MEMORY SEAL BALL VALVES

MAINTENANCE MANUAL
212, Class 150 & 300, Regular Port, Flanged Unibody

INTRODUCTION

These rugged, versatile, high performance, regular port, ball valves

meet all requirements for oil and gas pipeline service. The valves
can withstand a large variety of fluids and almost any corrosive
service in chemical, oil, petrochemical, gas, pulp, paper processing
and other industries. See catalog VEL-UB-2000 for pressuretemperature ratings. The valves comply with ASME/ANSI B16.34
(face-to-face, flange details), BS 5351 (minimum port size, wall
thickness and markings), ISO 5211 (actuator mounting), API 598
(inspection and testing) and TA-LUFT (emission). In terms of fire
safety, the unibody ball valve line meets or exceeds the minimum
requirements specified in the following standards: API 607 3rd &
4th editions and BS 6755 part 2. As a result, Velan ball valves are
ideally suited for applications in LP gas, petroleum and
petrochemical processing.

II

PREPARATION
Process requirements should be evaluated against valve
performance characteristics and component materials before
installation to assure that the valve is well suited for the intended
service. Valve components (specifically seats and seals) must
remain inert when placed in contact with the pipeline fluid. The
pressure and temperature of the fluid in the pipeline must not
exceed the maximum pressure at any given operating
temperature as defined in the catalogue (VEL-UB-2000). The seat
material and pressure rating are indicated on a tag fastened to
the valve. Contact Velan Technical Support with any questions
or concerns.
These ball valves are designed for bi-directional flow unless
there is an arrow on the body indicating a specific direction (in
this case, the ball is drilled for cavity relief).

Maintenance
Manuals

III

WARNINGS & PRECAUTIONS

For safety reasons, it is important to take the

following precautions before servicing any valve:

Read and follow the instructions in the

maintenance manual.

Personnel servicing or adjusting any valve

must wear appropriate apparel and safety
equipment.

For reference during reassembly, use a

digital camera to take pictures of the valve at

various stages of the disassembly process.

The pipeline and valve must be de-pressurized

and bled before service can begin. The
segment of the pipeline where the valve to be
serviced resides should be isolated by closing
all adjacent valves. Any fluid remaining in the
isolated portion of the line should be removed
using standard bleeding procedure. In order to
relieve any pressure in the ball cavity, the valve
of interest should be cycled (open to close to
open) and then adjusted so that it is
approximately half-open.

IV

Lay out the parts on a clean, flat surface in

the order that they are removed so that the

valve, when fully disassembled, resembles
the exploded view in Figure 3.

Do not scratch, nick or gouge any sealing

surfaces.
NOTES:
a) Velan recommends that all seats and seals be
replaced each time the valve is disassembled
and reassembled.
b) A special tool is required to disassemble the
seat retainer (item 71 in figure 3). The tool
should be fabricated, according to the
instructions below based on the valve size,
before the valve is removed from the line.

GENERAL MAINTENANCE

The Velan Unibody Ball Valve has been designed

for minimal routine maintenance. In general, the
following preventive maintenance should be
performed:

DISASSEMBLY

The packing is live loaded (using two Belleville

washers), so frequent adjustment of the
packing bolts is not necessary. However, the
four packing flange bolts will occasionally have
to be tightened to prevent or eliminate leakage
in the vicinity of the stem. Ideally, the system
pressure should be relieved before attempting
to adjust these bolts. Caution should be used,
however, when adjusting the packing flange
bolts in order to prevent over-tightening. If
excessive torque is used when tightening these
bolts, the valve will become difficult to cycle
and damage to the packing may result. See
Table 1 below for recommended packing bolt
torque values.

2" Valve
A hexagon bar (1.70" maximum across parallel
flats) and an adjustable wrench can be used to
remove the seat retainer from 2" valves.
3"-12" Valves
A symmetric, cross-shaped tool with a welded
nut (for torque application) is required to
remove the seat retainer from 3" to 12" valves.
See Table 2 and Figure 1 for pertinent seat
retainer pocket dimensions (dimensions
shown are actual pocket dimensions;
clearance must be added between the tool and
the seat retainer cavity to ease insertion).

