Econ ERIKS User manual

Installation & Operation Manual
Proven Quality since 1892
ECON trunnion mounted ball valves Fig. 6245, 6249, 6257, 6285, 6289, 6297 www.eriks.com
Rev. 3
Content
1. ERIKS operating companies
2. Product description
3. Requirements for maintenance staff
4. Transport and storage
5. Function
6. Application
7. Installation
8. Maintenance
9. Service and repair
10. Troubleshooting
11. Removal
1. ERIKS operating companies
ECON trunnion mounted ball valves are being delivered by several ERIKS operating companies
on a worldwide basis. In this manual these will be referred to as ‘ERIKS’, the individual terms of
delivery of the ERIKS operating company having executed the order are applicable.
2. Product description
The ECON trunnion mounted ball valves are designed according to ASME B16.34 and
EN 125616-1. Technical information about the ball valves can be found in our latest catalogue or
see our website www.eriks.com and should be used in accordance with the applicable pressure-
temperature rating as stated on this website.
Ball valves are provided with marking, according to MSS SP 25 and EN 19. The marking makes
the identification of the valve easier and contains:
- size
- pressure rating class
- body and endcap material marking
- Econosto logo
- heat numbers
- tag plate
ECON trunnion mounted ball valves have a two-piece construction and are available in 8”/DN200,
10”/DN250 and 12”/DN300. The ball valve has two seat rings which can be sealed in each
direction, without restrictions to the flow direction. Both upper and lower stems are equipped with
bearings, which reduce friction and ensure easy and stable operation. The acting force on the ball
made by upstream pressure is transmitted to upper and lower stem and the ball will not move out
of its position. The valve sealing is realized by a spring behind the seat. The seat-springs pre-
tightening unit features in self-sealing and ensures its sealing capability.
According to customers’ requirements, the valve can be provided with a grease injection system,
in order to extend the life-cycle of the valve, in case the ball or seats have been damaged.
Before using grease injection fittings, assure that the valve is in fully closed position. Connect a
grease gun to the fitting and inject an appropriate volume of grease. If the valve fails to seal after
the injection of grease, turn the handwheel gently back and forth, moving the ball against the seat
in order to assist the spread of the grease over the seat surface.
Due to the grease injection into the sealing surface, the friction and damage on the sealing surface
will be reduced and the life-cycle of the valve extended. In case when the valve seat is damaged,
grease injection will only function as a temporary seal until the valve can be repaired or replaced.
3. Requirements for maintenance staff
The staff assigned to assembly, operating and maintenance tasks should be qualified to carry out
such jobs and in any circumstance, ensure personal safety

Installation & Operation Manual
Proven Quality since 1892
ECON trunnion mounted ball valves Fig. 6245, 6249, 6257, 6285, 6289, 6297 www.eriks.com
Rev. 3
4. Transport and storage
Transport and storage should always be carried out with the ball complete open and the valves
should be protected against external forces, influence and destruction of the painting layer as well.
The purpose of the painting layer is to protect the valve against rust, during transport and storage.
The valves should be stored in an unpolluted space and should also be protected against all
atmospheric circumstances. There should be taken care of the temperature and humidity in the
room, in order to prevent condensate formation.
5. Function
ECON trunnion mounted ball valves are designed to stop the flow of a medium. The valve is
closed by turning the handwheel clockwise; please don’t use tools to increase the torque on the
handwheel. The maximum working pressure under maximum and minimum temperature is shown
on the nameplate of the valve. Throttling operation is prohibited; please do not keep the valve in
half-open position frequently. The pressure difference and the impact of the liquid may do damage
to the ball and seat.
6. Application
The ECON trunnion mounted ball valve can be applied in long distance pipelines as well as
normal industrial systems. This type of valve can be widely used in the industry such as chemical,
petrochemical, oil & gas, power, off-shore etc. The valves are designed for standard operating
conditions. For the use of extreme conditions e.g. aggressive or abrasive media, it is
recommended to mention this at the ordering stage, to verify whether the valve is suitable. The
installation designer is responsible for the valve selection, suitable for the working conditions. The
valves are unsuitable, without written permission of an ERIKS company, to apply for hazardous
media as referred into Regulation (EC) No 1272/2008.
ECON trunnion mounted ball valves can be operated by a worm gear box, pneumatic, electric,
hydraulic or electric-hydraulic actuator.
7. Installation
During the assembly of the ball valves, the following rules should be observed:
- make sure before an assembly that the ball valves were not damaged during the transport
or storage.
- make sure that applied ball valves are suitable for working conditions, medium used in the
plant and the right system connections, according to pressure and temperature limits as
per the tag plate.
- to take off dust caps if the valves are provided with them.
- the interior of the ball valve and pipeline must be free from foreign particles.
- the valve should be installed in the pipeline in open position, for a correct functioning, the
valve must be stress free connected to the pipeline, supports must be arranged to prevent
any additional stress, caused by the weight of the valve or the pipeline.
- steam line systems should be designed to prevent water accumulation.
- install pipelines so that damaging transverse, excessive vibrations, bending and tensional
forces are avoided.
- for easy operating, the free space around the handwheel shall be not less than 100 MM.
- before plant startup, especially after repairs carried out, flash out the pipeline, of course
with fully opened position.
- don’t leave the ball partly open (throttling operation), where the pressure drop and/or flow
rate can bring damage to the valve seats and/or ball.
- don’t open or close the ball valve too quickly, this might cause water hammer
- it is good practice to operate the valve periodically in order to assure that the ball is able to
move freely.

