Modentic HPV-40AT User manual

Document No. : MD-QO-04-52
Date : 2009/06/04
Version: 1.0
1.To use for company in Europe who will place the product on the market , please amend which
necessary.
2.Modentic reserves the right to change any details without prior notice.
HPV-40AT
ThreePieceHighPressureScrewedBallValve
Reduced Bore PN210
USER MANUAL
Modentic Industrial Corporation
14F-1,No.57Taya Rd.,Taichung,Taiwan,R.O.C.
Email:[email protected]
http://www.modentic.com.tw
WARRANTY
Modentic warrants its products against defects in manufacturing if the products
Are used for the purposes for which they are manufactured and sold. This warranty
Shall expire one year from date of shipments.

Contents
1. General Precautions
2. General Description of Product
3. Pressure-Temperature Ratings
4. Delivery Condition and Storage
5. Installation and Operation
6. Put into service
7. Dangers of inappropriate use
8. Maintenance
9. Corrosion Data
10. Use in potential explosive atmosphere areas
11. Marking
Importer, Agent or Distributor responsible for servicing

1. General Precautions
a. Operation:
Ball valve is a kind of isolating valve used in
a pipe line system, which intended for use
only in the closed or fully open position. In
the open position, it allows the flow passes
through.
b. Material Selection:
The possibility of material deterioration in
service and the need for periodic inspections
is depended on the contained fluid. Carbide
phase conversions to graphite, oxidation of
ferrite materials will decrease in ductility of
carbon steels at low temperature are among
those items. However information about
corrosion data is provided together with this
user manual, the user is requested to take
attention or consideration to determine the
suitability of material in their application.
c. Pressure-Temperature rating:
The Pressure-Temperature rating is
considered for static pressure. Please refer
to P & T rating section 3 for actual
application. The allowable temperature is
between -20°C and 180°C. Do not exceed
the temperature range to avoid danger.
d. Fluid thermal expansion:
It is possible, when the ball valve is in closed
condition, the sealed cavity within the valve
body to be filled with liquid. If this liquid is not
released, by partially opening the valve or
some other means, and it is subject to a
temperature increase, excessive pressure
sufficient to cause pressure boundary failure
can be occurred. However our products
have pressure self-relief seat to prevent
pressure built up, user is recommended to
prevent that the pressure in the valve will not
exceed that allowed pressure, by means of
piping design, installation, or operation
procedure.
e. Electro Static effect:
The ball valves are designed with electrical
continuity for ball-stem-body to prevent
electro static discharge. The user is
responsible for ensuring the earthing of the
pipeline system.
f. Fire safe condition:
Fire safe certificates are only available upon
request.
g. Liquids with high fluid velocity:
The ball valves might be operated frequently
with very high velocity liquids, a check shall
be made with the valve distributor or
manufacturer for appropriate advice to
minimize the possibility of seat deformation,
especially when they are highly pressurized
on high-temperature line.
h. Throttling service:
Ball valves are generally not recommended
for throttling service, where both the fluid flow
and the leading edge of the ball can damage
or deform the resilient ball seats causing
leakage. High fluid velocity or the presence of
solid particles in suspension will further
reduce seat life in throttling applications.
i. Do not open the bonnet or cap when bearing
pressure. Valve is not equipped with pressure
access device. User should check it by other
method through its piping system.
j. Do not touch the surface of valve at high
temperature condition.
k. Not allowed for unstable fluid, otherwise
specified with PED catogory III in Declaration
of conformity or/and in this user manual.
l. Lock design on the handle to avoid the valve
by un-intended operated by un-authorized
person.
m.Use in potential explosive atmosphere safely,
see section 10 for detail.
1

