Installation-Operation-Maintenance Manual
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Pipe cleaning
Foreign matters in the pipeline may damage the sealing surface of the valve or prevent the movement of the valve ball,
resulting in the valve not closing properly. In order to reduce the possibility of dangerous situations, all pipes need to be
cleaned before installing the valve. Check that pipe dirt, metal chips, welding slag and other foreign objects have been
removed. In addition, check the flange surface of the pipe to ensure that there is a smooth surface (If any cleaning
proces after the valve is installed in pipeline, the ball valve has to be in open position and must not be activated before
rinsing completed, to avoid damage of seat).
Valve installation
There shall be flange gasket on the flange surface when the valve is installed. It is recommended that the flange
installed with the valve meet the relevant standards.
□ Check that the pipes are in a straight line and the flanges are clean and parallel. Do not install the valve between two
non-parallel flange faces.
□ The distance between the flanges must correspond to the face to face dimension of the ball valve.
□ Carefully place the valve between the flanges. After the valve is aligned with the pipeline, then gently tighten the bolts,
and finally tighten them in a staggered order. Correct tightening can avoid uneven valve pressing force, prevent
leakage, and also help to avoid flange damage.
Fasteners used during the installation should comply with the laws, regulations and standards of the relevant countries.
Those which do not meet the requirements of the relevant regulations are strictly prohibited to use for the installation.
When tightening the flange bolts and nuts, a reasonable torque should be used according to the relevant regulations.
The following table lists the torque values for reference.
Operation instructions
□ The opening and closing of the valve is done by turning the handle a quarter turn (90° turn).
The valve handle is marked showing proper rotation direction for “ON” and “OFF” positions. Rotation is clockwise for
“OFF” (closed) and counterclockwise for “ON” (open).
- Valve in OPEN position: The handle is in line with the valve or pipeline.
- Valve in CLOSED position: The handle is across the pipeline.
Use and maintenance
The use of the valve shall be carried out in accordance with the instruction manual, and shall not exceed the design
parameters. The operator must go through on-the-job training to understand the basic operationprinciple of the valve.
Prevent incorrect opening and closing of valves. The operator should clearly understand the role of each valve and its
position in the process pipeline to prevent misuse. It should be ensured that the valve can be opened and closed at
least twice within a week to prevent the valve from being stuck due to long-term inactivity.
Valves should be inspected regularly, at least every three months, or in accordance with the corresponding laws and
regulations, or on-site process conditions to set the frequency of maintenance. Regularly check the valve connections
for looseness and tighten in time. Check whether the valve leaks or malfunctions. If leaks or malfunctions occur, the
valves and pipelines should be repaired in time on the premise of ensuring safety.
If there is an actuator, attention should be paid to the actuator and its connecting mechanism during valve maintenance.
Maintenance should be carried out according to the instruction manual of the actuator.
Replace the seat and packing
Note: Stem seal leakage may be corrected by tightening the packing nut to flatten the belleville washers. If leakage
continues or the valve torque becomes excessive, then the seal/packing must be replaced.
Before replacing the thrust washer and the packing, the pipeline must be de-pressurized.
□ Rremove flange nuts and bolts and carefully lift the valve from the pipeline to avoid scratching or damaging serrated
gasket. The big diameter valves are heavy and should be adequately supported before removing them from the line.
□ Loosen the stem nut and remove the handle or actuators. Then remove lock cap, packing nuts, belleville washers and
gland.
□ Use proper wrench to remove body bolt nuts, then lift the body end. The valve seat will come out with the body end
and then remove the body seat and gasket.
□ Rotate stem so the valve is in fully closed position. Carefully take out the ball to make sure there is no damage to the
ball surface, use a strap and lift device if necessary.
□ Take out the other seat.
□ The stem must be removed from inside of the body. Slightly push the stem head to loose the stem. The stem washer
and the O-ring should come out together with the stem.
□ Remove the stem packing from the body.
