CORRECTION
Internal
Leakage
Stroke the valve to the fully closed position.
Discharge the residual pressure left inside
the cavity through the drain valve and the
vent plug (when provided).
Allow the system to stabilize for half an
hour minimum.
If the valve is tight no water should drip out
the drain valve.
Small leaks can be stopped by
injecting sealant into grease
nipples
Bad ones require replacement
of seat seals.
Body Leakage
When any of the body flanged connections drips
verify the bolt tightening torque of the joint
concerned.
External leaks can be stopped
replacing body gaskets.
Increase in
torque
requirements
A slight increase in the valve torque
requirement is natural during the valve life
and has been taken in account when
designing the operator device.
This torque increment tends to stabilize with
time.
Torque increasing rate that does not trend
to stabilize can be caused by external affairs
such as sand / debris trapped between ball-
stem and bonnet flange or foreign objects,
left into the pipeline that gets trapped
between seats and ball.
Inject lubricant grease through
the ball-stem grease fitting.
If this operation does not bring
any benefit dismantle the
stem/gland flange group and
verify no galling, scores or
damages have occurred.
If possible, remove the foreign
objects from the pipeline.
Verify that the operator is
correctly set and is delivering
its nominal torque.
Ball-Stem
leakage
Leakages from ball-stem depend from
damage of primary and secondary seal
on the ball-stem in case the grease injector
is not between the two sealing areas. In this
case the leakage is recorded through ball-
stem seal.
In case the grease injector is positioned
between the seals (primary and secondary)
the leakage of primary seal can be recorded
removing the grease injector or plug forecast
during the design stage.
Small leakages can be stopped
or reduced injecting grease
sealant through the grease
injector.
Big leakages require the
dismounting of the valve.

Installation, Operation and Maintenance Manual
SERIES T/TE/TW/TWE
ONE-PIECE TOP ENTRY
TRUNNION BALL VALVE
Page: 12 of 12
Document Name: IOM-T
Revision: 15333
Release Date: 06/26/2015
Vent and
drain leakage
Leakage through drains and vents caused by
damage of elastomeric seal material or when
minimum torque required is not achieved
(wrong torque applied or threaded parts
damaged).
In this case there is a leakage of fluid or gas
from vent and drain.
If elastomeric seal material is
damaged it is substituted after
dismounting the vent and
drain.
In case there is any missing
torque the correct torque is
applied (after the verification of
integrity for threaded area).
Leak from the gasket seal can
require the dismounting of the
flange and substitution of
gasket seal.