Forum Quadrant F1 Series Assembly instructions

1
INSTALLATION, OPERATING, & MAINTENANCE INSTRUCTIONS
F1 Unibody Flanged-End Ball Valve IOM for:
1/2”- 6” F1-CS & F1–SS – ANSI CLASS 150 & 300
Read these entire instructions carefully before installation or servicing.
GENERAL INFORMATION
Safe and efficient operation of industrial installations
requires not only complete knowledge of the
engineering and functioning of all machinery and
equipment but their continuous proper maintenance
as well. Improper operation or maintenance of one
single valve may affect the whole operation. To help
you achieve trouble-free valve performance, general
information is provided here forthe optimumoperation
and maintenance of your Quadrant steel ball valves
with floating ball design.
DESIGN
All Quadrant F1 series unibody-floating ball valves
are a one-piece body design. The valves are non-
directional and can be installed with either end
upstream. These valves are designed and
manufactured in accordance with ASME B16.34 and
API 608. Valves have flanges drilled and faced in
accordance with ANSI B16.5.
1. HANDLING VALVES BEFORE
MOUNTING/STORAGE
1.1 Prior to shipment, blind covers are placed on the
inlet and outlet of each Quadrant valve for
protection from mechanical damage as well as
for prevention of intrusion of dust and other
foreign objects into the valve bore during transit.
Do not remove these end protectors before
valves are mounted.
1.2 For valve storage, a dust free place is
recommended. Care should always be taken to
avoid damaging stems. Placing valves directly
on the ground or concrete floor is not
recommended. Under no circumstances should
valves be stored outdoors. Valves are shipped
in the open position to protect the ball surface.
1.3 When moving with a crane, valves should be
positively rigged around valve bodies and end
flanges. In no case should the crane wire be in
direct contact with valve stems or operational
gears.
1.4 The valve must never be stored in the partially
open position. The soft seat can be damaged if
the valve is left partially open for long periods. It
is recommended that the valve be stored in the
full open position to protect the ball and seats.
WARNING
NOTICE
SAFETY FIRST! FOR YOUR SAFETY,
TAKE THE FOLLOWING
PRECAUTIONS BEFORE REMOVING
THE VALVE ASSEMBLY FROM THE
LINE OR BEFORE ANY
DISASSEMBLY.
WHAT'S IN THE LINE?
Be sure you know what fluid is in the line. If there
is any doubt, double check with the proper
supervisor.
VALVE SOLUTIONS - Quadrant
3711 Melancon Road
Broussard, Louisiana USA 70518
337-837-8650; 877-625-5858
IOM 002
Februar
y
2018

2
ARE YOU PROTECTED?
Wear any protective clothing and equipment
normally required to avoid injury from the
particular fluid in the line.
IS THE LINE DEPRESSURIZED?
Depressurize the line and drain the system fluid.
Cycle the valve several times to relieve any
pressure still inside the valve.
It is important to refer to the identification plate
fastened to each valve for maximum pressure ratings
and material description. In case there is any question
concerning the valve, refer to Quadrant for maximum
ratings.
WARNING
Warning: AT ALL TIMES KEEP
HANDS OUT OF THE BALL CAVITY.
A REMOTELY ACTUATED VALVE
COULD CLOSE AT ANY TIME AND
RESULT IN SERIOUS INJURY.
2. VALVE INSTALLATION
NOTICE
Handling equipment is required for the
weight involved. The Quadrant ball
valve catalog furnishes the approximate
weight of the specific valve.
PROCEDURE
2.1 Verify the valve is correct as shown on the piping
arrangement. Look at the identification plate,
tags, and markings on the valve for size,
pressure class, maximum operating pressure
and temperature, and materials.
2.2 Remove end connection protectors.
NOTE: As piping sites are usually dusty, be sure
not to remove valve end protectors before your
valves are ready for mounting.
2.3 Inspect the valve bore for foreign matter and
clean them if necessary. Valves are shipped with
ends sealed, but during the transit, foreign
material may be introduced into the bore.
2.4 Inspect gasket contact faces on valve flanges for
any scratches or defects. Correct such
scratches or defects with sand paper.
2.5 Install valve in line with either end upstream.
Tighten bolts evenly and alternately on
tangential line. The end of tightened bolts
should protrude equally above the nut.
NOTE: Make sure that valve and pipeline are
aligned accurately.
Valve and pipe interior should be flushed to
remove foreign objects which may later cause
a fluid leak.
Straightness of pipeline and flange faces
should be assured to avoid uneven piping
stresses against the valve.
Care should be taken to assure that general
stress of the pipeline is not concentrated on the
valve.
3. VALVE OPERATION
3.1 Rotation of the valve stem by 90
o
fully opens or
closes the valve. Clockwise rotation closes the
valve, and counterclockwise rotation opens it.
Note: To prolong the life of the seats, the ball
valve should be fully open or closed. Leaving the
ball in a half open/closed position could damage
the seats.
3.2 On the pilot run, be sure to detect fluid leakage
from the packing area, body-insert coupling,
flange gasket or piping flange gasket.
3.3 When leakage is detected from packing area.
Retighten packing nut [12] and observe result.
Refer to Sketch 1, Sketch 2, and Table 2
Note: Care should be taken not to overtighten
the packing nut, as it would reduce elasticity and
consequently sealing performance of packing. If
re-tightening does not solve the problem, gland
packing should be replaced with new packing.
Refer to Sketch 1, Sketch 2, and Table 2

