Neles PB2 Series Operating and maintenance manual

Neles™
PB2 series full bore ange
PFA lined ball valve
NPS 1/2” – 6”
Installation, maintenance and
operating instructions
1PB270EN 10/2020

1PB270EN - 10/20202
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about safe handling and
operation of the valve.
If you require additional assistance, please contact the
manufacturer or manufacturer’s representative.
SAVE THESE INSTRUCTIONS!
Addresses and phone numbers are printed on the back cover.
Table of contents
GENERAL 3
Scope of the Manual 3
Valve markings 3
Safety Precautions 3
Technical Specication 3
TRANSPORTATION
AND STORAGE 4
INSTALLATION 4
General 4
Installing in the Pipeline 4
Valve Insulation 4
Actuator 4
Commissioning 4
MAINTENANCE 4
General 4
Actuated Valve 5
Valve Disassembly 5
Checking Parts 5
Valve Assembly 5
Testing the Valve 6
ACTUATOR 7
Actuator Mounting Instructions 7
SERVICE / SPARE PART 7
EXPLODED VIEW 8
TYPE CODE 9
NELES PB2 FULL BORE
FLANGE PFA LINED
BALL VALVE 9

31PB270EN - 10/2020
1. GENERAL
1.1 SCOPE OF THE MANUAL
This instruction manual contains important information regarding
the installation, operation and maintenance of Neles™ PB2 Series
full bore, seat supported, anged PFA lined ball valves. Please read
these instructions carefully and save them for future reference.
WARNING:
THE USE OF THE VALVE IS APPLICATION SPECIFIC.
BE SURE THAT THE VALVE IS SUITABLE FOR ITS
INTENDED SERVICE. IF YOU HAVE ANY QUESTIONS
CONCERNING THE USE, APPLICATION OR
COMPATIBILITY OF THE VALVE WITH THE INTENDED
SERVICE, CONTACT NELES FOR MORE INFORMATION.
1.2 VALVE MARKINGS
The valve has a name plate attached to the valve body. The name
plate markings identify the size, materials of construction, pressure
rating, month and year of construction, and a unique manufacturing
order number.
1.3 SAFETY PRECAUTIONS
WARNING:
DO NOT EXCEED THE VALVE PERFORMANCE
LIMITATIONS!
EXCEEDING THE PRESSURE OR TEMPERATURE
LIMITATIONS MARKED ON THE VALVE NAME PLATE
MAY CAUSE DAMAGE AND LEAD TO UNCONTROLLED
PRESSURE RELEASE. DAMAGE OR PERSONAL INJURY
MAY RESULT.
WARNING:
SEAT AND BODY RATINGS!
THE PRACTICAL AND SAFE USE OF THIS PRODUCT IS
DETERMINED BY BOTH THE SEAT AND BODY RATINGS.
READ THE NAME PLATE AND CHECK BOTH RATINGS.
SOME SEAT MATERIALS HAVE PRESSURE RATINGS THAT
ARE LESS THAN THE BODY RATING. ALL OF THE BODY
AND SEAT RATINGS ARE DEPENDENT ON VALVE TYPE
AND SEAT MATERIAL. DO NOT EXCEED THESE RATINGS!
WARNING:
BEWARE OF BALL MOVEMENT!
KEEP HANDS, OTHER PARTS OF THE BODY, TOOLS
AND OTHER OBJECTS OUT OF THE OPEN FLOW
PORT. LEAVE NO FOREIGN OBJECTS INSIDE THE
PIPELINE. WHEN THE VALVE IS ACTUATED, THE BALL
FUNCTIONS AS A CUTTING DEVICE. DISCONNECT ANY
PNEUMATIC SUPPLY LINES, ANY ELECTRICAL POWER
SOURCES AND MAKE SURE SPRINGS IN SPRING-
RETURN ACTUATORS ARE IN THE FULL EXTENDED/
RELAXED STATE BEFORE PERFORMING ANY VALVE
MAINTENANCE. FAILURE TO DO THIS MAY RESULT IN
DAMAGE OR PERSONAL INJURY!
WARNING:
WHEN HANDLING THE VALVE OR VALVE/ACTUATOR
ASSEMBLY, TAKE ITS WEIGHT INTO ACCOUNT!
NEVER LIFT THE VALVE OR VALVE/ACTUATOR
ASSEMBLY BY THE ACTUATOR, POSITIONER, LIMIT
SWITCH OR THEIR PIPING / BRACKETS. PLACE LIFTING
DEVICES SECURELY AROUND THE VALVE BODY.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN DAMAGE OR PERSONAL INJURY FROM
FALLING PARTS (SEE FIGURE 1).
Figure 1. Lifting of the valve assembly
1.4 TECHNICAL SPECIFICATION
Series: PB2
Bore: Full bore
End connection: Raised face, anged
Service uid: Dangerous or non-dangerous gas or
liquid
Service temperature &
pressure: ASTM A395 Ductile cast iron body:
-10°C to 160°C, 17.2 bar to 7 bar
ASTM A351 CF8 body: -30°C to
160°C, 19 bar to 7 bar
Size: NPS 1/2” to 6”
Rating: ASME Class 150
Face-to-face length: ASME B16.10
Leakage rate: API 598

