Jag FB2 Instruction manual

12315 Parc Crest Dr. # 190
Stafford, TX 77477 USA
tel. 1+ 2 1.933-5775
fax: 1+ 2 1.933.5779
FB2
Floating
Quarter Turn Soft Seated
Ball Valves
2 Piece Valve
Storage, Installation, Operation
& Maintenance Manual
PUB ICATION No: JAG.FB2-IOM.Rev.0
Issued: 10/2012

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INDEX OF CONTENTS
SECTION 1: STORAGE
SECTION 2: UNPACKING & INSPECTION
SECTION 3: PRE-INSTALLATION
SECTION 4; HANDLING
SECTION 5: INSTALLATION
SECTION 6: OPERATION
SECTION 7: MAINTENANCE
SECTION : MAINTENANCE KITS
SECTION 9: SAFETY PRECAUTIONS BEFORE REMOVING VALVE FROM
PIPELINE.
SECTION 10 SAFETY PRECAUTIONS AFTER REMOVING VALVE FROM PIPELINE
SECTION 11 VALVE FASTENERS - APPROX TORQUE VALUES
APPENDIX I TYPICAL VALVE GA
APPENDIX II TYPICAL SEALANT INJECTION

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SECTION 1 - STORAGE
1.1 Pre Despatch
Non corrosion resistant valves shall be
primed and/or painted.
After testing and before shipment, valves
shall be drained of test fluid.
Parts and equipment shall have exposed
bare metallic surfaces protected with a rust
preventative which shall not become fluid
and run at temperatures less than 125°F.
Exposed sealing surfaces shall be protected
from mechanical damage for shipping.
Valves not destined for immediate use will
be adequately prepared and packed before
shipping in such a way as to avoid any
possible damage during transport and
during the subsequent storage period before
use.
Relevant valve certification is always
included in shipment.
1.2 Customer Storage Instruction
If possible it would be advisable to leave the
valves in their own packing cases and/or
pallets during the entire period of storage. In
either case, to prevent damage, the
protective covers on the flanges of every
valve must not be removed. The valves
must always remain in an OPEN position.
It is advisable that storage conditions be
closed and dry. The valves should be stored
in weatherproof conditions in a building with
an adequate roof.
Gearboxes and actuators are supplied and
shipped already assembled with their
relative Valves and fitted with additional
equipment (e.g. Limit Switches / Solenoids)
as required by the customer contract.
Caution must be taken to ensure that all
protective covers on this equipment are not
removed until installation.
2.1 Unpacking and Inspection
Care should be taken during unpacking of
valves.
It is advisable to check valve exterior for
shipping damage and any damage should
be reported to the Quality Assurance
Manager immediately.
All JAG flocomponents valves are supplied
with the ball in the open position and
protective covers on both ends.
Ensure end covers remain securely in place
until the valve is ready for installation.
This will prevent ingress of dirt and damage
to ball surface and end connection surface
finish.
Please also check that valve certification is
correct to the requirements.
SECTION 3 - PRE-INSTA ATION
3.1 Pre Installation
Before installation check to ensure size,
pressure rating, end connection and material
of construction are suitable for required
service conditions.
Remove dirt/debris that may have
accumulated in the valve during long term
storage and always maintain valve
cleanliness during installation procedure.
In particular weld spatter should be kept
clear of valve seats as this could result in
damage to the soft seats and valve
malfunction.
SECTION 4 - HAND ING
4.1 Handling
On valves with restricted space between the
flanges handling is achieved by slinging the
valve on the neck diameter behind each of
the pipe flanges.
NB. Webbed slings should be used at all
times.
SECTION 5 - INSTA ATION
5.1 Installation
JAG flocomponents valves can be supplied
with various end connections.
Ensure that the pipe work, flanges, etc., are
square, true and that pipes are properly
supported to prevent line buckling, which
could result in excessive stress on the valve.
Dependent on the application, the joint/
gasket selection and bolting torques as
recommended by the joint/gasket
manufacturer[s] should be observed to
maintain sound, tight joints.
Butt Weld End Valves - during welding all
possible efforts should be taken to stop the
ingress of weld slag into the pipeline.

