STEEL BALL V K92 WITH TRUNNION MOUNTED BALL · The Directions for Installation and Operation apply...

Edition No.: 1 Edition valid from: 01/07/2016 Revision No.: 1 Revision valid from: 01/02/2017

DIRECTIONS FOR INSTALLATION AND OPERATION

MPP-AG-K92-08/2015

STEEL BALL VALVES

K92 WITH TRUNNION MOUNTED BALL

DN 40 to 1400 or NPS 1 1/2" to 56"

PN 16 to 400 or Class 150 to 2500

1st edition

valid from : 01/07/2016

Revision No.: 1 Revision valid from: 1.2.2017

Prepared by Approved by

Name Ing. Josef Pavlík

Designer

Ing. Petr Heider

Director, Technical Section

Date 25/06/2016 25/06/2016

Signature

MPP-AG-K92-08/2015 /36


TABLE OF CONTENTS:

1. INTRODUCTION 3

1.1 BASIC CRITERIA OF SAFETY 3

2. SCOPE OF VALIDITY 4

3. APPLICATION 5

4. DESIGN 6

4.1 DESCRIPTION OF BALL VALVE DESIGN 6

4.2 DESCRIPTION OF OPERATING DEVICE 6

4.3 ACCESSORIES 7

5. MATERIALS 8

6. TESTING 8

7. VALVE COMPLETENESS AND MARKING 8

7.1 COMPLETENESS 8

7.2 VALVE MARKING 8

8. STORAGE 9

9. INSTALLATION, OPERATION AND MAINTENANCE 9

9.1 VALVE INSTALLATION 9

9.2 TESTING OF BALL VALVES BEFORE THEIR INSTALLATION INTO THE PIPING 11

9.3 TESTING OF BALL VALVES AFTER THEIR INSTALLATION INTO THE PIPING 12

9.4 OPERATION AND MAINTENANCE 13

9.5 SERVICE LIFE 15

10. REPAIRS 15

10.1 TROUBLESHOOTING 16

11. SPARE PARTS 18

12. BASIC CRITERIA OF OPERATIONAL RELIABILITY OF BALL VALVES UNDER SERVICE CONDITIONS 18

ANNEX NO. 1 BALL VALVE IDENTIFICATION – TYPE DESIGNATION 20

ANNEX NO. 2 TYPICAL DESIGN OF BALL VALVES K92.3X, DN 40 TO 50 (NPS 1 ½“ TO NPS 2") 21

ANNEX NO. 3 TYPICAL DESIGN OF BALL VALVES K92.2X, DN 80 TO 100 (NPS 3“ TO NPS 4") 23

ANNEX NO. 4 TYPICAL DESIGN OF BALL VALVES K92.1X AND K92.2X FOR DN 150 (NPS 6") AND LARGER 25

ANNEX NO. 5 TYPICAL DESIGN OF BALL VALVES K92.3X 27

ANNEX NO. 6 TYPICAL DESIGN OF BALL VALVES K92.3Х FOR HIGHER TEMPERATURES 29

ANNEX NO. 7 EXAMPLES OF BALL VALVES WITH ACCESSORIES 31

ANNEX NO. 8 RECOMMENDED METHOD OF BALL VALVE SLINGING 35

ANNEX NO. 9 LIST OF APPLICABLE STANDARDS SHEET 1/1 36

The Directions for Installation and Operation apply to steel ball valves,

type K92 with trunnion mounted ball, supplied by

ARMATURY Group a. s., Dolní Benešov, Czech Republic

MPP-AG-K92-08/2015 /36


1. Introduction

This document (Directions for Installation and Operation) applies to ball valves

DN 40 to 1400 or NPS 1 1/2" to 56", PN 16 to 400 or Class 150 to 2500,

type K92 with trunnion mounted ball. This document respects the Buyer’s requirements specified in

Technical Delivery Conditions, Data Sheet or Purchase Contract. Service parameters respect the system of

pressure-temperature ratings and are specified on the valve nameplate and in the identification number of

the ball valve.

Ball valves are bi-directional industrial valves intended for full opening or full closing of the service fluid

flow in the piping. The ball valves shall not be used in intermediate positions.

This document applies to ball valves K92 with bolted design – type BB (BOLTED BODY) and all-welded

design – type FW (FULLY WELDED BODY).

1.1 Basic criteria of safety

When performing activities connected with or related to the valve (transportation, installation,

commissioning, operation, service, maintenance, repairs, etc.), all safety regulations, standards,

directives, instructions, rules and orders shall be followed and adhered to.

The duty of the Buyer is to acquaint all persons involved in any activity related to the ball valve or

the actuator with this document in order to avoid improper installation, putting into service and/or

damage. Training of those persons shall be documented in written form and the document shall

specify who, when and what has been trained.