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2. TRANSPORTATION AND
STORAGE
Check the valve and the accompanying devices for any damage
that may have occurred during transport.
Store the valve carefully. Store indoors in a cool, dry place.
Do not remove the ow port protectors until installing the valve.
Move the valve to its intended location just before installation.
If the valve(s) are to be stored for a long duration, follow the
recommendations of IMO-S1.
3. INSTALLATION
3 .1 GENERAL
Remove the ow port protectors and check that the valve is clean
inside. Clean valve if necessary.
Flush the pipeline carefully before installing the valve. Foreign
objects, such as sand or pieces of welding electrodes, will damage
the ball and seats.
3.2 INSTALLING IN THE PIPELINE
WARNING:
THE VALVE SHOULD BE TIGHTENED BETWEEN
FLANGES USING GASKETS AND FASTENERS
COMPATIBLE WITH THE APPLICATION, AND IN
COMPLIANCE WITH APPLICABLE PIPING CODES
AND STANDARDS. CENTER THE VALVE AND FLANGE
GASKETS CAREFULLY BETWEEN FLANGES. DO NOT
ATTEMPT TO CORRECT PIPELINE MISALIGNMENT BY
MEANS OF FLANGE BOLTING!
The valve may be installed in any position and o󰀨ers tight
shut-o󰀨 in either ow direction. When in a horizontal line, it is not
recommended to install a valve with the stem on the underneath
side as debris in the pipeline may enter the body cavity and damage
the gland packing.
Refer to Section 4, MAINTENANCE for gland packing adjustment. If
there is seepage past the gland packing upon installation, it means
the valve may have been subject to wide temperature variations in
shipment. Leak-tight performance will be restored by a simple stem
seal adjustment described in the MAINTENANCE section.
3.3 VALVE INSULATION
Neles™ ball valves do not require insulation. If desired, the valve
may be insulated; however, the insulation must not continue above
the upper level of the valve. See Figure 2.
Figure 2. Insulation of the valve
3.4 ACTUATO R
WARNING:
WHEN INSTALLING THE ACTUATOR ON THE
VALVE, MAKE SURE THAT THE VALVE ASSEMBLY
FUNCTIONS PROPERLY. INFORMATION ON ACTUATOR
INSTALLATION IS GIVEN IN SECTION 7 OR IN THE
SEPARATE ACTUATOR INSTRUCTIONS.
The actuator should be installed in a manner that allows plenty of
room for its removal.
The actuator must not touch the pipeline, tanks, walls, or other
equipment because vibration may interfere with its operation.
3.5 COMMISSIONING
Ensure that there is no dirt or foreign objects left inside the valve
or pipeline. Flush the pipeline carefully. Make sure that the valve is
fully open when ushing.
Ensure that all nuts, ttings, and cables are properly fastened.
If so equipped, check that the actuator positioner and/ or switch(s)
are correctly adjusted. Actuator adjustment is in Section 5. To
adjust any accompanying device(s) refer to the separate control
equipment instruction manuals.
4. MAINTENANCE
4.1 GENERAL
Although Neles™ valves are designed to work under severe
conditions, proper preventative maintenance can signicantly help to
prevent unplanned downtime and reduce the total cost of ownership.