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5.2 In- ine Testing
Do not leave valves in the half open position
as this could result in damage to the soft
seat.
Ensure that after welding (if applicable) all
valves are flushed out and left in the fully
open or fully closed position.
The valve is now ready for line testing.
Ensure that after testing all valves are
flushed out and left in the fully open or fully
closed position.
SECTION 6 - OPERATION
6.1 Operation
JAG flocomponents (manual operation)
floating ball valves are operated by a simple
quarter turn of the stem to the fully open or
fully closed positions against the stops.
The valve position is indicated by the stem
flats and / or handle.
When the stem flats and/or handle is in line
with the pipeline the valve is in the fully
open position. When stem flats and/or
handle are at right angles to the pipeline
the valve is in the fully closed position.
Floating Ball Valves contain two seats.
Each seat is made of RTFE or similar
material.
The valve seals by pressure in the line
pushing the ball into the opposite seat
ensuring a positive seal on the outlet sides
of the valve.
As more pressure is applied a tighter seal is
formed.
If the valve is provided with a gear, the
position stops that are located in the manual
gearbox are adjusted and factory set to give
true alignment in both the open and closed
positions.
JAG flocomponents recommends that the
position stops should not be tampered with
as it may affect the operational efficiency of
the valve.
The valve closes in a clockwise direction.
Where manual operation is not required an
actuator may control the valves.
Actuator operation shall be in accordance
with the actuator manufacturers
Installation, Operation and Maintenance
Instruction.
Note: Like any other piece of precision
machinery, JAG flocomponents ball valves
should not be immobilised for long periods of
time. Where possible, the valve should be
cycled at periodic intervals to ensure
continued correct operation.
Tight closure valves are intended to be
either FULLY OPEN or FULLY CLOSED.
Leaving the ball in some intermediate
position can rapidly cause severe damage
and / or failure.
SECTION 7 - MAINTENANCE
7.1 Maintenance
All JAG flocomponents floating ball valves
are designed with an anti-blow out stem.
JAG flocomponents floating ball valves do
not require lubrication.
Maintenance is seldom required.
If necessary, the valves may be refurbished
by relatively unskilled labour using a small
number of parts, none of which require
matching on site.
The only parts likely to require attention are
Ball, Seats, Stem, 'O' Rings and Fire Safe
Seals.
JAG valves are designed for ease of service
and assembly in the field. The only
preventative maintenance recommended is
to periodically inspect the valve for leaks
around the stem. Should a leak be noticed,
the following procedure is for adjusting the
packing.
Stem Packing Adjustment -
Remove the nut and handle from valve.
Bend up the lock washer and snug up the
nut in a clockwise direction. Once complete
bend back lock washer and replace handle
and nut.
Leakage at Body Joint: This is invariably due
to damage to the cap seal and it will be
necessary to dismantle the valve.
In-Line Leakage: Check that the valve is fully
fully closed. If the valve is fully closed, then
leakage will be due to damaged seat or ball
sealing surface. Further maintenance on

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seat or ball necessitates dismantling the
valve.
Leakage at Pipeline Joint: Test for tightness
of flange bolting. If slack, tighten bolting to
gasket/bolting manufacturer's recommended
torque. Ensure pipe work flanges etc., are
square, true and that piping is properly
supported to prevent line buckling.
Note: Over tightened bolts can cause flange
leaks as excessive force can cause flanges
to bow.
7.2 Dismantling the Valve
Remove the gland nut (14) and handle
(22) (or gear box if applicable);
Remove stopper (16), gland nut (14), lock
washer (1 ), locking plate (17), belleville
washers (21) and packing ring (6);
Remove nuts (13);
Remove cap (2);
Place Valve in closed position and
remove Ball (3);
Push stem (4) through body (1) from
the outside in;
Remove seats (5) from body (1) and cap
(2)
Remove old packing (10) from body (1)
The valve has now been dismantled. It can
be cleaned and checked for wear and
damage. Damaged seats must be replaced
and therefore a new set of seats should be
fitted into body of cap. New sets of 'O' Rings
and firesafe seals should be fitted and any
other defective parts replaced.
7.3 Assembling the Valve
Replace seats in body (1) and caps (2);
After replacing thrust washer (7) and O-ring
(11) push stem (4) internally through the
body (1)
When fully located turn stem one complete
revolution to ensure smooth action;
Line up stem (4) and replace ball (3) into
body (1);
Replace body seals ( ) (9)
Fit cap (2) over studs (12) and replace and
tighten nuts (13). (See Section 11.1 for
tightening torques);
Replace packing (10) over Stem (2) and into
body (1);
Replace packing ring (6) over stem (2) and
onto packing (10);
Replace belleville washers (6) over stem (2);
Replace gland nut (14) and torque nut to
30ft/lbs of torque;
Replace lock washer (1 ) and bend over
gland nut (14)
Replace stopper (16) and locking plate (17),
Replace Handle (22) and gland nut (14)
Check stem action. (4)
Check Open and closed position.
Always maintain valve cleanliness during
assembly procedure.
The valve has now been assembled ready
for test.