Any activity related to the ball valve or the actuator during the guarantee period shall be recorded

in the Service Journal or another document kept by the Buyer. The document shall specify, as a

minimum, what activity has been done (e.g., sludge removal) and who and when has done it.

During the guarantee period, only the Manufacturer or (by agreement) the User may make repairs.

If the User tampers with the valve without receiving the Supplierʼs prior approval, no justified

claim can be lodged with the Supplier.

Bolting material, bonnets, covers, etc. of the valve or its accessories shall not be loosened, opened

or removed during the guarantee period without the consent of the Manufacturer.

Welding operations on the valve or its parts shall be done by duly qualified welders with valid

documents, in accordance with approved welding procedures (WPQR), on the basis of permission

given by Armatury Group a.s., and in accordance with internal safery regulations of the User.

When performing installation activities at height, safety regulations shall be adhered to, and only

ladders, work platforms and tools approved for this purpose shall be used.

When lifting and handling the valve or its parts, they shall be correctly slinged and secured and the

slings and lifting equipment shall be duly approved.

During installation, safe and adequate access to the place of valve installation and necessary space

in the place of installation shall be provided.

It is necessary to provide for correct installation into the piping so that the direction of pressure

application and the fluid flow direction are in accordance with valve marking and technical

documentation.

Precondition for commissioning of the valve is strict adherence to this document (Directions for

Installation and Operation), operating manuals and related safety regulations, safety instructions

specified in assembly drawings, instructions for use of protective equipment in the place of

installation, fire safety regulations, and regulations of personnel protection during use of the valve.

Prior to commencing any work on or in the valve or its parts, internal pressure shall be completely

removed from the valve, unless otherwise indicated hereinafter.

Temperature of all parts of the valve shall be reduced to the ambient temperature in order to avoid

any burn injury and to follow the occupational safety rules.

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Whenever replacing worn-out parts, only original spare parts or parts manufactured in accordance

with original production documentation of Armatury Group a.s. shall be used. In addition, only

standardized components and original parts from manufacturers of service equipment and

purchased components belonging to the valve shall be used.

It is forbidden to change, modify or reconstruct the valve without consent of the Manufacturer.

Safe operation, inspection and maintenance shall be provided by appropriate measures taken by the

User of the system (training of personnel, directions for operation, etc.).

When in service, the valve and its accessories shall be examined visually at regular intervals. The

examination intervals shall be determined by the User of the valve on the basis of experience or

after consultation with the valve Manufacturer.

When in service, the allowable operating and service conditions shall not be exceeded, i.e.

maximum allowable service pressure, maximum service temperature and minimum service

temperature, maximum differential pressure for operation of the obturator (opening/closing),

maximum ambient temperature, minimum ambient temperature. If the service fluid contains hard

and solid particles, they affect the reliability, functionality, tightness and service life of the valve

adversely.

If lubricating and/or cleaning agents are used when the valve is in service, it is necessary to act

carefully and in accordance with relevant standards and regulations to avoid any contamination of

the environment.

This document (Directions for Installation and Operation) applies exclusively to products delivered

by Armatury Group a.s. Operating devices (electric actuators, pneumatic actuators, hydraulic

actuators) installed on the valve or service equipment delivered together with the valve have their

own manuals issued by the respective manufacturers (they are enclosed to this document). If this

document is lost or damaged, it is necessary to ask the Manufacturer for its copy without delay.

If the guarantee period exceeds 2 years, any activity related to the valve shall be done only by

persons who have been trained by the Manufacturer.

The breach of provisions hereof may be considered as a breach of the Purchase Contract by the

Buyer which may lead to the loss of guarantee given by the Supplier.

2. Scope of validity

The scope of production as shown below applies to all designs of the K92 ball valves, K92.xx, made by

Armatury Group a.s. Table No. 1 specifies the standard sizes of ball valves being produced. Other sizes not

specified in the Table are based on Buyerʼs requirements (e.g., atypical designs, reduced bores, etc.).

Table No. 1

PN Class

NPS / DN

1

1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 28" 32" 36" 40" 42" 48“ 56“

40 50 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 1050 1200 1400

16, 25 150 x x x x x x x x x x x x x x x x x x x x

40 300 x x x x x x x x x x x x x x x x x x x x




250 1500 x x x x x x x x x x x x x

400 2500 x x x x x x x x x x

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3. Application

The ball valves, type K92, are suitable for many applications with different types of fluids.

They find application in gas industry, power engineering, water-supply engineering, paper industry,

chemical and petrochemical industry, cryogenic applications, etc.

Ball valves are industrial valves designed only to open or close the service fluid flow in the piping fully.