51PB270EN - 10/2020
Neles recommends inspecting valves at least every ve (5) years.
The inspection and maintenance frequency depend on the actual
application and process condition. Routine maintenance consists
of tightening the gland ange bolts (item 16 in exploded view)
periodically to compensate for stem seal wear.
Always loosen and tighten fasteners with the appropriate wrench to
avoid damaging the valve, handle, linkage, actuator, ttings or ats.
Overhaul maintenance consists of replacing seats and seals.
These parts may be obtained from Neles or an Authorized Neles
Distributor.
WARNING:
FOR YOUR SAFETY, IT IS IMPORTANT THE FOLLOWING
PRECAUTIONS BE TAKEN PRIOR TO REMOVAL OF
THE VALVE FROM THE PIPELINE OR BEFORE ANY
DISASSEMBLY:
1. BE SURE YOU KNOW WHAT FLUID IS IN THE
PIPELINE. IF THERE IS ANY DOUBT, DOUBLE-
CHECK WITH THE PROPER SUPERVISOR.
2. WEAR ANY PERSONAL PROTECTIVE EQUIPMENT
(PROTECTIVE CLOTHING OR EQUIPMENT)
REQUIRED WHEN WORKING WITH THE FLUID
INVOLVED.
3. DEPRESSURIZE THE PIPELINE AND CYCLE THE
VALVE AS FOLLOWS:
A. PLACE THE VALVE IN THE OPEN POSITION
AND DRAIN THE PIPELINE.
B. CYCLE THE VALVE TO RELIEVE RESIDUAL
PRESSURE IN THE BODY CAVITY BEFORE
REMOVAL FROM THE PIPELINE
C. AFTER REMOVAL AND BEFORE DISASSEMBLY,
CYCLE THE VALVE AGAIN SEVERAL TIMES.
4.2 ACTUATED VALVE
It is generally most convenient to detach the actuator and its auxiliary
devices before removing the valve from the pipeline. If the valve
package is small or if it is di󰀩cult to access, it may be more practical
to remove the entire assembly.
NOTE: To ensure proper reassembly, observe the position of the
actuator and positioner/limit switch with respect to the valve before
detaching the actuator.
WARNING:
ALWAYS DISCONNECT THE ACTUATOR FROM ITS POWER
SOURCE, PNEUMATIC, HYDRAULIC OR ELECTRICAL,
BEFORE ATTEMPTING TO REMOVE IT FROM THE VALVE!
WARNING:
DO NOT REMOVE A SPRING-RETURN ACTUATOR UNLESS
A STOP-SCREW IS CARRYING THE SPRING FORCE!
1. Detach the air supply, electrical supply, hydraulic supply and
control signal cables or pipes from their connectors.
2. Remove the actuator mounting bracket screws.
3. Lift the actuator straight up in line with the valve stem until
the connection between actuator drive and valve stem is
completely disengaged.
4. Place actuator in a safe location to avoid damage
or personal injury.
4.3 VALVE DISASSEMBLY
NOTE: It is good practice to replace all seats and seals any time a
valve is disassembled.
NOTE: Always use original OEM parts to make sure that the valve
functions properly.
Numbers in ( ) refer to items shown in the exploded view
1. Follow the steps in all the WARNING sections above before
performing any work on the valve.
2. Open and close the valve and leave in the closed position.
3. Remove the handle bolts (12), washers (10), handle (8).
4. Remove the C-ring (11), and then remove the stop plate (9).
5. Remove the gland bolts (14), washer (13), and then the gland (6).
6. Place the valve in the vertical position with the cap (2) end up.
7. Remove the body nuts (16) and remove the cap (2). Be careful
not to scratch the ball.
8. Remove the seat (5) from the body cap.
9. Close ball (3) by rotating stem (4) and lift ball (3) from body.
10. Remove the lower seat (4) from the valve body. Be careful not
to scratch the body sealing surface behind the seat.
11. Press the stem (4) from the top into valve body and carefully
remove it.
12. Remove the gland packing (7).
4.4 CHECKING PARTS
1. Clean all disassembled parts.
2. Check the stem (4) and ball (3) for damage. Pay particular
attention to the sealing areas.
3. Check all sealing and gasket surfaces on the body (1) and cap (2).
4. Replace any damaged parts.
5. Replace any fastener where the threads are damaged or have
been heated, stretched or corroded.
6. Replace any parts that have cracks, gouges or pits that will
a󰀨ect sealing.
NOTE: When ordering spare parts, always include the following
information:
a. Valve type code as per technical bulletin and model
number from name plate,
b. If the valve is serialized - the serial number (stamped
on the valve body or name plate) or applicable
manufacturing order number,
4.5 VALVE ASSEMBLY
Numbers in ( ) refer to items shown in the exploded view.
It is advisable to replace seats and seals if complete disassembly
and reassembly become necessary.
1. Clean all valve components, if not previously done.
2. Inspect all components for damage before assembling the
valve. Look for damage to the sealing areas on the ball, stem,
and body.