2. General description of the product
a. Technical specification
Model: 3PC
Port: Reduced Port
End connection: Threaded End
Service fluid Dangerous or non-dangerous gas or liquid
Service temp. -20°C to 180°C
Nominal Size NPS 1/4’’ 3/8’’ 1/2’’ 3/4’’ 1” 1¼” 1½” 2”
Nominal Size DN 8 10 15 20 25 32 40 50
Nominal pressure Psi 3000 3000 3000 3000 3000 3000 3000 3000
Shell Material SS316
Note 1: User shall consider the material’s anti-corrosion feature of components which directly
contact with the fluid. The corrosion data information is available in this user manual.
b. Safety features
Appropriate shell strength
Anti-blow out stem design
Anti-static design
Pressure release hole at ball
Pressure release channel at ball seat
c. Dimensions and Parts list
See the following drawing for the detailed
external dimensions of each nominal size,
the components list and materials available.
User shall consider the material’s
anti-corrosion feature of seals and packing
which directly contact with the fluid. The
corrosion data information is available in this
user manual.
d. Equipment category according to ATEX
Directive (94/9/EC)
Designed and constructed to good
engineering practice and the ignition hazard
assessment ensure that the equipment does
not contain any effective ignition sources in
normal operation and during expected
malfunctions. Therefore we classified as
Group II, Category 2 equipment. The Type
of ignition protection is ‘c’, constructional
safety according to EN 13463-5:2003.
e. Equipment category according to PED
Directive (97/23/EC)
Nominal
Pressure S.E.P Category II
3000PSI
DN8
DN10
DN15
DN20
DN25
DN32
DN40
DN50
2

f. Dimensions/ Parts List
3

3. Pressure-Temperature Ratings
The pressure-temperature rating of ball valves
are determined, not only by valve shell
materials, but also by sealing materials used for
ball seats, stem packing, and body seal.
Sealing materials may be high molecule,
elasticity and hardness, however, the choice is
limited by the characteristics of the service fluid,
temperature, pressure, velocity of fluid,
frequency of valves operation and sizes of ball
valves etc. User shall notice the maximum
temperature labeled on the name plate.
Followings are the general rating charts for
non-shock fluid service for floating ball valves
by nominal pressure.
Temp. (°C) 3000PS Bar
-20 to 0 248.2
0 to 50 240.6
50 to 100 211.0
100 to 150 192.5
150 to 200 178.3
200 to 250 166.9
4. Delivery Condition and Storage
Valves stay in the open condition during the
transportation. Valves must store in an indoor
warehouse to avoid dusts and other foreign
object. Do not take off the dust cover except
ready to install immediately.
5. Installation and Operation
5.1 Cleaning
Even the valves was transported under a clean
environment, operator must check is there any
foreign body or dusts inside the bore. If yes,
clean it before installation. Operator clean the
ession air, or steam
eaned only with
water or steam, the compression air is not
allowed.)
5.2 Valve Installation
e system)
a.
quence to do
d close the valve.
b.
ea. It will cause deformation
c.
lve to the pipeline adequately
a.
ction for opening and
b.
on with the flow
c.
flow direction
ed.
valves by water, compr
(automation valve shall be cl
(Install to the pipelin
Direction
Ball valve does not restrict the flow direction.
Just consider the natural se
opening an
Position
Ball valve can be installed in any position,
but the operator shall consider the load of the
pipe line system not to apply at the
connection ar
and leakage.
Connecting to pipeline
Select the correct specification of pipeline.
Tight the ball va
5.3 Operation
For manual operation, shift the handle in
counter-clockwise dire
clockwise for close.
If the handle is in parallel position with the
flow direction, the valve is open. If the
handle is in right angle positi
direction, the valve is close.
When installing actuator, the user should
ensure the position of the valve whether
open or close. The rectangular shape of the
stem top or the direction mark at the stem
top is in parallel with the
means the valve is open
6. t
a.
Pu into service
After install to the pipeline, it is necessary to
check the function of the product. Thus,
4