Some design configurations are allowed to be used for short-term throttling. However, the process of

throttling, if applied in combination with a fluid containing mechanical impurities, can cause subsequent

loss of tightness of the valve obturator.

Basic data on pressures and temperatures are specified on the valve nameplate. Other data are specified in

the Data Sheet or the Purchase Contract.

Service pressure is the pressure of the fluid which exists under the defined service conditions and depends

on the valve materials used and on the temperature of the fluid.

Maximum allowable pressure is the highest pressure for which the equipment is designed, as specified by

the Manufacturer.

Service temperature is the temperature of the fluid which exists under the defined service conditions and

depends on the valve materials used.

Maximum/minimum allowable temperature is the temperature for which the equipment is designed, as

specified by the Manufacturer. For ball valves K92, the temperature range is from -196°C to +450°C.

Ambient temperature can be within the range from -60°C to +80°C.

Pressure drop at which the ball valve can be opened depends on the size and on the pressure class of the

valve, and its values are specified in Table No. 2.

The ball valve can be closed at any pressure that does not exceed the maximum allowable pressure.

Table No. 2

PN CLASS DN ∆p (MPa)

16-25 150 40-1400 (1 1/2"-56") Pp

40 300 40-300 (1 1/2"-12") Pp

350-1400 (14"-56") 2.5

63, 100 400, 600 40-300 (1 1/2"-12") Pp

350-1400 (14"-56") 2.5

160 900 40-300 (1 1/2"-12") Pp

350-1400 (14"-56") 2.5

250 1500 40-100 (1 1/2"-4") Pp

150-1400 (6"-56") 12.5

400 2500 40-100 (1 1/2"-12") Pp

150-1400 (6"-56") 12.5

∆p – pressure drop, Pp – service pressure

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4. Design

The complete ball valve consists of:

a) the ball valve itself,

b) operating device,

c) accessories.

4.1 Description of ball valve design

The typical design of ball valves made by ARMATURY Group a.s. falls into the QSL2 category as a

standard feature and is obvious from the sectional view drawings shown in Annexes No. 2 to No. 6

hereto. The Annexes specify the standard materials also.

Particular design of ball valves and material specification are shown on the sectional view drawing

which is enclosed to each ball valve delivery.

It is obvious from the drawings that the ball valves have trunnion mounted balls and meet the

requirements of API 6D, ANSI B16.34 and EN 14141. The main parts of a ball valve are the

pressure-containing and pressure-controlling parts within the meaning of definitions in API 6D. The

body is either a two-piece body (for DN 40 to 100) or a three-piece body (for DN 150 to 1400).

Individual parts of the body are made of forgings and are either connected by bolts (type BB) or

welded together (type FW). The stem is sealed with two or three sealing components that are

independent of each other, see Figure No. 5 and Figure No. 6. The fire safety of ball valves is

achieved by graphite gaskets. The standard design of ball valves incorporates the DOUBLE BLOCK

AND BLEED (possibility of body cavity pressure relief), ANTI BLOW OUT (stem cannot be

ejected out of the body), ANTISTATIC (removal of static electricity) and FIRE SAFE features.

Pressure-containing parts are, according to API 6D, parts whose failure to function as intended

results in a release of contained fluid into the environment, and include at least the body (1), the

body cap (2), the flange (6), and the stem and the trunnion (4, 7).

Pressure-containing parts are designed so that the pressure-temperature rating of the valve is met.

The valves are not designed as self-standing. In case they are equipped with supporting brackets and

feet, these are intended to transfer the weight of the valve to the foundation only, they do not provide

for stability of the valve and do not prevent its overturning.

The ball valves are intended to be used with fluids that do not contain mechanical impurities. If there

are scratches or other defects of similar character on the ball surface caused by large mechanical

particles, the leakage rate A according to ISO 5208 cannot be guaranteed. The Manufacturer shall

not be held responsible for scratching of the ball by mechanical impurities contained in the service

fluid.

4.2 Description of operating device

The ball valve is operated by a lever or an actuator. Actuators can be manual (worm gear operator),

electric, pneumatic, hydropneumatic or electrohydraulic. Each actuator has its own documentation which is

enclosed to each ball valve delivery.

The actuators are attached to the ball valve and adjusted by the Manufacturer as a standard feature.

Big actuators, especially hydropneumatic ones, which for transportation reasons cannot be

delivered assembled with the ball valve shall be installed by the Buyer according to the

following procedure:

Any work related to installation of actuators has to be performed by trained and qualified workers

who are acquainted with the product being installed and safety regulations and trained in use of

lifting devices.

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Remove the actuator from the packaging and examine it. For handling purposes, only holes and bolts

intended for that purpose may be used.

Secure the ball valve to prevent its overturning. Pay special attention to the possible change of the

centre of gravity of the complete valve-and-actuator assembly.

