SC FEPA SA

BRLAD
API SPEC 6D
CE 1370-PED-H-FEP-001-09-ROM 6D-1123
INSTALLATION, OPERATION&MAINTENANCE
BALL VALVE TYPE TOP ENTRY
SC FEPA SA
Str.REPUBLICII nr.316, Cod postal 731120, Brlad-Romnia
Tel.+40 0235 411812
Fax +40 0235 421 618/0235 413729
e-mail: fepa@fepa.ro / marketing@fepa.ro
FIRE SAFE !
API 607
API 6FA
1. INTRODUCTION
The manual is designed to give the user complete information regarding installation,
operation, adjustment, perform periodic inspections and maintenance of valves RSD-BB type Top
entrywhose producer is FEPA Birlad.
READ THE INSTRUCTIONS CAREFULLY BEFORE INSTALLING AND USING THE
PRODUCT!
For any further information it is recommended to contact the manufacturer.
User's responsibility to know all the information presented in this manual and the specific application
for which it was purchased valve.
It is also the responsibility of the user to use for installation, operation and maintenance only qualified
and trained
On request the valve manufacturer can provide training to its headquarters or beneficiary.
The user is obliged to ensure all measures for safe operation, the health of staff, environment and
function of the equipment.
Before delivery valves are tested by the manufacturer.
If the instructions are not clear, please contact us address
SCFEPA SA str.Republicii nr.316cod 731120BRLAD, or fepa@fepa.ro.
At www.fepa.ro can find other information about the products FEPA.
2. DESCRIPTION
The Top entry ball valve is specifically designed for in- line maintenance. The removal of the
bonnet from the valve allows free access to the body cavity.
Limited space is required around the valve for maintenance; therefore the top entry ball valve
can be installed in areas where space is critical.
Upon completion of the in-line maintenance the integrity of the seat seals can be easily
checked by pressurizing the body cavity without involving the pipeline system or other expensive test
apparatus.
The top entry ball valves have complete flexibility in the use of materials for body trim and seal gasket
selection. For this reason, they can be trimmed to meet your most severe application.
Seat sealant
injection
Stem
Bonnet
Stem sealing
Stemsealant
injection
Seat
Ball
Body
Drain plug
Body spiral wound
gasket
Body O-ring
ISO 5211
Mounting flange
Gland
BODY/BONNET DESIGN
The body is designed and manufactured in accordance with ANSI B16.34. Flange dimension in
accordance with ANSI B 16.5 or EN1092-1 or welding ends in accordance with ANSI B 16.25
Face to face/internal bore dimensions in accordance with API 6D
The bolted bonnet design complies with ASME Code Section VIII, Div.1.
A wide variety of sealing materials are available for special needs, such as low temperatures and
sour gases.
The spiral wound gasket (AISI316+graphite) can also be used to further guarantee the performance
of design under fire condition. (Fire safe tested acc. to API6FA&API607)
SEAT DESIGN
2 pieces design 1 piece design
The valve is double block and bleed, self reliving seats. Choice of soft seated, metal to metal seated
or both. Secondary seat sealing system
DOUBLE BLOCK AND BLEED
The sealing system of valves, acting on both sides of
the ball, leads to the block and bleed principle.
Whenever line pressure increases, both upstream and
downstream seats move against the ball providing
positive sealing. The bleed valve may be opened to
verify tightness or to relieve body pressure for other
purposes.
SEAT SEALAT INJECTION
An emergency sealant injection system through the seat up to
the ball contact circle may provide temporary sealing until the
primary seal is restored.
STEM CONSTRUCTION
The stem of the ball valve is of the anti-blow-out design. The stem and ball connection is of rugged
construction.
Therefore, the maximum allowable stem torque is approximately 3 times the required valve torque
(shop functional test) at the maximum differential pressure.
The stem design incorporates a triple barrier sealing system (CHEVRON packing-rings and graphite
packing) which is provided with our standard construction. The stem sealing can be replaced when
the ball is in the closed or open position provided that the body cavity is fully vented.
The top entry ball valve standard design features are : trunnion mounted ball for ease of operation at
high pressure antistatic device, stem sealant injection; drain plug.
ANTISTATIC DEVICE
The ball valve is provided with the anti-static
structure and adopts the static electricity
discharge device to directly form a static channel
between the ball and body or between the ball
and body through the stem.
This device discharges the static electricity
produced by friction during the opening and
closing of ball and seat or by eddy/turbulence of
fluid in the pipeline, and ensures system safety
by preventing fire or explosion from static spark.
STEM SEALANT INJECTION
An emergency sealant injection point between the
second and third O-ring is provided to temporarily seal
the stem until the primary seal is restored.
Extended stems are easily fitted to top entry ball valves. Extended stems are suitable for
inaccessible areas or where the valves are to be installed underground.
The length of the extension is measured from the centre line of the valve to the top of the actuator
mounting flange(this dimension is to be specified at time of quotation or order).
The drains are normally piped to the top of the extension for ease of venting.
We offer the full range of automation and control systems conforming to international standards,
supplying custom solutions to meet customer specifications and requirements for pneumatic, electric
and hydraulic actuators and controls.