operate the valve about 3 times to ensure
b. S
to
c. A
in about 3 times to ensure the
function.
the function.
ystems hydrostatic test
Before delivery, valves are tested 1.5 times
the allowable working pressure at ambient
temperature in open position. After
installation, the pipe line system may
subject to system tests, as condition not
exceed the maximum working pressure.
fter pressure testing, user shall operate the
valve aga
7.
a.
ion, such as pressure, temperature and
b.
the product to avoid danger in the
future.
Dangers of inappropriate use
Never uses the product exceed its allowed
condit
fluid.
If the product has any inappropriate use, the
product was damage however there are no
signals occurs immediately. User shall
change
8.
a.
re effect and high-temperature
effect etc.
b.
ement between stem and
stem packing.
c. em
ry,
(1) valve must follow the
(2)
and inflammability
(3)
dure is protecting the surface of the
(4)
the seat retainer fall down from end
(5)
d the ball
d ion, maintenance, and
(1
damage factors as far as possible as
(2
Maintenance
Maintenance frequency
The maintenance frequency is determined
upon the application. User shall consider the
time interval depend on the kinds of fluid,
flow velocity, operation frequency,
high-pressu
Adjustment of the Gland
Tighten the gland nut about ¼ turn
periodically to compensate for the wear
caused by mov
Disass bly
(NOTE If complete disassembly is necessa
replacement of all seats and seals is recommended.)
To dismantle the
procedure below.
It doesn’t matter where the position of
valve located is; usually it contained the
seal up fluid, so operator must be very
carefully when moving the valve on the
pipe. It must open the ball a little and let
the fluid come out slowly, it also need to
watch out the poisonous
objects if there is any.
It must turn the ball in the close position
before dismantle the valve. The ball cannot
be taken out from valve body if the ball is in
the open or semi-open position. The right
position for store the valve is put the flange
end on the ground. If it is a valve with the
hand wheel, than it must dismantle the
hand wheel from the valve first than put
the valve flange end on the ground. This
proce
ball.
To dismantle the valve body and end cap,
release retainer with a special tool. It
must be careful to dismantle the ball to
avoid
cap.
To lift the ball by hoist, it must make the
protection on corner to avoi
damaged by metal contacted.
. Parts inspect
replacement:
)Check the surface of ball if it is scraped
use the PT for inspection if necessary. If
there is any damage on the surface, then find
out the root cause such as the dirt fluid…etc.
avoid the
we can .
)The damage of the ball surface, to gauge if it
is locate on the contacting area of ball and ball
5

seat. If it is the case, then the ball must take
a fine milling. If it cause a heavy damaged,
then it must welded and re-machined. If it
(3)
nd cause a heavy
(4)
ecide the frequency for
(5)
t be reconsidered to choice a right
(6
grease, water, oxidation or
(7
land nut too tight to avoid
(8
ng on pipeline under higher
e.
pen and
close operation will be opposite.
cannot be repaired then change a new ball.
If the scraped area is not at the location
described in the item (2)above, then it must
re-fine milling the damage area again.
Otherwise, the ball will damage the soft seat
during the open and close operation or it will
dig out the ball seat a
damage to ball and seat.
Check the thickness of valve body and cap.
As defined in section 1. the body and cap
material may wear be cause of the status of
fluid.User should d
checking thickness.
To inspect the surface of soft seat, if there is it
any scrap mark, concave, dust (including
weld dregs, iron bit, sands…etc.), abrasion,
abnormal press scrape, and a tiny scrap.
Usually, the scrape mark and damage by dust
will occur in the same time with ball damage.
It is the root cause for leakage. If the
leakage occurs before the repairing, then this
is suggest to change a new soft seat (PTFE
or RTFE). The mark from press or fine scrap
happen in an abnormal operation pressure.
It mus
valve.
) To check the worm gear if it can be operated
correctly, the operated correctly means people
can use one finger to turn the wheel. when
the torque higher then 25KG-M, if must open
the gear- box and check the connection of the
tooth of gear. To check has there is any
grease, spoiled
dust in the box.
) Worm gear operator has a switch of
open/close indicator get back to the original
location after dismantle or assembly. It must
do the pressure inspection before install onto
pipe line, otherwise, it will become very difficult
to do adjustment on the pipe line.The stem
packing must be replaced by new parts after
dismantle the valve. Its material has PTFE,
Graphite and Carbon Fiber. The material of
new packing must be the same as the old one.
To tight the gland nut, it must pass the 1.5
times water pressure test without leakage.
Do not make the g
the higher torque.
) To do the final inspection for a valve, 10
times of open and close operating must be
done to ensure all the parts are assembled
correctly. To ensure the torque is in a same
value during the open/close operation. If the
torque is not the same in operation, then there
may has some parts in an correct position or
interference.please dismantle and re-assembly.
Otherwise, the valve will get damaged easily
when worki
pressure .
Assembly
For assembly process, it takes the opposite
way of dismantle process. The must in the
close position during assembling the body
and end cap, the stopper must be located at
the right place; otherwise, the o
9.
S316 Stainless steel is suitable
ion , but below conditions
a. H
olerance for dry
Corrosion Data
CF8M,1.4408,S
for the general
Application of corros
shall be concerned:
CL in humid or high temperature is more
corrosive, wet HCL is more corrosive than
dry HCL under 700ºF, while the corrosive,
wet HCL and dry HCL are almost the same
above 700ºF. the max. t
HCL and HCI is 320ºC
6