3
3.4 When leakage is detected from body-insert joint,
torque the insert [2] to the specified torque in
table 1. Refer to Sketch 1
4. DAILY VALVE INSPECTION
DURING OPERATION –
ON STREAM MAINTENANCE
4.1 In order to operate your valve safely and
satisfactorily, daily inspection is very important.
The following are the main items for your daily
inspection.
Fluid leakage
a. leakage from the gland area
b. leakage from the flange connector
c. leakage through the valve body surface
d. leakage through the insert/body area
Generation of abnormal noise
a. from the valve itself
b. from the loose bolting
c. from the vibrating pipelines
Visual confirmation
a. correct valve operating position
b. bolting securely tight
4.2 If any of the above problems are detected,
remedial measures are to be taken immediately
as follows:
Fluid leakage
Refer to section 3.3 “Valve Operation” to
remedy leakage from the packing area. For
the leakage through the valve body surface, a
valve repair specialist should be called.
Generation of abnormal noise
Abnormal noise can be distinguished easily
from normal noise, if your maintenance
engineer gets used to it during daily
inspection. For the abnormal noise
generated from the valve itself or the
pipelines, your piping engineer should be
called. Loose bolting should be immediately
re-tightened.
Visual Confirmation
Make sure that the valve is operated in the
fully opened or closed position. No
intermediate position is recommended.
CAUTION: Ball valves are generally not
recommended for throttling service, where the fluid
flow or the edge of the ball bore may damage or
deform plastic ball seats and cause leakage when
they are fully closed. You might have an increased
concern with the possibility of seat damage or
deformation when your ball valves are used for
servicing liquid with extremely high fluid velocity
and/or high abrasive service such as slurry or a fluid
containing many materials.
For this reason, ball valves are basically to be
considered as a measure to fully open or shut off the
fluid flow. Leaving your ball valves slightly open
(intentionally or unintentionally) should be particularly
prohibited because of excessive increase of the fluid
velocity through the very narrow slit between the seat
and edge of the ball bore, which may damage or
deform the ball seats.
PERIODIC VALVE INSPECTION
OFF STREAM MAINTENANCE
Inspection should be made periodically to detect
wear of the ball stem, corrosion of the body or insert
interior, and wear of the threads. Usually, stem
packing, gaskets, insert seal, stem seal, body O-ring,
and ball seats are replaced as a part of basic
maintenance operations. For a list of recommended
spare parts, see Quadrant ball valve catalog or
contact a Quadrant Valve representative.
5. DISASSEMBLY PROCEDURE
(Refer to Assembly Illustration for part identification
and location.)
5.1 If the valve is in line, isolate the valve from the line
pressure.
5.2 Release the pressure from the inlet and outlet
ports.
5.3 It is recommended to cycle the valve four to five
times to make sure there is no pressure trapped
inside the body cavity.
5.4 Before dismantling the valve from the pipeline,
mark the flanges adequately in their original
location and position to avoid confusion or
mistake on subsequent re-installation of valve.
5.5 Remove the valve from line.