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SECTION 8 - MAINTENANCE KITS
8.1 Maintenance Kits
Maintenance kits are available from JAG flocomponents and consist of the following:
2 off Seats
1 set of O Rings and
1 set of Fire Safe Seals.
RECOMMENDED SPARES FOR ONE-YEAR OPERATION
No. Of Valves
In Service
1 - 10 11 - 25 26 - 50 51 - 100
Spare Kits 1 2 3 6
In event of valves requiring repair rather than maintenance, additional spare parts are available from JAG
flocomponents.
These parts are typical recommended spares.
If additional parts other than this list are required it may be recommended that the complete valve is replaced.
IMPORTANT
Spare parts from different valve types should not be interchanged. This will ensure that the valve remains capable
of being used for its original design and construction purpose. There can be no risk to health and safety when the
valve is properly used.
JAG flocomponents shall not be liable for any Failure/Damage/Injury where valve parts are not of the Company's
original design or specification.
SECTION 9 - SAFETY PRECAUTIONS
BEFORE REMOVING VA VE FROM PIPE INE
9.1 Safety Precautions - Before removing
valve from Pipeline
Media flowing through a valve may be
corrosive, toxic, inflammable or of a
contaminant nature.
Where there is evidence of harmful fluids in
the valve pipeline the utmost care must be
taken.
It is suggested that the following safety
precautions should be taken when handling
valves of this nature.
Always wear eye protectors.
Always wear gloves and overalls.
Always wear protective footwear.
Always wear protective headgear.
Ensure that running water is readily
available.
Ensure suitable fire extinguisher is readily
available.
Ensure that no pressure exists on either the
upstream or downstream sides of the valve;
ask responsible pipeline personnel, to check
pipeline pressure gauges to ascertain
pressure is zero before handling valves.
Ensure that any trapped media is released
by slowly operating the valve to the half
open position. Leave valve in the fully open
position before removing from the pipeline.
SECTION 10 - SAFETY PRECAUTIONS AFTER
REMOVING VA VE FROM PIPE INE
10.1 Safety Precautions - After removing valve
from Pipeline
If, after removing the valve from pipeline, it is
discovered the valve is closed and not in the
fully open position, ensure that any trapped
media is released by slowly operating the
valve to the half open position.
The safest place to stand when opening the
valve is away from the end of the stem, and
to one side of the valve.
Leave valve in the fully open position prior to
dismantling.

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SECTION 11 - VA VE FASTENERS
11.1 Valve Fasteners - Approximate Torque Values
Bolt Size
Material B7/ 7
Material B7M/ 7M
3/ ” 16 UNC 33.50 ft/lbs 25.50 ft/lbs
1/2” 13 UNC 73. 0 ft/lbs 36.40 ft/lbs
5/ ” 11 UNC 149.00 ft/lbs 110.75 ft/lbs
3/4” 10 UNC 279.00 ft/lbs 210.00 ft/lbs
7/ ” 9 UNC 414.74 ft/lbs 317.00 ft/lbs
1” UN 614.00 ft/lbs 469.00 ft/lbs

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