Degrease contact surfaces of both the valve and the actuator, apply silicone putty to them in order to

prevent moisture penetration and to increase friction between the valve and the actuator.

When attaching the ball valve to the actuator, both of them shall be in the open position!!

If the ball valve is to be used with an actuator with the ”FAIL CLOSE“ function, it is possible to ask

the Manufacturer for attaching the actuator to the ball valve or to follow instructions that can be

found in the ball valve bore!!

Check the serial numbers and the open position of both the actuator and the valve (see Figure 1).

Install the actuator so that the valve stem is guided by the actuator adapter.

Lubricate the valve stem with vaseline or oil in order to facilitate the installation.

When installing the actuator, no force must be applied, only its dead weight may be utilized.

Position the actuator on the valve according to lines marked on the circumference of valve and

actuator flanges (see Figure 2).

Install washers and nuts, tighten the nuts with tightening torque according to this document.

Caution – the actuator must NEVER be used to lift the complete valve-and-actuator assembly.

Connect the actuator to relevant power sources (oil, air).

Check tightness of threaded joints of pipes or hoses connecting the actuator to power sources.

Check the operating function, end positions (open, closed), duration of valve obturator movement.

In the open position, the axis of the keys is parallel to the piping axis.

Figure No. 1 Figure No. 2

Stem

Positioning line Actuator

Ball valve (stem extension assembly)

Flanged joints between the actuator and the ball valve or between the stem extension assembly and the ball

valve or the actuator are made in conformity with ISO EN 5211. For safer transmission of the operating

torque and elimination of moisture between flanges, the flanges of these joints are treated with W-SIL-EX

or MAKROFLEX TA145 or another agent with similar properties by the Manufacturer.

For control of mutual position of these flanges, the flanges are secured by a control weld 5 to 10 mm long

in an easily accessible place, made with a suitable electrode in accordance with the material of components

to be welded together.

4.3 Accessories

Details of the particular design of ball valve inclusive of accessories and actuator are enclosed to each ball

valve delivery.

Accessories can include the following features:

- stem extension assembly or underground set

- venting by a plug or a ball valve

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- draining by a plug or a ball valve

- sealant injection by two check valves (independent of each other) and a cap *

- pressure relief between body cavity and body cap cavity

- gas supply to the actuator

An example of standard accessories is shown in Annex No. 7 hereto.

* - Number of sealant injection places – one for both the stem and the seats of ball valves up to 4"

inclusive. Ball valves of larger sizes have separate sealant injection places for the stem and the seats.

When injecting the sealing paste to the seats or the stem of an underground ball valve, the sealing paste is

injected through two check valves as a standard feature, namely 1/2“ NPT and 3/8“ NPT. If another check valve 3/8“ NPT is required in the sealant injection pipe, either in the body or in the body

cap, this requirement shall be specified when ordering the ball valve. However, the Manufacturer warns: - The pressure for injecting the sealing paste will be higher. - If damaged, that check valve cannot be replaced or repaired and sealing paste cannot be injected through

that pipe any longer!!!

5. Materials Typical materials of main parts and components are specified in tables in Annexes No. 2 to No. 6.

Other materials as required by the Buyer may be used as well.

For the production of main parts (body, body cap), only forged semi-finished products are used.

6. Testing

The ball valves are tested and examined in accordance with API Spec 6D or in accordance with other

standards (e.g. API 598 or ČSN EN 12266-1, ČSN EN 12266-2), if required by the Buyer.

Each ball valve is tested as follows at the manufacturing plant:

Hydrostatic shell test

Hydrostatic seat test

Operability test

7. Valve completeness and marking

7.1 Completeness

The complete delivery includes the assembled product (including actuator) and, if required, counterflanges

and bolting material.

If spare parts belong to the scope of delivery, they are delivered together with the valve.

In addition, the product is delivered with accompanying technical documentation according to the Pressure

Equipment Directive 2014/68/EU which contains the following documents usually:

- test report (inspection certificate of 3.1 type and certificate of quality and completeness of 2.1 type)

- Directions for Installation and Operation (MPP)

- marking with identification nameplate specifying the Manufacturer on the valve

The scope of documentation to be delivered shall be discussed with the Buyer and specified in the technical

specification or characteristic.

7.2 Valve marking

Ball valves are marked in compliance with API Spec 6D.

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The following information must be stated on the valve body:

Manufacturer

Pressure class

Body material

Nominal size

Identification of ring joint (RTJ) on the flange edge

Serial number

An identification nameplate is permanently and visibly attached to the valve body or, in case of small

valves, secured with a steel wire and contains information required by API 6D.