4
NOTE: Care should be taken when disassembling
not to scratch the stem, ball, or the body interior.
All valve components should be kept isolated for
easier examination and reassembly.
5.6 Before disassembly, remove and collect residual
objects from valves if any, and note their location.
Examination of these records and materials will
be found useful for better valve maintenance.
5.7 Scribe witness marks across edges of the coupled
body [1] and insert [2] for correct and easy
reassembly. Refer to Sketch 1
5.8 Fully close the valve, loosen handle bolt [18], and
remove the handle [15]. Refer to Sketch 1
Note: For ½” - 1” valves, remove the handle nut
[11] and lock washer [10] from the top of the
stem [4]. Then remove the handle [12]. Refer to
Sketch 2
5.9 Remove the snap ring [14] and stop plate [13].
Refer to Sketch 1
Note: For ½” - 1” valves the design does not
include these components, skip this step. Refer
to Sketch 2
5.10 Remove the packing nut [12], packing bolt [10],
and Belleville washers [11]. Refer to Sketch 1
Note: For ½” - 1” valves, remove the Packing
Nut [9] these valves do not have packing bolts
or Belleville washers. Skip step 5.11 Refer to
Sketch 2
5.11 Remove the gland plate [9]. Refer to Sketch 1
5.12 Remove the insert [2] from the body [1]. Refer
to Sketch 1
NOTE: This will require the valve to be placed
on a soft flat surface not to damage the raised
face on the flange. It will be necessary to use the
flange bolt holes to secure the valve in place. If
the torque required to loosen the insert is over 1.5
times the assembly torque, stop and examine the
valve for damage. It is suggested to bring that
valve in to a Quadrant facility for further
evaluation.
5.13 Remove the ball [3] from the body [1]. Refer to
Sketch 1
NOTE: Removal of the ball should be made with
extreme care so that it will not be scratched.
5.14 Remove the seats [5] from body [1]. Refer to
Sketch 1
5.15 Remove the body seal [7] from the insert [2].
Refer to Sketch 1
5.16 Remove the stem [4] by pushing stem into the
body cavity. Refer to Sketch 1
5.17 Remove the stem thrust washer [6] from the
stem. Refer to Sketch 1
5.18 Remove the stem packing [8] from the stuffing
box. The packing consists of graphite or TFM (R-
PTFE) rings. Refer to Sketch 1
6. INSPECTION AND CLEANING
6.1 Wipe off metal parts with a soft cloth using
petroleum solvent, steam, or oil.
6.2 Inspect metal parts for damage or burrs on all
surfaces. Worn or corroded area of part shall be
carefully examined visually or, if necessary, with a
magnifying glass. Cracks should be carefully
detected. Wall thickness should be periodically
measured for recording corrosion with the
passage of time.
6.3 Part replacement. For recommended spare parts
list see Quadrant ball valve catalog.
NOTE: Soft goods should never be re-used
after the valve has been disassembled.
Always replace soft goods after disassembly
with new pieces. The soft goods include:
seats, stem packing, body seal, and thrust
washer.
7. RE-ASSEMBLY PROCEDURE
(Refer to Assembly Illustration on last page for part
identification and location.)
Valve should be assembled in the following sequence
after all the component parts have been cleaned and
new spare parts have been prepared. Be sure that
rust and other soils are out of the seat retaining areas
ofthe bodyand insertfor optimalsealing performance.
7.1 Placethebody[1],insert[2],andball[3]onaclean
solid surface and inspect for damage, paying
close attention to sealing surfaces such as stem
hole, stuffing box, seat pockets, gasket surfaces,
and raised face surfaces. Refer to Sketch 1 & 2
7.2 Clean the body [1], insert [2], and ball [3] to ensure
that no dirt or metal debris are trapped in the
assembly. Refer to Sketch 1

