Force CNC BTN Series User manual

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 1/43
Installation, Operation, and Maintenance
Manual
API 6D Two Piece Cast Trunnion Mounted Ball
Valves – BTN Series

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 2/43
This manual will describe the method of installation, operation and maintenance of the Force “BTN” series
flanged ball valves.
CAUTION AND WARNING
To ensure safe and trouble-free function and performance, please read all the contents of this manual
before handling, transportation, mounting and operation of the valves.
Keep this manual accessible to the operator.
The signs “WARNING” and “CAUTION” are defined as follows:
Responsibility for valve application
The End User is responsible for ordering the correct valves for the intended application. Force valves are to
be installed in observance of the pressure rating and design temperature. Prior to installation, the valves
and nameplates should be checked for proper identification to be sure the valve is of the proper type,
material, and is of a suitable pressure class and temperature limit to satisfy the application requirements.
Indicating potentially hazardous conditions which may result in injury
to personnel or property damage if such conditions are ignored.
Indicates mandatory implementation of an action.
Indicates prohibition of an action
Do not use any valve in applications where either the pressure or temperature is
higher than the allowable working values. Also, valves should not be used in service
media if not compatible with the valve material of construction, as this may cause
premature failure.
Indicating potentially hazardous conditions which may result in
injury to personnel if such conditions are ignored.

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 3/43
Index
Page
Ⅰ. Construction and Design features ･･･････････････････････････････ 4
Ⅱ. Operator ･･･････････････････････････････････････････ 9
Ⅲ. Shipping, Handling and Storage ･････････････････････････････････ 12
Ⅳ. Valve installation ･･････････････････････････････････････････ 15
Ⅴ. Valve operation ･･････････････････････････････････････････ 19
Ⅵ. Periodic inspection ･･･････････････････････････････････････････ 26
Ⅶ. Disassembly and Reassembly ････････････････････････････････････ 35

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 4/43
Ⅰ. Construction and Design features

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 5/43
Ⅰ. Construction and Design features
1. Construction and Design features
1.1 Construction and part names are as illustrated below.
1.2 The valve can be operated by rotating the stem by 90°to open or close.
1.3 The valve is designed for use in the fully open or fully closed position only.
1.4 The valve has a stem at the top and trunnion at the bottom to support the ball, the design of
which gives the valve less impact on its operationtorque.
1.5 This is a bi-directional valve.
This illustration shows typical construction
NOTE: This figure is for reference only, as components may vary according to size/class
and design. Consult CNC Flow Control for appropriate component list.
NO. NAME OF PARTS
1 BODY
4 END CAP
5 STEM
6 BALL
11 GLAND FLANGE
14 SEAT INSERT
16 TRUNNION
18 SEAT CARRIER
20A O-RING
20B GASKET
22 STEM FIRE SAFE SEAL
25 THRUST WASHER
30 CAP STUD
31 CAP NUT
32 GLAND BOLT
49A
O - RING
49B
49C
49D
49E
51 SEAT SPRING
54 SEAT FIRE SAFE SEAL
67 LANTERN RING
69A DU-BUSHING
69B DU-BUSHING
69C DU-BUSHING
82 GASKET
83 TRUNNION STUD
84 TRUNNION NUT
91 MOUNTING STUD
92 MOUNTING BOLT NUT
100 KEY
101 INJECTION FITTINGS
103 BLEED FITTING
200 GEAR BOX

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 6/43
Ⅰ. Construction and Design features
2. Design features
2.1 Double block and bleed (DBB) (both seats unidirectional-Self relieving seats)
Single valve with two seating surface that, in the closed position, provides a seal against
pressure from both ends of the valve of venting/bleeding the cavity between the seating
surfaces. Valve seat designed to relieve pressure in the valve cavity. Depending upon the
valve type, the pressure may be relieved to the pressure source or the low-pressure side.
Self-relieving seat (Unidirectional seat) (Unidirectional seat)
2.2 Double isolation and bleed -1 (DIB-1) (both seats bidirectional – DPE seats)
Single valve with two seating surfaces, each of which, in a closed position, provides a seal
against pressure from a single source, with a means of venting/bleeding the cavity between
the seating surface. Valve seat designed to seal against pressure source in either direction.
Double Piston Effect (DPE) (DPE) (DPE)
2.3 Double isolation and bleed – 2 (DIB-2), (One seat unidirectional x one seat bidirectional)
A combination of unidirectional seat (self-relieving) in the upstream and bidirectional seat
(DPE) in the downstream side of valve. This design feature maintains the sealing capacity of
the valve in case of failure of the upstream seat and release of the body cavity over pressure
through the upstream seat. Valves with DIB -2 feature will be Uni-directional and equipped
with highly visible arrow flow plate.
(Unidirectional seat) (Bidirectional seat)
NOTE: The term upstream and downstream refer to the pressure source and open
end/equipment respectively and do not refer to flow direction.