8. Storage

When handling the ball valve, generally applicable safety regulations shall be adhered to. The ball valve

Manufacturer recommends to store ball valves with or without actuators with vertical position of the stem.

Ball valves may be stored in covered or uncovered areas but always protected against direct weather

effects, damages and penetration of mechanical impurities into the valve bore. The recommended storage

temperature shall be between -10°C and +30°C.

If the ball valves are stored for more than 2 years, they shall be subjected to pressure tests and operability

tests prior to installation into the piping. In case of leakage, the Manufacturer shall be contacted.

In case of any damage caused by handling, the packaging, the protective covers or the coating have to be

restored immediately. Repairs of coating shall be consulted with the Manufacturer of ball valves.

The valves shall be transported, stored and handled on pallets, skids or in boxes as delivered by the

Manufacturer. Damaged pallets, skids and boxes shall be repaired.

When storing valves together with actuators, the storage conditions specified in the technical

documentation for actuators shall be adhered to.

Damages caused by wrong storage and/or handling are not covered by the guarantee.

9. Installation, operation and maintenance

9.1 Valve installation

Any work related to installation of ball valves has to be performed by trained and qualified workers

who are acquainted with the product being installed, see 1.1 hereof.

The recommended ball valve handling method is shown in Annex No. 8 hereto. The ball valve

Manufacturer recommends to store ball valves with or without actuators with vertical position of the

stem.

After removing the shipping packaging before installation and during the installation, it is necessary

to provide for stability of the valve by an ancillary supporting structure or by its anchoring or

suspending. The supporting brackets, which some of the valves are usually equipped with, do not

provide for stability of the valve.

Prior to installation, check and clean the piping into which the ball valves will be installed.

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Prior to installation into the piping system, remove all protective covers, check the ball valve

thoroughly and, if necessary, remove any preservative agent and clean the ball valve. It is necessary

to inform the Manufacturer about any damage as soon as possible and the Manufacturer shall take

decision on the way of repair on the basis of the character of the damage. Installation of ball valves

shall be made with the ball valves in open position.

The ball valves are equipped by the Manufacturer with a special seat cover that prevents penetration

of impurities between the ball and the seats. This cover shall be removed before performing pressure

tests of the ball valves prior to their installation or before installing the ball valves into the piping.

Ball valves from DN 150 are equipped with feet to be placed on a rigid concrete block. It is

necessary in any case to protect the ball valve against additional stress induced by the piping.

Minimization of this stress can be achieved by providing for due alignment of the ball valve with the

piping axis. Permissible height and lateral deviation is 2.5° max.

The usual installation position of the ball valves is the horizontal position with the stem in the upper

position with a possible deviation of 0° to 90° from the upper position, unless otherwise specified in

the technical specification of the Purchase Contract. The limiting factor of the service position of the

ball valve is the actuator used and recommendations following from its technical description.

If values of axial forces and bending moments are not specified by the designer, the ball valve

installation shall be made in a way which will guarantee that these effects will not act on the valve.

Installation of ball valves with welding ends into the piping shall be done in compliance with

relevant technological procedure and safety regulations of the User. The selected welding process

shall meet the requirement for the temperature at a distance of 2

DL from the welded joint not to

exceed +100°C, where L = end-to-end dimension and D = diameter of the ball bore. The valve bore

shall be protected against penetration of impurities. If this happens, the piping has to be cleaned by

exhausting, blowing or flushing before operating the ball valve for the first time.

When installing ball valves with flanged ends, the bolts (nuts) shall be tightened in a crosswise

manner. The tightening torques shall be specified by the User according to the type of flange gaskets

used and material of bolts. Table No. 3 below may be used as a guide.

After installation, check the performance of the ball valve by turning the ball from one end position

to the other end position and back. In case any deficiency is found, remove it immediately.

If transport dimensions or actuator transportation instructions do not permit delivery in fully

assembled condition, the ball valve is delivered partly disassembled. Installation of the stem

extension assembly and the actuator shall be done in a way which will maintain the same position of

the obturator as it was at the manufacturing plant. This activity shall be performed by duly trained

personnel only. Bolted joints shall be duly tightened in a crosswise manner with tightening torques

shown in Table No. 3 below.

For ball valves with guarantee period exceeding 2 years, the Buyer shall order a supervision from the

Supplier for the process of welding of the ball valve into the piping and cleaning the valve interior.

Prior to pressure testing or putting into service, the tightness of all bolted joints of the ball valve as

well as tightness of drain and vent plugs shall be checked. Bolted joints shall be retightened in a

crosswise manner with tightening torques shown in Table No. 3 below.

Regarding actuators (putting into service, use, operation), the User shall observe instructions issued

by the manufacturer of actuators. Operating instructions and directions applicable to the actuator are

enclosed to the product documentation.