5
7.3 Apply a thin layer of lubricant to the seat pocket in
both the body [1] and insert [2]. Refer to Sketch 1
7.4 Inspect seats [5] for nicks, scratches, or other
damages. DO NOT install if damaged. Refer to
Sketch 1
7.5 Insert one seat [5] into the body [1] seat pocket.
Refer to Sketch 1
Note: Apply a thin layer of lubricant to the top
surface of the seats after installing them in the
valve.
7.6 Push stem thrust washer [6] onto the stem [4] until
washer contacts with the stem flange. Refer to
Sketch 1
Note: Before installing the stem [4] in the
valve, apply a thin layer of lubricant to the stem.
7.7 Carefully insert the stem [4] into the body [1] from
inside body cavity. Refer to Sketch 1
7.8 Rotate stem [4] to closed position and carefully
install ball [3] into the valve body [1] by sliding
ball stem slot onto stem. Refer to Sketch 1
7.9 Spray some aerosol lubricant (WD 40) on top of
ball [3] and rotate stem [4] open and closed
several times to make sure the ball does not
interfere with the body casting. Refer to Sketch
1
7.10 Insert the stem packing [8] into stuffing box
seal area. Refer to Sketch 1
Note: Make sure not to damage packing
when inserting into the stem seal area.
Graphite packing is very fragile.
7.11 Place gland plate [9] over stem [4] and into
stem seal area in the body. Refer to Sketch 1
NOTE: ½” - 1” valve does not include a
gland plate or gland bolting. Apply a small
amount of anti-seize compound on Packing
Nut [9] thread, torque the Packing Nut to the
torque specified in table 2 and skip steps
7.12 thru 7.13. Refer to Sketch 2 and Table 1
7.12 Install packing bolting [10]. The packing bolts
will be inserted from the top; install two
Belleville spring washers [11] with the large
diameters together then install the packing nut
[12]. Tighten the packing nut evenly to the
torque specified in table 2. Refer to Sketch 1
and Table 2.
7.13 Place stop plate [13] over the stem [4].
achieved. Refer to Sketch 1
7.14 Insert the second seat [5] and body seal [7]
into the body [1] and insert [2]. A small amount
of grease may be necessary to retain the seal
in place. Refer to Sketch 1
7.15 CRITICAL: Rotate ball [3] to closed position
before installing the insert [2]. Refer to Sketch
1
7.16 Apply a small amount of anti-seize compound
on insert [2] threads. Install insert into the body
[1] and torque the insert to the torque required in
table 1. Refer to Table 1 & Sketch 1
7.17 Place stop plate [13] over the stem [4]. Refer to
Sketch 1
NOTE: ½” - 1” valve does not include a stop
plate or snap ring. Skip steps 7.17 and 7.18.
Refer to Sketch 2
7.18 Install the snap-ring [14] on the stem groove.
Refer to Sketch 1
7.19 Install handle [15] on valve: put handle over
stem [5] and tighten handle bolt [18]. Refer to
Sketch 1
NOTE: For ½” - 1” valve place handle [12]
over stem [4], then place handle nut [11] on
top of handle, and tighten with appropriate
wrench. Refer to Sketch 2
TEST AND INSPECTION
8.1 Check the valve operating condition by fully
opening and closing several times. Make sure
that lock plate matches extreme operating position
of the valve.
8.2 All valves, after reassembly, should be subjected
to hydrostatic or pneumatic seat test to insure
valve performance.

6
Table 1) Insert Torque (Ft-Lbs.) according to Valve Size
Valve Size 1/2” 3/4” 1” 1 1/2” 2” 3” 4" 6”
Torque
(Ft.-Lbs.) 147 147 347 453 547 918 1179 1445
Table 2) Gland Bolting Torque
Valve
Size
Minimum Gland
Bolting Torque
(In.-Lbs.)
1/2 87
¾” – 1” 130
1 ½” – 2” 45
2 ½” – 3” 71
4”- 6” 107

7
Assembly Illustrations
Sketch 1

8
Sketch 2

9
Quadrant Valve & Actuator – Valve Solution is a wholly owned subsidiary of Forum Energy Technologies.
Quadrant ® is a registered trademark of
FORUM ENERGY TECHNOLOGIES
3711 Melancon Road, Broussard, Louisiana 70518
[phone] • [phone]
Forumvs.sales @f-e-t.com
Contact your local Quadrant ® representative for more information about other Quadrant ® Brand flow control
products, or learn more about other fine Quadrant ® products by visiting www.f-e-t.com
For any questions or comments regarding this product, please contact FET-Valve Solutions:
FET-Valve Solutions
3711, Melancon Road
Broussard, Louisiana 70518
[phone]
[phone]
Email: [email protected]