Installation & Operation Manual
Proven Quality since 1892
ECON trunnion mounted ball valves Fig. 6245, 6249, 6257, 6285, 6289, 6297 www.eriks.com
Rev. 3
8. Maintenance
Before starting any service jobs, make sure that the medium supply to the pipeline is cut off,
pressure was decreased to ambient pressure, the pipeline is completely cleaned and ventilated
and the plant is cooled down. Always keep safety instructions in mind and take all personal safety
precautions.
During maintenance, the following rules should be observed:
- Always keep personal safety precautions in mind and always use appropriate protection
e.g. clothing, masks, gloves etc.
- be alert that the temperature still can be very high or low and can cause burns.
- check the valve on all possible leaking possibilities.
- dust, grease and medium residual, must be frequently cleaned of the valve body and all
moving parts, such as stem and actuator to maintain all operating functions.
- check if all bolts and nuts are still fastened. (also of the supports when used)
- before attempting to dismantle any ball valve, the valve should be opened and closed a
complete cycle to assure that there is no pressure trapped within the body cavity.
- if required replace the stem seal, for safety reasons, these valves only can be repacked
when depressurized, drained and ventilated.
- the thickness of body and endcap must be checked to ensure safety operation at an
interval of at least three months.
1) Re-tighten packing
⚫Should a leakage occur at the gland packing, retighten the gland nuts.
⚫Take care that the gland nuts are not tighten too much; normally the leakage can be
stopped by simply turning the stem nuts by 300to 600.
2) Replacement of seats and seals.
A) Disassembly
⚫Place the valve in half-open position and flush the line to remove any hazardous material
from the valve body.
⚫Put the valve in a vertical position with the body end cap facing up-wards.
⚫Place the valve in the closed position; remove both counter flange bolts & nuts and lift the
valve out of the pipeline.
⚫Remove the gear box or actuator, gland nuts, gland and bonnet bolts and lift the bonnet
including the stem out of the valve body. Now the stem and stem seals can be removed
from the bonnet.
⚫Remove the body bolts or studs and nuts to allow the endcap, to be separated from the
body, remove body gasket.
⚫Remove the trunnion which supports the ball at the bottom side and make sure that the
ball is in ”Close” position. Now the ball can be taken out easily from the body, by using
lifting equipment. Make sure the ball will be handled with care in order to avoid scratches
and dents.
⚫Finally the ball seats can be removed from the valve body and end cap.
Caution: Use care to avoid scratching the surface of ball, stem and packing chamber.

Installation & Operation Manual
Proven Quality since 1892
ECON trunnion mounted ball valves Fig. 6245, 6249, 6257, 6285, 6289, 6297 www.eriks.com
Rev. 3
2-piece trunnion mounted ball valve
B) Reassembly
⚫Reassembly process is reverse sequence of disassembly.
⚫Clean and inspect all parts, full replacement of all soft parts (seats and seals) is strongly
recommended.
⚫Put the valve in the “open”position, otherwise the seats can be damaged.
⚫Tighten the body bolts crosswise.
⚫Tighten the gland nuts
⚫Cycle the valve slowly with gentle back and forth motion to build gradually to full quarter
turn.
⚫If possible, test the valve before placing it back to line for service.

Installation & Operation Manual
Proven Quality since 1892
ECON trunnion mounted ball valves Fig. 6245, 6249, 6257, 6285, 6289, 6297 www.eriks.com
Rev. 3
9. Service and repair
All service and repair jobs should be carried out by authorized staff, using suitable tools and user
shall use valve genuine packing, gasket, bolt and nut of the same size and material as the original
one.
- welding repair and drilling of the valve is forbidden.
- it is forbidden to replace seats or seals when the valve is under pressure.
- before you replace seats or seals you have to clean the valve body on these areas.
- after replacement of seats or seals it is necessary to check the valve operation and
tightness of all connections. Tightness test should be carried out.
- after installation, the valve should be checked and maintained periodically at least every 3
months, depending on the medium.
10. Troubleshooting
It is essential that the safety regulations are observed when identifying the fault.
Problem
Possible cause
Corrective measures
No flow
The ball valve is closed
Open the ball valve
Dust caps were not removed
Remove dust caps
Little flow
Valve not completely open
Open valve completely
Piping system clogged
Check piping system
Valve difficult to open
Stuffing box seal too tight
Slacken nuts
Wrong direction of rotation
Turn counter clockwise to open
Ball seat damaged by foreign
particles.
Replace the ball seats
Leakage on the connection
between valves and pipes
The flange nuts haven’t been
turned down or haven’t been
fastened evenly.
Turn down the nut evenly
Flange sealing surface or valve
sealing surface was damaged
or there is dirt on it.
Repair the sealing surface or
clean the valve and flange.
Gasket is out of use
Replace the gasket
Leakage across the stem
Stuffing box gland slack
Tighten stuffing box gland
evenly, if necessary renew
stuffing box packing
Leakage across valve seat
Valve not properly closed
Pull the wheel tight without tools
Seat damaged by foreign
particles
Replace the ball seats
Medium contaminated
Clean valve and install dirt
screen
Operating failure
Packing too tight
Loosen gland nuts
11. Removal
All dismantled and rejected valves cannot be disposed with household waste. The valves are
made of materials which can be re-used and should be delivered to designated recycling centers.
General warning:
General note for products which may be used for seawater:
Although our products can be used in seawater systems it should always be noted that, in case of
installation in a piping system made of materials which are frequently used because of their excellent
seawater resistance (e.g. Cunifer), large potential differences may occur possibly causing corrosion
which could permanently damage the proper functioning and integrity of our product.
A combination of different materials should always be mentioned prior to the purchase of our products
in order for us to give the best possible advice on a safe functioning.