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3. With a brush, clean body blots (15) and gland bolts (14)
of foreign material such as paint, thread locker, grime and
commodity. Inspect the threads for damage or defect with
appropriate ring or plug gage. Repair any out-of-tolerance
threads or replace in-kind.
4. Re-inspect all components for damage to the sealing areas,
stem (4), body (1), and cap (2). Replace any damaged parts.
5. Carefully clean and polish the ball (3) sealing surface: It should
be free of all scratches and grooves.
6. If the ball is damaged, or scratches are present, replace the ball.
7. With the body cavity facing up, insert one valve seat (5) into
the body (1) to below the stem bore. Tilt the seat into place
and position so the proper surface will be in contact with the
ball.
8. Insert the stem (4) into the body (1), and press it gently up into
the stem.
9. Holding stem (4) in place from the bottom and insert the gland
packing (7) over the stem. See Figure 2 for proper V-ring
orientation.
7
Figure 3. V-ring packing orientation
10. Install the gland (6), washers (13), and gland bolts (14).
11. Tighten the gland bolts (14) evenly until the gland packing (7) is
compressed and then tighten an additional ¼ turn. Visually inspect
to ensure the gland (6) is parallel with top of actuator mounting
ange.
12. Rotate the stem (4) so the ball drive is in the closed position.
Place the ball (3) into the body cavity by partially rotating and sliding
the ball onto the stem (4) and against the seat (5). Make certain the
stem is roughly in the middle of the ball slot.
13. Place the second seat (5) into the cap (2) in the correct
orientation so the proper surface contacts the ball.
14. Carefully place the cap (2) on top of the body (1) and loosely
install the body nuts (16). Lightly lubricate bolts and face of nut with
anti-seize grease. Tighten the body nuts in an alternating sequence
across the body, gradually increasing the tightening torque in
multiple steps to applicable torque from Table 1.
Table 1
Valve Size Spec of Bolt holes Bolt torque Nm 0...+30%
NPS
1/2 M12 x 4 15
3/4 M12 x 4 15
1 M12 x 4 15
1 1/2 M16 x 4 44
2 M16 x 4 49
2.5 M16 x 4 53
3 M16 x 8 53
4 M16 x 8 104
6 M20 x 8 137
10. After fully tightening the gland packing and body joint ange,
operate valve to verify smooth operation during opening and
closing.
11. If the actuator was removed, reinstall and set the actuator
stops as described in the ACTUATOR MOUNTING
INSTRUCTIONS Section.
4.6 TESTING THE VALVE
WARNING:
WHEN PRESSURE TESTING, EXERCISE CAUTION
AND MAKE SURE ALL EQUIPMENT USED IS IN GOOD
WORKING CONDITION AND APPROPRIATE FOR THE
INTENDED PRESSURE.
If the valve is to be tested prior to returning to service, make sure
the test pressures are in accordance with an applicable standard.
When testing the valve for external tightness, keep the ball in the
half open position.
If testing for seat tightness, please contact Neles for advice.
WARNING:
WHEN PERFORMING ANY TESTS, NEVER EXCEED
THE MAXIMUM OPERATING PRESSURE OR MAXIMUM
SHUT-OFF PRESSURE LISTED ON THE IDENTIFICATION
PLATE.