3. INSTALLATION-OPERATION
Inspect the piping system prior to valve installation whenever possible, to insure that it has
been properly flushed and cleared of construction and fabrication debris. The seating surfaces in soft
seated valves are particularly susceptible to weld slag and sand blasting grit. Pipe scale, metal chips
and other foreign materials should be removed.
Verify that Actuator, and mounting hardware as appropriate were included with the valve and
are in good shape, that proper tagging is in place and any warning labels are eligible and observed .
Just prior to installation, remove each valve from its packing and remove any end covers.
Examine the flow bore for debris. All FEPA ball valves are shipped in the open position to
prevent damage to the ball surface. Any grit or foreign matter must be removed. Scratched or damage
balls must be replaced. Do not install a damaged valve.
It is also important to check for valve operation clearances. Valves may be installed in any position
using standard pipe fitting practices. If possible, mount the valve in such a position that the actuator
can, if necessary, be detached without removing the valve from the pipeline. The actuator must not
touch the pipeline, as pipeline vibrations may damage it or cause disturbance.
Flanged End Valve Installation
After determining that the valve is in good condition, extra attention should be given to the raised face
surface. Dents and heavy scratches should be repaired.
Weld-End Valve Installation
Both butt-weld and socket -weld valves require special consideration for installation. In addition to
the general cautions already discussed, the heat of welding may damage seats and seals. The valves
are mounted in the pipeline by using standard welding methods and must be supported during the
welding. When welding or annealing the joint, assure that the temperature of the body in PTFE or
rubber sealing material,e.g.120C.The increase of temperature can be prevent by wet protection
cloth around the body during the welding.
Threaded-End Valve Installation
After removing the valve from its packing inspect the NPT threads for damage. Occasionally threads
may require chasing prior to installation to remove burrs or other minor imperfections.
Apply a good grade of pipe sealant compound to the male pipeline threads only. Do not use sealant
on the female threads because excess compound would be forced into the valve body. This could
cause sticking of the ball or encourage the accumulation of dirt and debris that could prevent good
valve shutoff.
FEPA valves are shipped with a securely fastened nameplate. Information included on each is
documented in next fig. Although each valve is thoroughly tested and inspected before it leaves the
factory, nameplate could be lost or destroyed during shipment or while in storage. If either is missing
or not legible, contact your distributor or the factory for assistance before operating valve.
Identification plate
Each valve is provided with label (identification card) that includes:
Depending on the requirements of the technical specification of the beneficiary may appear on the
nameplate - CE, API 6D no. License / marking fire test API607 or API 6FA.
0 Design/producer
1 API /CE marking
2 Key number
3 Length
4 Nominal diameter
5 Nominal pressure
6 FEPA identification cod
7 design standard
8 Rating
9 Body material
10 Stem material
11Ball material
12 Seat material
13 Serial number
14 Date(mm-yy)
Ball valves are intended to be on-off devices operating through 90 rotation of the stem.
Operation is clockwise to close.
The most common service failures not related to the installation and start-up processes are:
Exceeding the operating temperature or pressure limits of the valve due to a process upset condition.
A chemical attack on valve components due to either misapplication or changes in the service.
Violating temperature and pressure limits can result in immediate valve failure where chemical attack
or corrosion generally occurs overtime.
Prior to installation or system pressurization, evenly tighten all bonnet bolting using the
criss-cross method .
CAUTION: Do not loosen bonnet bolts while the valve is pressurized.
Always utilize factory authorized replacement parts.
Good operating procedure requires periodic inspection of valves and replacement of necessary parts
to ensure proper valve function.
NOTE: Valves showing through leakage or high operating torque may be damaged. DO NOT use
excessive force or bars to operate valve. Disassemble valve, inspect components, and replace
damaged parts.
CAUTION: before attempting removal/repair, always cycle valve with system pressure isolated
to relieve excess pressure which may be trapped in body cavity.
4. MAINTENANCE INSTRUCTIONS
4.1 Bonnet Gasket Repair
Periodically inspect condition of external valve components. Replace all parts showing
excessive wear or corrosion.
If bonnet gasket leaks, immediately tighten bonnet bolting as described under Installation-
operation instructions (criss-cross method).
If tightening bonnet bolting does not stop leak, remove pressure from valve and place valve in
open position.
-Remove bonnet bolting and lift bonnet assembly off of valve body.
-Carefully remove bonnet gasket from body recess or from bonnet.
-Inspect sealing surfaces of both valve body and bonnet for damage. Replace damaged components
as necessary.
-Replace bonnet gasket and install bonnet assembly onto valve body.
NOTE: When replacing bonnet gasket, always place the gasket on the bonnet and carefully
install the bonnet (with gasket) onto the body to avoid damage to the seal.
Install and tighten bonnet bolting in accordance with Installation -operation instructions (criss-cross
method).
4.2 Stem Seal Replacement
The stem packing was adjusted at the factory to provide a leak tight seal when the valve was
new, but compaction can occur within these seals that may make re-adjustment necessary. Stem
leakage should be stopped as soon as it is detected.