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Electrical installation (i.e. wiring) of power, control and signalling cables necessary for operation of

ball valves shall be provided by the Buyer. The connection of the control system and/or the

adjustment of positions (usually set up by the Manufacturer) and signalling devices shall be done by

trained and qualified workers. It is possible to charge ARMATURY Group a.s. with those activities.

Table No. 3

TIGHTENING TORQUES FOR BOLTED JOINTS (Nm)

BOLT/

SCREW SIZE

BODY/

BODY

CAP

all mater.

BODY/THIRD FLANGE BOLT/

SCREW

SIZE

BODY/

BODY

CAP

all mater.

BODY/THIRD FLANGE

B7, L7,

ISO 8.8

B8, B8M

Class 2 B7M, L7M

B7, L7,

ISO 8.8

B8, B8M

Class 2 B7M, L7M

5/16 UNC 17 20 17 M8 18 20 18

3/8 UNC 30 35 30 M10 35 40 35

1/2 UNC 75 85 75 M12 60 70 60

9/16 UNC 100 120 100 M14 100 110 100

5/8 UNC 140 170 140 M16 140 170 140

3/4 UNC 260 300 260 M20 300 350 300

1 UNC 600 600 600 M24 500 600 500

1 1/8 UN8 730 1050 730 900 M27 600 850 600 750

1 3/16 UN8 860 1250 860 1050 M30 820 1200 820 1000

1 1/4 UN8 770 1450 770 1250 M33 850 1600 850 1400

1 3/8 UN8 1050 2000 1050 1700 M36x3 1150 2200 1150 1900

1 1/2 UN8 2300 2600 - 2300 M39x3 2400 2900 - 2400

1 5/8 UN8 2900 3400 - 2900 M42x3 3000 3600 - 3000

1 7/8 UN8 4600 5400 - 4600 M48x3 4800 5600 - 4800

2 UN8 5600 6600 - 5600 M52x3 6000 7000 - 6000

2 1/8 UN8 6700 7800 - 6700 M56x4 7300 8500 - 7300

2 1/4 UN8 7900 9200 - 7900 M60x4 9000 10500 - 9000

2 3/8 UN8 9300 10800 - 9300 M64x4 11000 12800 - 11000

9.2 Testing of ball valves before their installation into the piping

Each ball valve has been tested and adjusted by the Manufacturer in terms of operability and seat tightness

in accordance with specification of the customer or at least in accordance with API Spec 6D. If the Buyer

wishes to test the ball valve before installing it into the piping, the following procedure is recommended to

be used:

o Operability test

For this test, the ball valve shall be equipped with the actuator which will operate it in service. The

test shall be performed in pressure-free condition by making a cycle of closing and opening. In the

open position, the bore of the ball shall be flush with the bore of the seat and the body cap with a

deviation of ±1 mm. In the closed position, the surface of the ball shall fully cover the bore of the

seat with an overlap. A more detailed method of setting the position of the ball is not described in the

Directions for Installation and Operation. If unallowable deviations are found, it is necessary to

contact the Manufacturer.

o Seat tightness test for DPE seat (bi-directional seat)

The ball valve shall be tested with the obturator in closed position. The valve body cavity shall be

filled with air or nitrogen through the drain or vent valve and pressurized to a pressure as defined in

API Spec 6D, Section H.3.3 (pressure between 5.5 and 6.9 bar). Leakage shall be checked visually

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by means of a foam-forming solution applied to the gap between the seat and the ball. Both the

upstream side and the downstream side of the ball valve shall be checked. If any leakage is detected,

a seat tightness test with air having the pressure as specified in Section H.3.3 from both the right-

hand side and the left-hand side of the ball valve shall be performed with the leakage being measured

from the valve body cavity. If any leakage is detected also during this test, it is necessary to contact

the Manufacturer. Scheme of this test is shown in Figure No. 3.

Figure No. 3

BC = 5.5-6.9 bar

IB

OB

o Seat tightness test for SPE seat (uni-directional seat)

The ball valve shall be tested with the obturator in closed position. The valve body cavity shall be

filled with air or nitrogen through the drain or vent valve and pressurized to a pressure as defined in

API Spec 6D, Section H.3.2 (pressure between 0.34 and 1 bar). Leakage shall be checked visually by

means of a foam-forming solution applied to the gap between the seat and the ball. Both the

upstream side and the downstream side of the ball valve shall be checked. If any leakage is detected,

a seat tightness test with air having the pressure as specified in Section H.3.3 from both the right-

hand side and the left-hand side of the ball valve shall be performed with the leakage being measured

from the valve body cavity. If any leakage is detected also during this test, it is necessary to contact

the Manufacturer. Scheme of this test is shown in Figure No. 4.