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5. ACTUATO R
WARNING:
BEFORE INSTALLING THE VALVE AND ACTUATOR, BE
SURE THAT THE INDICATOR POINTER ON TOP OF THE
ACTUATOR IS CORRECTLY INDICATING THE VALVE
POSITION. FAILURE TO ASSEMBLE THESE PRODUCTS
TO INDICATE CORRECT VALVE POSITION COULD
RESULT IN DAMAGE OR PERSONAL INJURY.
CAUTION:
When installing or servicing a valve/ actuator assembly, the best
practice is to remove the entire assembly from service.
CAUTION:
An actuator should be remounted on the valve from which it was
removed. The actuator must be checked and readjusted for proper
open and close position each time it is remounted.
WARNING:
THE VALVE BODY AND MOUNTING INTERFACE
HAS BEEN DESIGNED TO SUPPORT THE WEIGHT
AND OPERATION OF NELES ACTUATORS AND
RECOMMENDED ACCESSORIES. USE OF THIS
INTERFACE TO SUPPORT ADDITIONAL EQUIPMENT
SUCH AS PEOPLE, LADDERS, ETC. MAY RESULT IN THE
FAILURE OF THE VALVE OR ACTUATOR AND MAY CAUSE
PERSONAL INJURY.
WARNING:
BEWARE OF BALL MOVEMENT!
KEEP HANDS, OTHER PARTS OF THE BODY, TOOLS
AND OTHER OBJECTS OUT OF THE OPEN FLOW PORT.
LEAVE NO FOREIGN OBJECTS INSIDE THE VALVE OR
PIPELINE. WHEN THE VALVE IS OPERATED, THE BALL
FUNCTIONS AS A CUTTING DEVICE.
5 .1 ACTUATOR MOUNTING
INSTRUCTIONS
1. When a spring-return actuator is being mounted, the valve should
be in the closed position for spring-to-close operation or in the
open position for the spring-to-open operation. When an electric
or double-acting pneumatic actuator is being mounted, the valve
position should correspond to the indicated actuator position.
2. Assemble actuator onto the valve, ensuring full engagement
between the stem and actuator drive, and the actuator fully
contacts the mounting face on the valve.
3. Tighten actuator mounting screws to the torque listed in Table 2.
CAUTION:
Do not exceed the tightening torque. Applying excessive tightening
torque can damage the aluminum threads in the actuator body.
TABLE 2
Torque to Aluminum Body Actuators
Bolt Size No Lubrication to Screws
mm N.m
M6 6.8
M8 15
M10 30
M12 52
M16 122
M20 230
4. Cycle actuator and verify proper ball position in both open and
closed positions. Adjust the actuator travel stops as necessary.
6. SERVICE / SPARE PART
We recommend that valves be directed to Neles service centers for
maintenance. The service centers are equipped to provide rapid turn-
around at a reasonable cost and o󰀨er warranty for reconditioning
based on condition of each valve.
NOTE: When sending goods to the service center for repair, do not
disassemble them. Clean the valve carefully and ush the valve
internals. Include the material safety datasheet(s) (MSDS) for all
media owing through the valve. Valves sent to the service center
without MSDS datasheet(s) will not be accepted.
For further information on spare parts and service or assistance visit
our web-site at www.neles.com/valves.
NOTE: When ordering spare parts, always include the following
information:
a. Valve ype code as per technical bulletin and model
number from name plate,
b. the valve is serialized - the serial number (stamped
on the valve body or name plate) or applicable
manufacturing order number,

1PB270EN - 10/20208
7. EXPLODED VIEW
Bill of Material and Parts List
Part no. Part name Material
Ductile Iron
D2
Stainless Steel
S4
1 Body ASTM A395 Ductile Iron+PFA ASTM A351 CF8+PFA
2 Cap ASTM A395 Ductile Iron+PFA ASTM A351 CF8+PFA
3 Ball ASTM A351 CF8+PFA or ASTM A276 304+PFA
4 Stem ASTM A276 304+PFA
5 Seat TFM 1600
6 Gland ASTM A351 CF8
7 Gland packing PTFE
8 Handle ASTM A216 WCB ASTM A351 CF8
9 Stop plate ASTM A276 304
10 Washer ASTM A276 304
11 C-ring ASTM A276 304
12 Bolt ASTM A193 Gr. B8
13 Washer ASTM A276 304
14 Gland bolt ASTM A193 Gr. B8
15 Body bolt ASTM A193 Gr. B8
16 Body nut ASTM A194 Gr.8
17 Washer ASTM A276 304
18 Anti-static spring ASTM A313 302

91PB270EN - 10/2020
8. TYPE CODE
NELES PB2 FULL BORE FLANGE PFA LINED BALL VALVE
12345678
PB2 C A 01 D2 Z T A
1. sign Valve series & Style
PB2 PFA lined ball valve, full bore, Face-to-face: ASME B16.10
2. sign Pressure rating
C ASME Class 150
3. sign Construction
A Standard construction, PFA lining.
4. sign SIZE NPS
0H 1/2"
3Q 3/4"
01 1"
1H 1 1/2"
02 2"
2H 2 1/2"
03 3"
04 4"
06 6"
5. sign Material of body & trim
Body Ball Stem
S4 CF8+PFA 304+PFA 304+PFA
D2 DI+PFA 304+PFA 304+PFA
6. sign Material of seat
Z TFM 1600
7. sign Packing material
T PTFE Live loaded packing
8. sign Version
AModel A
NOTE:
As the use of the valve is application specific, a number of factors should be taken into account when selecting a valve for a given application.
Therefore, some of the applications in which the valves are used are outside the scope of this document. If you have any questions concerning
the use, application or compatibility of the valve with the intended service, contact nearest Neles sales office for more information.

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111PB270EN - 10/2020

1PB270EN - 10/2020
Neles
Vanha Porvoontie 229, P.O. Box 304, FI-01301 Vantaa, Finland.
Tel. [phone]. Fax [phone]
neles.com
Subject to change without prior notice. Neles, Jamesbury and Easyow by Neles, and certain other
trademarks, are either registered trademarks or trademarks of Neles Corporation or its subsidiaries or
a󰀩liates in the United States and/or in other countries. For more information www.neles.com/trademarks