For manual valves it will be necessary to remove handle and the gland to make the packing
adjustment.
For actuated valves it is necessary to remove the actuator and the gland to adequate access
to make the packing adjustment.
Inspect and clean stem and the gland and replace any components which appear damaged.
Replacing stem seals:
-PTFE rings or die-formed grafoil rings
-PTFE chevrons and O-rings.
Then install the following parts over stem in the order listed:
-Stem seal - apply a light film with compatible lubricant
-gland
CAUTION: Do not over tighten. Over-tightening will result in excessive operating torque. If
stem leakage continues, or operating torque becomes excessive, depressurize the valve and replace
the stem seals after above instructions.
Cycle valve several times to assure proper operation and break in of seals.
If the valve has been removed from pipeline for maintenance, reinstall in accordance with
Installation-operation instructions.
4.3 Seat Replacement
Relieve pressure from valve and place valve in open position. Remove bonnet bolting and lift
bonnet assembly off of valve body. Use suitable tool to lift the ball and seats out of the body. If the ball
and seats do not slide easily out of the valve, check to make sure that the ball is in the open position.
The slot for stem engagement should be perpendicular to the pipeline during removal and insertion of
the ball. Care should be taken not to damage the surface of the ball while the ball and seats are being
removed from the body.
Inspect and clean the ball and the body sealing surfaces. Replace any components which are
badly scratched or gouged.
Apply a light film of compatible lubricant, to the ball and both sides of each of the seat
assemblies. Hold the ball and seats such that the I.D.'s of the seats are aligned with the I.D. of the ball
port. That is, place the seats on either side of the ball to simulate their position with the valve in the
open position. Simultaneously slide the two seat assemblies and the ball into the valve body. Force is
not necessary to properly position the components in the valve. Should the ball and seats not slide
easily into place, check to make sure that the ball is being inserted while in the open position.
Clean and inspect bonnet gasket recess in valve body and bonnet. Inspect gasket. If
damaged, replace bonnet gasket in accordance with item 4.1 Bonnet Gasket Repair Instructions
Install and tighten bonnet bolting in accordance with Installation -operation Instructions, item 3.
Cycle valve several times to assure proper operation and break in of seats.
If valve has been removed from pipeline for maintenance, reinstall in accordance with
Installation Instructions.
5. CORROSION PROTECTION
- High-strength epoxy.
6. ACTUATION
-
Manual lever including up to NPS4 (DN100) / NPS4(DN 100) with gear over
7. TESTS
-
Products are tested by the manufacturer
- Test pressure and loss rates are allowable according to SR EN12266 (without losses) /
API598/API6D
9. CODIFICATION
-
Coding RSD-BB top entry type is presented in the general product specification 839/2008
Rev.2
10. PACKING, TRANSPORT, STORAGE,
10.1 Packing
Each valve must be drained of fluid test.
The ends of the body must be covered to prevent foreign bodies and moisture-protective covers are
removed only when installing.
The valves are delivered with the obturator in the open position.!
Products are delivered on a support of timber.
10.2 Transport -handling
Because of physical dimensions and heavy equipment will be used properly and lifting
methods for transport, storage and installation.
-valve are furnished in open position, in order to minimize the effect of mechanical loads and
impurities on seats, gaskets, and other pressure parts.
Before handling the valve, verify it is open position. Lift valve with sling suitable for its weight. Never
use lever, actuator or gear operator to lift the valve.
The valves are handles with care, shock, vibration, drops can damage the valve.
Handling and transport to local installation is done with maximum attention to an insulation
compromised by impact and scratching
10.2 Storage.
Valve must be stored packed in closed rooms free of dust or corrosive agents, fungi or mold.
11.
HEALTH, SAFETY, ENVIRONMENT
- products are designed, manufactured, tested and equipped in the system if necessary, so as to
guarantee safety of the user and the environment.
- the installation shall comply with all applicable law labor protection
- will wear all required personal protective equipment
- do not use the valve than the designed parameters
-beneficiary will not make changes without consulting the manufacturer / or if the manufacturer
recommends
- please check before installation if there reglementaride environmental, safety or other restricting use
of the product.
- Please firstly return to repair products that have circulated hazardous fluids decontaminated them.
Also any faucet returned must be accompanied by minimal information regarding the conditions of
use, changes in the product, operations decontamination and / or cleaning fluid and safety data sheet
- used packaging and waste from the retirement harness the special without regulatory requirements.
However please consider conditions of use of the product and to indicate the applicable legislation
and packaging equipment.
14. MATERIAL
The material will be chosen according to the conditions imposed by the data sheet
(needs beneficiary) in compliance with the essential requirements
European Directive (EC)-harmonized standard and / or requirements
As the American Petroleum Institute (API6D)
15. SPARE PARTS
The spare parts list is supplied with the overall drawing
SC FEPA SA
Str.REPUBLICII nr.316, Cod postal 731120, Brlad-Romnia
Tel.+40 0235 411812
Fax +40 0235 421 618/0235 413729
e-mail: fepa@fepa.ro / marketing@fepa.ro