Figure No. 4

BC = 0.34-1 bar

IB

OB

o Seat tightness test with water

The examiner shall guarantee the composition of water to be in conformity with API Spec 6D,

Section 9.1. After the test with water, the ball valve shall be completely drained, dried and, where

applicable, preserved again. Nonobservance of this process can cause damage to the ball valve and

loss of Manufacturer’s guarantee for the product.

If the ball valve is not to be installed into the piping at once, it shall be immediately (within 24 hours)

re-equipped with all protective covers and preserved with preservative wax ANTICORIT W 366 made

by Fuchs or another equivalent product.

9.3 Testing of ball valves after their installation into the piping

Prior to pressure testing or putting into service, the tightness of all bolted joints of the ball valve as

well as tightness of drain and vent plugs shall be checked. Bolted joints shall be retightened in a

crosswise manner with tightening torques shown in Table No. 3.

When testing the piping system with water, the ball valves may be loaded with a pressure of:

a) Ball valves in “OPEN” position

- DN, PN designated valves max. 1.5 x PS at 20°C

= 0

= 0

MPP-AG-K92-08/2015 /36


- NPS, CLASS designated valves max. 1.5 x MOP at 20°C

where PS is maximum allowable pressure

MOP is maximum operating pressure

b) Ball valves in “CLOSED” position

- DN, PN designated valves max. 1.1 x PS at 20°C

- NPS, CLASS designated valves max. 1.1 x MOP at 20°C

where PS is maximum allowable pressure

MOP is maximum operating pressure

When testing a piping system containing ball valves the actuators of which are connected to a pressure

extraction point of the piping or the ball valve, all the extraction points shall be closed prior to

commencing the tests.

After pressure and tightness tests, it is absolutely necessary to discharge water from the ball valve

cavities completely in order to avoid freezing of the water with subsequent damage to the ball valve.

The procedure is as follows:

- Discharge water from the ball valve body cavity through the drain ball valve. In order to discharge

water completely, also the vent ball valve shall be opened.

- Use the drain ball valve or the vent ball valve to blow the ball valve through.

- After draining the ball valve and blowing it through, close the drain ball valve and the vent ball

valve and/or screw on the plugs.

If the time period between pressure tests and filling-up of the piping system with service fluid exceeds

7 days, the functional parts of the ball valves shall be preserved with oil. The Manufacturer can either

do this work or submit a written procedure for this work to the User.

Preservation can be done by means of the drain and vent system. Open the vent ball valve or plug and

fill the body cavity of the ball valve with preservative oil, for instance ANTICORIT made by Fuchs or

another equivalent product. Then discharge the preservative oil through the drain ball valve or plug in

a collecting vessel. An oil film remains on the surfaces inside the ball valve. Then close the drain ball

valve and the vent ball valve and/or screw on the plugs.

9.4 Operation and maintenance

All ball valves are duly adjusted and tested prior to shipping so as to provide for their proper operation

during service. Under normal conditions (that means, if no problems due to improper handling occur),

it is not necessary to change the adjustment anyway.

The ball valves are sized for opening and closing at the full pressure drop. However, when opening the

ball valve in a situation with a great volume of gas or liquid being present before the ball valve and

free discharge behind the ball valve, heavy dynamic effects of the fluid flow will occur in ball valves

DN 300. Those effects can have an adverse impact on the whole piping system. The Manufacturer

shall not be held responsible for such effects and recommends to operate the ball valves only after a

full equalization of pressures before and behind the ball valve or at a difference of those pressures

lower than 25 bar.

When in service, the condition of the ball valves has to be checked regularly and routine maintenance

of the ball valves shall be done (for instance, retightening of bolted joints loosened due to vibration,

inspection of obturator position, etc.). If the guarantee period exceeds 2 years, these checks and

inspections shall be carried out at least once a year by the Manufacturer or by duly trained personnel.

The Manufacturer recommends to drain the ball valves once a year or during planned shutdowns in

order to avoid clogging of the drain line with impurities. The Manufacturer recommends also to move

the obturator from one end position to the other end position (cycle of opening and closing) during the

shutdown. The purpose of this operation is to prevent “freezing” of the obturator and to eliminate

MPP-AG-K92-08/2015 /36


formation of deposits on the spherical surface. If the guarantee period exceeds 2 years, these

operations shall be carried out at least once a year by the Manufacturer or by duly trained personnel.

Figure No. 5

Detail of stem seals – DN 50-100

Spare rings for the stem – No. 13 and No. 52

Figure No. 6 Detail of stem seals – DN 150-700

Spare rings for the stem – No. 51 and No. 52 are replaced with rings No. 55 and No. 56

The replacement of sealing components of the stem can be done without the necessity of removing

the ball valve from the piping system. CAUTION! THE REPLACEMENT OF

SEALING COMPONENTS HAS TO BE DONE ONLY WITH THE BALL

VALVE BODY CAVITY CONTAINING NO PRESSURE. THE BALL

VALVE BODY CAVITY MUST BE VENTED (DEPRESSURIZED).