TABLE 1: Required Packing Flange Bolt Torque

Valve size
(inches)

Bolt Torque
(lbf in)

Bolt Torque
(Nm)

2
3
4
6
8
10
12

18
18
36
71
80
164
164

2.1
2.1
4.1
8.0
9.0
18.5
18.5

TABLE 2: Dimension for Seat Retainer Tool Cavity

Valve size
(inches)
3
4
6
8
10
12

Periodically, the valve should be visually

inspected to ensure that it is functioning
properly. Frequent observation is suggested
when the valve is subjected to severe
operating conditions.

Dimension A Dimension B
(inches)
(inches)
3.00
3.80
5.60
7.78
9.75
11.75

R.32
R.38
R.38
R.38
R.38
R.50

DISASSEMBLY
A

point up while the continuous raised face

should be placed on a clean, soft, flat surface
to ensure that it is not scratched, nicked or
gouged while the valve is being serviced.
See Figure 2 below for proper valve
orientation. Secure the valve to the work
surface so that it will not rotate.

R B

SEAT
RETAINER
SECTION

A-A

FIGURE 1: Seat Retainer Tool Cavities

DISASSEMBLY PROCEDURE:
D1. Review the Warnings and Precautions portion
(Section III) of this manual.
D2. Remove the valve from the pipeline. Adjust
the handle lever or gear operator until the
valve is in the fully closed position.
D3. If the valve is fitted with a handle:

WORK
SURFACE

NOTE: HANDLE PARTS

OMITTED FOR CLARITY

Remove the handle bolt (item 56 in Figure 3)

and handle washer (item 57)

FIGURE 2: Valve Orientation for Disassembly

Remove the handle (item 33 in Figure 3)

from the stem
or

D9. Use a pen, marker or other instrument (do

not use anything that will permanently
scratch the face) to make a continuous, radial
line from seat retainer (item 71 in Figure 3)
portion of the raised face to the body (item 1)
portion of the raised face. This line will be
used during re-assembly to guarantee that
the seat retainer face and body face are
coplanar.
D10. Using the seat retainer removal tool,
described under Note b (page 2) and
fabricated before the valve is removed from
the pipeline, unscrew (counterclockwise) and
remove the seat retainer (item 71 in Figure 3)
from the body (item 1).
D11. Remove and discard the body seal (item 19 in
Figure 3, off-white, large diameter, thin
Teflon piece) that resides on the cylindrical
area of the seat retainer (item 71).
D12. Carefully remove the ball (item 5A in Figure
3) and place it on a clean, flat, soft surface.
Orient the ball so that it will not roll off the
work surface. When handling the ball, use
special care to avoid damaging the polished
outer surface. If this surface becomes
scratched, nicked or gouged, valve
performance will be adversely affected.

If the valve is fitted with a gear operator or

an actuator:

Remove the gear operator or actuator from

the bracket (typically four bolts)

Remove the gear operator or actuator

mounting bracket (typically four bolts)

Remove the driver from the stem

Remove the key(s) from the stem
D4. Remove the four packing flange bolts
(item 17A in Figure 3) and the packing flange
(item 11).
D5. Remove the gland bushing
(item 12 in Figure 3).
D6. Pry out and discard the gland bushing sleeve
(item 18 in Figure 3, an off-white, Teflon,
thin walled tube) from the gland bushing.
D7. Remove and discard the two O-ring seals
(items 74A and 74B in Figure 3) from the gland
bushing (item 12).
D8. Orient the valve so that the waterway axis is
perpendicular to the work surface. The raised
face that includes the seat retainer should
3

DISASSEMBLY

56
57

33
17A
11

74A

12

74B

18
13A

63A

07
36
06

13B
63B

17B
04
01
09

05A

19

71

FIGURE 3: Exploded View

PARTS DESCRIPTION
QTY
01 - Body
1
04 - Stem
1
05A - Ball
1
05B - 316 SS grounding ball
(not shown)
2
06 - Thrust washer
1
07 - Stem bushing
1
09 - Seats
2
11 - Packing flange
1
12 - Gland bushing
1
13A - Packing ring (graphite)
1
13B - Packing rings (PTFE) 1 set of 3
17A - Packing flange socket head
cap screws
4
17B - Handle stop socket
head cap screws
2
18 - Gland bushing sleave
1
19 - Body gasket
1
33 - Handle
1
36 - Belleville washers
2
46 - 302 SS grounding spring
(not shown)
2
56 - Hex head bolt
1
57 - Flat washer
1
63A - Large diameter
packing washers
2
63B - Small diameter
packing washer
2
71 - Seat retainer sleeve
1
74A - Dynamic (small dia.) O-ring
1
74B - Static (large dia.) O-ring
1

