Floating ball valves provide more rapid action and better air tight closure than conventional type globe or gate valves. They are a combination of a perfectly round sphere that rotates on a virtually friction free metallic seat with PTFE inserts. They can be used for services that used to be destined to conventional type valves only. They can be made of different kinds of metals with a variety of elastic material seats and designs.

1. INSTALLATION:

For proper installation of floating ball valves the following steps should be followed:

1.1 The pipeline where the valve is going to be installed should be thoroughly clean and free from slags, rust, dust, dirt, etc.

1.2  Proper support of valve and/or pipeline should be provided to eliminate strain and fatigue of end connections.

1.3  Remove the protective covers from the flanges.

1.4  Make sure the valve opens and closes correctly.

1.5 Install the valve in “open” position to protect the surface of the ball during installation.

1.6 Follow the indications on the valve identification plate concerning limits of pressure, temperature and materials.

CAUTION:

Ball valves should be lifted so that the body supports the load. They should never be lifted by the lever or the gear operator.

2. OPERATION:

To operate ball valves properly, the following indications should be taken into account:

2.1 The valve must be operated either “fully open” or “fully closed”. Leaving the ball in some intermediate position can rapidly cause severe damage.

2.2 In lever operated valves, when the lever is aligned with the valve axis (bore) indicates “open”. Viewed from the top, the valve stem rotates 90 degrees clockwise to go from “open” to “closed”.

2.3 All gear boxes or actuators have a device which indicates “open” and “closed” positions. The handwheel on all gear operators rotates clockwise to close the valve.

2.4 Ball valves should not be immobilized for long periods of time. If possible, they should be cycled at periodic intervals to ensure continued and proper operation.

3.  MAINTENANCE:

Floating ball valves maintenance is really simple since when losing their airtightness, some of the internal pieces can be replaced, which makes the valve virtually new again. The instructions to follow are:

3.1.  LUBRICATION:

Ball valves do not normally require internal lubrication; their seat rings and PTFE gaskets are considered self-lubricating since their material has a very low friction coefficient. However, if the valve has a grease injection system (when required by customer) the following procedure must be followed:

3.1.1.  POINTS OF LUBRICATION:

3.1.1.1.  In the stem (6) grease fitting.

3.1.1.2.  In the body adapter (2) grease fittings and body (1) grease fitting at the level of the seats (7).

3.1.2.  RECOMMENDED LUBRICATION SCHEDULE:

The frequency of valve lubrication should be based on user´s common sense and experience with the installed equipment. The following indications should be used as minimum guideline until operating experience indicates otherwise.

3.1.2.1  Lubricate minimum once a year.

3.1.2.2. Every three months if the valve is operated infrequently.

3.1.2.3. Every 1000 cycles if the valve is operated more than ten times a day.

3.1.2.4.  Every 500 cycles if the valve is used in corrosive or other severe services and operated more than ten times a day.

3.1.3.  RECOMMENDED LUBRICANTS:

The type of lubricant to be used will depend upon the service conditions of the valve (temperature, type of fluid, etc.). Lubricants can be used to reduce friction or as a sealer in both points of lubrication 3.1.1.1. and 3.1.1.2. We also recommend that whenever possible the lubricant be used to facilitate the movement and the sealer only in case of leaks.

NOTE:

Do not use grease with a bentonite base.

3.2.  REVISION:

Floating ball valve revisions consist of:

3.2.1.  Dismount the valve (if necessary) and disassemble it following the instructions in point 4.

3.2.2.  Clean all metallic parts using a solvent.

3.2.3.  Check all movable metallic and sealing surfaces and make sure they are not damaged.

3.2.4.  Check and replace if necessary: the body gasket (82); the body adapter “O” ring (65); the stem gasket (84); stem “O” ring (67); gland gasket (88); seat ring “O” ring (68) and primary seat rings (7) (or the insert in metallic rings). If the latter has to be replaced, it should be pressed in the metallic ring and the part of it that stands out should be machined.