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 7/43
Cavity
Body
Ball
Seat Retainer
Line
2.4 Self-relieving seat mechanism
Seal is made on the upstream side by the seat retainer whose seat spring pushes the seat against
the ball at fully closed position. In case the line fluid trapped in the body cavity evaporates and
causes excessive rise in the cavity pressure, especially when the cavity pressure exceeds the line
pressure, the seat will move slightly away from the ball surface to relieve the excessive cavity
pressure into the pipeline.
2.5 Fire safe ball design
When the seats are decomposed or deteriorated by a plant fire, the edge of the metal seat
retainer preloaded by the seat spring comes into contact with the ball to shut off the line fluid to
minimize internal leakage through the valve bore.
Before exposure to fire After exposure to fire
2.6 Drain port
The valve has the block and bleed structure that allows a valve or other types of connections to
be installed at the drain port through which the fluid in the cavity can be discharged.
2.7 Pressure Temperature Chart
The selection of sealing material is the end user’s responsibility and dependent upon the medium
passing through valve, valve working temperature, pressure, and velocity of flow. As the Pressure-
temperature rating varies according to different valve working conditions, the following Pressure-
temperature rating value is calculated assuming stable valve working condition.
Body
O-Ring
Seat
Ball
Line
Seat Retainer
Flexible Graphite
Body
Ball
Line
Metal‐to‐Metal Contact

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 8/43
P-T rating for class 150 to 600 P-T rating for class 900 to 2500

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 9/43
Ⅱ. Operator

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 10/43
II. Operator
1Lever type operator
1.1 The lever handle is directly mounted on the valve stem.
1.2 Rotate the lever handle clockwise by 90°to close and counterclockwise by 90°to open the ball.
1.3 Rotation of the stem by 90°fully opens and fully closes the valve for Bare Stem Type.
An appropriate tool or handle shall be applied to operate the valve and the flow direction shall
be checked by the top orientation of stem.

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 11/43
II. Operator
2Gear operator
2.1 Gear operator is the device to multiply and convey force from the operator to the stem
through reduction gear.
2.2 The gear operator shall be mounted directly to the valve.
2.3 There should be an arrow or letter on the gear handwheel to indicate the proper direction to
rotate the wheel for opening (counterclockwise) or closing (clockwise) valves.
2.4 Handwheel operation forces differ in the valve opening position and fluid pressure and /or
temperature.
Gear operator shall be correctly sized for the valve. Incorrect sizing may result in
damage to personnel and the valve.

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 12/43
Ⅲ. Shipping, Handling and Storage

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 13/43
Ⅲ. Shipping, Handling and Storage
1. Shipping and Handling Valves
1.1 Care for Shipping and Handling Valves
•
Keep off the valve lifting area to prevent injuries caused by the unsecured valves.
Unstable stacking may also result in personal injuries.
• Lifting equipment’s safe
working load (SWL) shall always be double checked
prior to any lift.
• Recommended handling procedure when lifting with slings shown in figure 1.
• Pay attention not
to damage painted valve surfaces during transportation, which
may subsequently cause corrosion to the valve. Repair is required if
the surface
is damaged.
• Pay attention to handling and storage of
carton packed products. The high
humidity may damage the cartons.

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 14/43
1.2 Shipment
1.2.1 Maintain original packing during shipment. Provide appropriate protection covers if they are
found missing during transportation.
1.2.2 Handle valves carefully so that they may not fall or drop on the ground. Any extraordinary
mechanical impact should be avoided.
2. Storage
2.1 Care for Valve storage
• DO NOT store valves in a corrosive environment, which may cause
corrosion
from the valve threaded areas.
• DO NOT remove protection covers until installation. They prevent any
foreign
objects from intruding valves.
• DO NOT place any objects on valves, and DO NOT step on them.
Overloading
may cause damage to valves.
• DO NOT pile up products carelessly to avoid damage to the products
and
personal injury caused by unstable piling.
•
Keep the valves in the opened position, during storage. Storing the valves in
halfway position may deform the ball seats, leading to cause of
the seat
leakage. And storing the valves in fully closed position may damage the ball,
when the flange protections or covers are torn or removed.
2.2 Storage
2.2.1 Indoor storage of valves in a dust-free, low humidity and well-ventilated place is recommended.
2.2.2 Storage of valves directly on the ground or concrete floor is not recommended. Place packed
valves on the pallets or the racks for storage.
2.2.3 Take some appropriate measures to protect valves from direct exposure to dust, rain, or
sunlight if they are temporarily stored outdoors.
2.2.4 Perform pressure tests before using the valve if the valve has been stored over twelve months.