b. H acid corrosion easy cause
c. P e in
the boiling
d. H s
oint the
f. U mum content should
ydrofluoric
corrosion.
hosphoric acid under 65ºCis applicabl
any thickness. And so is
Phosphoric acid in 40%
2SO4 in normal temperature the thicknes
under 20% or above 85% are applicable,
but the thickness between 20% and 85%
are not. Under 50ºCthe thickness must be
under 10%, when reach boiling p
thickness should be under 1%.
e. HCI under 2% in low temperature.
sed in seawater mini
be more than 2.75%
10. potential explosive atmosphereUse in
areas
a.
xpected malfunction.
b.
ill be earthed through the pipe
c.
als more than
d.
losive
e.
provided in the corrosion data
f.
the hazard cause by internal
pressure.
Maximum surface temperature
It is depends on the heated fluid inside the
valve. The limitation of the application
temperature is marked on the label. There is
no additional temperature raise cause by
normal operation and e
Electro static charges
The only non-conductive part of the
equipment is the plastic handle grip. The
surface resistance of the material does not
exceed 1GΩat (23 2) C and (50 5)%
relative humidity. The equipment also
designed and constructed with an electrical
continuity design between ball, stem and
body. Any occurrence of efficient electro
static charge w
line earthing.
Containing light metals
Materials used in the construction of external
parts do not contain light met
7.5% of magnesium.
Equipment was tested in factory according to
high pressure leakage test before delivery. It
will not release flammable gases to exp
atmosphere outside the equipment.
The internal parts, such as seals and packing
can be adversely affected by some solvents.
List of solvents which are known to be
compatible with the seal and packing
material are
information.
The equipment also conforms to Pressure
Equipment Directive (97/23/EC), The
mechanical strength of the structure can
withstand
11.
ICHUNG, Taiwan
CE mark:
32 and larger
For 3000PSI:
178.3bar at 180°C
Marking
Mfg logo: MD
Mfg location: TA
Mfg year: 2008
CE for DN 25 and smaller
CE 0035 for DN
Max. working pressure:
248.2bar at -20°C,
ATEXmark
II2DGc: pment,
y according to
T.F ref. N
provided by ATEX
Other ide
marked on the shell respectively.
Group II, category 2 equi
Dust & Gas application,
Constructional safet
EN 13463-5:2003.
o. ATEX-TF-0701: Technical file
reference number
certification body.
ntification such as DN (size in mm),
Shell Material (1.4408 or 1.4308 or
1.0619), PN (bar), Heat number are
7

8