D16. Remove the Belleville washers (item 36 in

Figure 3, quantity 2), the upper packing
washer (item 63B), the Teflon packing rings
(item 13B, quantity 3) and the lower packing
washer (item 63B). Again, it is important to
use caution when removing these
components. Damage to the body (scratches,
nicks or gouges) in the sealing area will
adversely affect packing performance.
Discard the Teflon packing rings.
D17. Apply a force, through the packing chamber,
to the top surface of the stem bushing (item 7
in Figure 3) until it breaks free from the body
(item 1). Remove the stem bushing and
thrust washer (item 6, off-white, Teflon
washer) from the waterway and discard these
parts. The thrust washer may remain on the
stem shaft when the stem is removed from
the body in step D14.
D18. Inspect the body to verify that all components
(especially the stem bushing and the thrust
washer) have been removed from the
waterway.

D13. Remove and discard both seats (item 9 in

Figure 3). One seat resides within the body
while the other can be found in the seat
retainer.
D14. Remove the stem (item 4 in Figure 3) by
pushing it into the body. A soft rubber mallet
can be used to facilitate removal of the stem.
It is important to use caution when removing
the stem. Damage to the stem (scratches,
nicks or gouges) in the sealing area will
adversely affect packing performance.
D15. Remove the upper packing washer (item 63A
in Figure 3), the graphite packing ring (item
13A) and the lower packing washer (item
63A). It is important to use caution when
removing these components. Damage to the
body (scratches, nicks or gouges) in the
sealing area will adversely affect packing
performance. Discard the graphite packing
ring.

ASSEMBLY
TABLE 4: The Seal Kit Parts List

and follow the instructions in the

Read
maintenance manual.

Part

Inspect all sealing surfaces before

reassembly.

Thrust Washer
Stem Bushing
Seat
Packing Ring (Graphite)
Packing Ring (PTFE)
Gland Bushing Sleeve
Body Gasket
Small Diameter O-Ring
Large Diameter O-Ring

Order, stock and carry extra seal kits.

stock and carry extra O-rings. These
Order,
O-rings are commercially available in a wide
range of materials. Typically, valves are
configured at the factory with O-rings made
from Vitron. See the table below for
specific O-ring dimensions listed by valve
size.

Dimensions Listed by Valve size

Cross-sectional Inner Diameter

Diameter (inches)
(inches)

2& 3
4
6
8
10&12

0.070
0.139
0.139
0.103
0.139

0.864
1.109
1.484
1.987
2.484

TABLE 3B: Static (large diameter) O-ring

Dimensions Listed by Valve size

Valve
Size

Cross-sectional Inner Diameter

Diameter (inches)
(inches)

2& 3
4
6
8
10&12

0.070
0.070
0.070
0.070
0.070

Item No. in Fig. 3 Qty.

6
7
9
13A
13B
18
19
74A
74B

1
1
2
1
3
1
1
1
1

ASSEMBLY PROCEDURE:
A1. Using a solvent that is compatible with both the
process and the valve parts, clean all
components and body sealing surfaces before
assembly. Visually inspect all parts and replace
any components that appear worn or damaged.
A2. Orient the valve so that the waterway axis is
perpendicular to the work surface. The portion
of the body where the seat retainer is inserted
should point up while the continuous raised
face should be placed on a clean, soft, flat
surface to ensure that it is not scratched,
nicked or gouged while the valve is being
serviced. See Figure 2 above for proper valve
orientation. Secure the valve to the work
surface so that it will not rotate.
A3. Install a new seat (item 9 in Figure 3) from the
Velan Seal Kit into the body (item 1). The seat
has a small diameter (inside and outside) area
and a large diameter (inside and outside) area.
The small diameter area should face down as
the seat is inserted in the body. See Figure 4
below. If the seat does not slide easily into the
pocket in the body, use a rubber mallet, a metal
bar and an old seat to tap the new seat into
position. The old seat should be placed on top
of the new seat to prevent any damage caused
by the hammering operation. When the seat is
located in its final assembled position, there
should not be any gap between the inside
diameter of the seat and the corresponding
pocket in the body.