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 15/43
Ⅳ. Valve installation

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 16/43
Ⅳ. Valve installation
1Care for Valve installation
1.1 Allow enough room for operation, installation, removal, and subsequent maintenance of valves,
considering the valve height and the stem direction.
1.2 Take appropriate measures for smooth operation, inspection and maintenance of valves if they
are forced to be installed in small spaces.
1.3 Try not to install valves in the places where valve functions may be hampered by outer forces
such as vibrations.
1.4 It is recommended to install valves to horizontal pipes with stem in the upright position.
 Check the valve specifications with the identification plate or tag and the relevant
catalogue, to ensure that the exact valves specified in your piping arrangement plan
was provided. The service fluid, pressure and temperature determine the compatibility
of sealing materials. Incorrect application of a specific valve could be hazardous.
 DO NOT install for pipe end service, In such a case, use the blind flange.
 Keep a secure footing for valve installation and operation.
 Piping should be properly supported, if needed.
 Valve lifting with chain/cord tiled to lever, gearbox or actuator is not permitted.

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 17/43
Ⅳ. Valve installation
2Care for Piping
 Keep off the valve lifting area to prevent injuries caused by the unsecured valves.
 Care should be taken to keep hands clear of valves while placing them between
pipe flanges.
 Pay attention not to damage flange surfaces and gaskets
 Piping should be properly supported to align pipes on both sides.
 For valves with the gland packing structure, retighten gland packing before
operation. Pressure applied to the gland packing may be lowered due to the
stress relaxation taking place during transportation or storage, which may cause
leakage.
 Use new gaskets when installing valves into pipelines.
2.1 Check the following items before installation of the valves.
2.1.1 The service conditions should be within the range of the relevant valve specification.
2.1.2 Valve flanges should correspond with pipe flanges.
2.1.3 Gasket contact surfaces of pipe and valve flanges must be free from scratches or any other
damages.
2.1.4 The appropriate length should be kept between pipe flanges for the valve face-to-face
dimensions including the gasket thickness.
2.1.5 Pipes and valves should be accurately aligned.
2.1.6 Pipe flanges should face parallel to each other. The bolt holes of flanges should be
symmetrically lined up against the center line of flanges.
2.2 Before installation of the valves, the connecting pipes should be cleaned to remove any foreign
objects such as sand, dust and welding spatters.
2.3 Do not give extraordinary shock to valves by throwing, dropping, dragging or toppling them
down.
2.4 Remove flange covers from valves just before installation.
2.5 Thoroughly check all threaded areas after installation and retighten them, if needed.
2.6 Flush the valve in the open position and pipes after installation to remove foreign objects. Do
not operate the valves while flushing.

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 18/43
Ⅳ. Valve installation
3Valve installation procedure
3.1 Pipes and valves should be accurately aligned.
3.2 The appropriate length should be kept between pipe flanges for the valve face-to-face
dimensions including the gasket thickness.
3.3 Place the valve between the pipe flanges. Insert bolts through the bottom bolt holes and
tighten them lightly. This will support the valve during the remaining steps of installation.
3.4 Insert gaskets between the valve and pipe flanges.
It is recommended to apply lubricant (gasket paste) to gasket faces.
3.5 Make sure the correct alignment of gaskets, which are held in place with the bottom bolts.
3.6 Thread bolts through the other holes of flanges and slightly tighten them.
3.7 Evenly tighten the bolts alternately in a star pattern as shown below. Once the bolting is
properly tightened, both ends of each bolt should evenly protrude beyond the nuts.
3.8 Gradually raise the line temperature and pressure during the test run. Retighten valve
bolting, if needed.

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 19/43
Ⅴ. Valve operation

Force – Two Piece Trunnion
Mounted Ball Valve
Document Number:
Revision:
Release Date:
EDC 514
A
05/09/2022
IOM: Installation, Operation and Maintenance Manual 20/43
Ⅴ. Valve operation
1. Care for Valve Operation
 DO NOT apply excessive force to operate the valves by using a pipe or hand
wheel rotating device.
 Never loosen bolts or nuts used in the gland, cap flanges and end flanges of
pressurized valves.
 DO NOT use valves in partially open/closed position. Such use may damage
seats
and cause internal through-bore leakage.

Valves should be kept fully open during the line test or pressure test. Fully closing
valves during the test may deform the seats, leading to the occurrence of internal
through-bore leakage.
 In case service temperature fluctuates, retighten all bolts and nuts after the
temperature is stabilized against occurrence of stress relaxation of the gland
packing and/or gasket. DO NOT EXCEED TORQUE MORE THAN RECOMMENDED
IN SECTION 5.2
 Gradually open valves to prevent damage of pipe when high temperature fluids
such as steam are handled.
 Take some appropriate measures to prevent freezing, as needed.
2. Valve operation
2.1 Lever handle operation
Rotating the lever handle clockwise by 90° to close the valve and counterclockwise by 90° to open
the valve.
2.2 Gear operation
Rotating the handwheel according to the letters and the mark indicating the direction will close
the valve. Counterclockwise rotation will open the valve.