NOTES:

A.  This group of pieces will be the spare part list of floating ball valves.

B.  The gasket material will depend on the valve service conditions. For additional information, please consult us.

4.  DISASSEMBLY:

4.1.  FLOATING BALL VALVE. THREADES ENDS.

4.1.1.  Rotate the stem (6) until it reaches “closed” position.

4.1.2.  Unscrew one of the body adapters (2).

4.1.3.  Remove the body gasket (82).

4.1.4.  Remove the ball (5) being careful not to damage its surface.

4.1.5.  Unscrew the lever nut (14) and remove the lever (15).

4.1.6.  Remove from the stem (6): the gland nut (115), the spring washers (137), the butterfly plates (11), and the gland gasket (88).

4.1.7.  Remove the stem (6) through the inside of the body (1) and also remove its gasket (84).

4.1.8  Unscrew the other body adapter (2) and remove the other body gasket (82).

4.2. FLOATING BALL VALVE.

FLANGED ENDS.

4.2.1  Rotate the stem (6) until it reaches “closed” position.

4.2.2.  Unscrew the body-body adapter nuts (111) and separate both parts: the body (1) and the body adapter (2).

4.2.3.  Remove the ball (5) being careful not to damage its surface.

4.2.4.  If the valve has PTFE seat rings (7), they will remain in place since removal would ruin them. If it has metallic rings with non-metallic inserts, however, they will be removed as well as the ring “O” ring (68).

4.2.5.  To have access to the stem, unscrew the bolt from the stem hood and take it off.

4.2.6.  Unscrew and remove the stem nut (115), the stem washer (27) and the gland nut (115); also remove the spring washers (137), the gland bushing (27) and the gland gasket (88).

4.2.7.  Remove the stem (6) through the inside of the body (1) as well as the stem gasket (84) and the stem “O” ring (67).

5.  REASSEMBLY:

5.1.  FLOATING BALL VALVES. THREADED ENDS.

Follow the disassembling instructions in reverse order.

5.2.  FLOATING BALL VALVES. FLANGED ENDS.

Follow these instructions:

5.2.1.  Insert the seat rings (7) in their places in the body (1) of the valve and in the body adapter (2). For valves using metallic seat rings with PTFE inserts, place the “O” rings (68) first in the rings before pressing each metallic seat ring in its cavity.

5.2.2.  Insert the PTFE gasket (84) and the “O” ring (67) in the stem (6). Place the stem (6) back in its place, from the inside to the outside of the valve body.

5.2.3.  Through the outside of the body place the PTFE gland bushing gasket (88) and the gland bushing (27). Next, put the spring washers (137) and the gland bushing nut (115) back on. Tighten the nut until the spring washers are partially compressed.

5.2.4.  Put the stem hood on (24) and fix it in place with the allen screw (123).

5.2.5.  Insert the body-body adapter gasket (82) and the body adapter “O” ring (65). Bring together the body (1) and the body adapter (2) placing the stud nuts (111) and the studs (106) and tighten them to the required torque.

6.  INSTRUCTIONS TO PRESERVE VALVES DURING STORAGE:

The instructions below should be followed to ensure that valves are in their best conditions at the moment of installation:

6.1.  For better protection of the sphere, store valves in “totally open” position. In case that purchaser requires his valve(s) closed, both flanges must have their protective covers.

6.2.  If ball valves are going to be stored for a long period of time the following instructions should be followed every three months approximately:

6.2.1.  Operate the valve operator (lever or actuator) to make sure that the valve opens and closes correctly.

6.2.2.  Clean up the bore area from dirt and foreign particles.

6.2.3.  Lubricate sphere and bore if necessary.

6.2.4.  Replace the protective covers of both flanges if damaged.

NOTE:

For major maintenance services, please contact us.

WARRANTY:

The seller warrants its products against defects in material or workmanship, when used on those applications approved by seller´s option of such defective products. The products will have a period of warranty of 12 months under service and 18 months in storage from date of original dispatch. The seller´s liability under this warranty shall be limited to repair or replacement at seller´s option of such defective products.

Any product claimed to be defective must be returned prepaid for inspection. Items showing abusive use, used for purposes other than intended or having been altered in any manner will not be repaired or replaced except at the expense of the user. Products found to be defective by our examination will be repaired or replaced at no expense to the user.