TABLE 3A: Dynamic (small diameter) O-ring

Valve
Size

VI

1.114
1.489
1.989
2.364
2.989

a commercially available O-ring

Use
lubricant on all exposed O-ring surfaces.
assembling any threaded component,
Before
lubricate the external thread surface with a
thin coat of Never Seez or an equivalent,
nickel-graphite based (copper-free),
commercially available thread lubricant.
a torque value is indicated, use a
When
torque wrench to tighten the component to
the specified value.
not interchange parts from different valve
Do
assemblies (especially handles and seat

SEAT

retainers).
PARTIAL VIEW
OF THE BODY

FIGURE 4: Seat Installation in Body

5

VI

ASSEMBLY

A4. Slide a new thrust washer (item 6 in

Figure 3) and a new stem bushing (item 7)
down the stem (item 4) shaft until the thrust

or
If the stem has machined keyways:
Orient the machined "V"-groove on the top
surface of the stem so that it is perpendicular
to the waterway centerline. See Figure 6
above.
A8. Carefully insert the ball (item 5A in Figure 3)
into the body (item 1) with the stem slot
oriented so that it will interface with the stem.
The ball should be assembled in the closed
position. A slight rotational motion will help
ease the ball into its assembled location. See
Figure 7 below.

washer bottoms out on the stem shoulder.

A5. Install the stem subassembly in the body (item
1 in Figure 3).
A6. From the inside of the body (item 1 in Figure
3), tap the stem (item 4) lightly with a plastic
hammer or rubber mallet to ensure contact
between the stem shoulder, the thrust washer
(item 6) and the body.
A7. In order to facilitate insertion of the ball (item
5A in Figure 3), the stem (item 4) must be
properly aligned.
If the stem has a double "D" configuration:
Orient the double "D" flats so that they are
perpendicular to the waterway centerline.
See Figure 5 below.

TRANSLATE & ROTATE BALL INTO

ASSEMBLY POSITION

STEM
CUTOUT

STEM
FLATS

FIGURE 7: Ball Installation

PACKING
FLANGE

WATERWAY
CENTERLINE

FIGURE 5: Stem Double D Orientation

GLAND
BUSHING

LARGE
DIAMETER
PACKING
WASHER

GRAPHITE
PACKING
RING

BELLEVILLE
WASHERS
SMALL
DIAMETER
PACKING
WASHER

V GROOVE

TEFLON
PACKING
RING

FIGURE 8: Packing Arrangement

WATERWAY
CENTERLINE

NOTE: For Steps A9 through A18, refer to

Figure 8 above.

FIGURE 6: Keyed Stem Orientation

6

ASSEMBLY
A9. Install the smaller diameter packing washer
(item 63B in Figure 3) over the stem (item 4)
and into the packing chamber.
A10. Install new Teflon packing rings (item 13B in
Figure 3) over the stem (item 4) and into the
packing chamber. The packing arrangement
should resemble Figure 9 below.

VI

A18. Carefully slide the gland bushing

subassembly (items 12, 18 and 74 in figure 3)
over the stem (item 4) and into the packing
area.
A19. Install the packing flange (item 11 in Figure 3)
over the stem (item 4). The contoured surface
on the packing flange should mate with the
contoured top surface of the gland bushing
(item 12). Four counterbored holes should be
visible when the packing flanged is
assembled properly. See Figure 11 below.

FIGURE 9: Teflon Packing Arrangement

MATING
CONTOURED
SURFACES

A11. Install the second, small diameter packing

washer (item 63B in Figure 3) over the stem
(item 4) and into the packing chamber.
A12. Install the Belleville (cupped) washers (item
36 in Figure 3), arranged as shown in Figure
10 below, over the stem (item 4) and into the
packing chamber.

FIGURE 11: Packing Flange-Gland Relative

Orientation
A20. Lubricate the threads of the packing flange
bolts (item 17A in Figure 3) with Never-Seez
or an equivalent, nickel-graphite based
(copper free), commercially available thread
lubricant and insert these bolts through the
packing flange (item 11) into the body (item
1). Using the values given in Table 1,
gradually tighten the flange bolts, with a
torque wrench, following the sequence
indicated in Figure 12 below. Bolt 1 should
betightened to a certain torque value below
that suggested in Table 1. Then, bolt 2, bolt 3
and bolt 4 should be tightened to the same
torque value as bolt 1. Following the
sequence shown in the Figure 12 below,
repeat until all bolts are gradually tightened
to the torque values listed in Table 1.

FIGURE 10: Belleville Washer Configuration

A13. Install the large diameter packing washer
(item 63A in Figure 3) over the stem (item 4)
and into the packing chamber.
A14. Lubricate the internal and external surfaces of
the graphite packing ring (item 13A in Figure
3, charcoal colored) with Molly-Koat GNSpray
or an equivalent molybdenum-disulfide based
commercial lubricant. Install the graphite
packing ring over the stem (item 4) and into
the packing chamber.
A15. Install the second large diameter packing
washer (item 63A in Figure 3) over the stem
(item 4) and into the packing chamber.
A16. Push a new gland bushing sleeve (item 18 in
Figure 3, an off-white, Teflon, thin walled
tube) into the gland bushing (item 12).
A17. Install a new large diameter O-ring (item 74B
in Figure 3) in the external machined groove
of the gland bushing (item 12). Install a new
small diameter O-ring (item 74A) in the
internal machined groove of the gland
bushing (item 12). Select a commercially
available O-ring lubricant that is compatible
with the O-ring material and apply it to the
exposed surfaces of both O-rings.

FIGURE 12: Packing Flange Bolt Sequence

VI

ASSEMBLY

A21. Install a new seat (item 9 in Figure 3) in the

machined pocket of the seat retainer (item
71). See Figure 13 below for proper seat
orientation.

A24. If the valve is fitted with a handle:

Install the handle (item 33 in Figure 3) on the
stem (item 4).
or
If the valve is fitted with a gear operator or
an actuator:
Assemble the key(s) into the machined
keyway(s) of the stem (item 4 in Figure 3).
Install the driver on the stem (item 4 in
Figure 3).
A25. In order to assure that the ball is positioned
properly between the seats, cycle the valve
(close to open to close) twice before
continuing (for valves fitted with a gear
operator or an actuator, use an adjustable
wrench across parallel flats of the driver and a
long lever pipe).
A26. Using a torque wrench, verify that the valve
has been reassembled properly by measuring
the torque required to turn the stem. The
torque should be at least 25% of the
maximum torque specified in the Velan
Unibody Catalogue (VEL-UB-2000), but not
greater that the maximum torque specified in
the catalogue.
A27. If the valve is fitted with a handle:
Assemble the handle washer (item 57 in
Figure 3) and handle bolt (item 56).
or
If the valve is fitted with a gear operator or an
actuator:
Attach the gear operator or actuator
mounting bracket to the body (item 1 in
Figure 3, typically four bolts required for
attachment).
Attach the gear operator or actuator to the
bracket (typically four bolts required for
attachment).
A28. Reinstall the valve in the pipeline.

FIGURE 13: Seat Installation in Seat Retainer

A22. Install a new body seal (item 19 in Figure 3)
over the external cylindrical surface of the
seat retainer (item 71).
A23. Lubricate the external threads of the seat
retainer with Never-Seez or an equivalent,
nickel-graphite based (copper free),
commercially available thread lubricant and
insert the seat retainer (item 71 in Figure 3)
into the body (item 1). Using the tool
fabricated previously and described in the
Disassembly Section of this manual under
Note b, tighten the seat retainer until the body
face and seat retainer face are coplanar. The
mark across the raised face created in
Disassembly Step D9 must line up to assure
metal-to-metal contact between the body and
the seat retainer (metal to metal contact is
required to guarantee that the valve will
perform adequately during a fire). The torque
required to restore the seat retainer to its
original position is approximated, according
to valve size, in Table 5.

VELAN, INC
7007 Cte de Liesse
Montreal, Quebec
Canada H4T 1G2

TABLE 5: Approximate Seat Retainer Torque

Valve size
(inches)

Torque
(lbf ft)

Torque
(Nm)

2
3
4
6
8
10
12

400
600
900
1125
1400
1800
2200

542
813
1220
1525
1898
2440
2980

PRINTED IN CANADA

VELAN VALVE CORPORATION

94 Avenue C
Williston, Vermont
USA 05495-9732
Tel: (514) 748-7743
Fax: (514) 748-8635
8

VEL-BVUB4-2001