Depressurization of the body cavity is possible because the ball valves are double-block-and-bleed

valves. If pressure remains in the body cavity due to untight seats, the replacement is possible only in

case of a small leakage.

Recommended procedure of replacement:

MPP-AG-K92-08/2015 /36


- remove the operating device and the stem extension assembly, if any

- remove the components that hold the sealing components of the stem, No. 32 for ball valves up

to DN 100 – Figure No. 5 or Nos. 19, 51 and 52 for larger ball valves – Figure No. 6

- clean the body space holding the removed components

- re-install all the above components that were removed with new sealing components

- install the operating device and the stem extension assembly, if any

- check the operability of the ball valve – by turning the ball from one end position to the other

end position and back

- after putting into service (restoration of service), check the tightness of the stem

For the necessity of sealant injection to the area of seats and stem, it is recommended to ask the

Servicing Department of the Manufacturer for provision of the relevant service. Otherwise this activity

can be done by trained and qualified workers of the User. The procedure of sealant injection is

described in the tables of Section 10.1, Troubleshooting.

9.5 Service life

The terms “service life and reliability” mean the ability of the ball valve to perform the basic

required functions:

- ability to be used under conditions specified in this document

- guarantee of tightness towards the environment

- guarantee of operability under conditions specified in this document

Specification of service life:

- service life of the complete valve body – 40 years minimum

- reliability of tightness towards the environment – 10 years minimum. If necessary, however, it

is allowed to replace the sealing components of the ball valve

- number of operating cycles DN 10 to 100 – 5000 cycles

DN 150 to 250 – 3000 cycles

DN 300 to 1400 – 2000 cycles

After the end of service life, the valve shall be disposed of in an environment-friendly manner.

CAUTION! Do not mistake service life for guarantee period!

10. Repairs

During the guarantee period, only the Manufacturer or (by agreement) the User may make repairs.

After the guarantee period expires, only valve qualified workers or a servicing company and/or the

Manufacturer of valves may make repairs. Prior to repair, the extent of damages and the method of

repair or the servicing company to make the repair shall be specified.

Actuators may be repaired only by trained and qualified workers who are authorized by the

Manufacturer of actuators to install, adjust and repair actuators, or (by agreement) by trained and

qualified workers of the User.

If the valves are to be repaired by a servicing company, they have to be removed from the piping in

a way similar to that of installation by trained and qualified workers who will observe all relevant

safety regulations.

The DPE function provides tightness on the downstream side of the ball valve as well. Thus, fluid

escape from the intermediate cavity does not indicate an inoperative valve.

Contact information: Armatury Group a.s., Dolní Benešov Establishment, Nádražní 129,

MPP-AG-K92-08/2015 /36


747 22 Dolní Benešov, Czech Republic

tel.: +420/ 553 680 111, fax: +420/ 553 680 333

e-mail: [email protected]

10.1 Troubleshooting

Description of possible defects related to condition of valve components, assemblies and joints of

ball valves that have to be regularly checked is given in Tables No. 4 and No. 5 below.

Table No.4

VALVE FUNCTION

Defect characteristics Possible cause Symptoms Remedy

Place of repair

1. Increase of operating

torque

- Mechanical damage

to stem, keys, etc. - Audible manifestation

- Actuator switches off

- End positions are not

indicated by the

signalling device

- Replacement of

defective components

- Ball valve shall be

removed from piping

and repaired at the

manufacturing plant

- Defective actuator,

gearbox

- Replacement of

actuator, gearbox

- Replacement of

actuator, gearbox – on

site

2. Ball does not reach

end position (open or

closed)

- Incorrect adjustment

of end switches of

electric actuator or

mechanical stops of the

gearbox

- End positions are not

indicated by the

signalling device

- Leaky valve

- Change in behaviour

of electric actuator

- Incorrect position of

the notch on the stem

- Adjustment of end

switches of electric

actuator or mechan.

stops of the gearbox

- Electric actuator,

gearbox – on site

- Ball movement

blocked by foreign

body

- Removal of foreign

body


removed from piping

and repaired at the

manufacturing plant

3. Impossibility to

operate the valve with

its operating device

(gearbox, electric

actuator, etc.)

- Low operating torque.

The valve is used at

higher parameters than

those specified in the

specification

- Impossibility to open

or close the valve

- Replacement of the

existing operating

device (with a more

efficient one)

- Removal of the old

operating device and

installation of a new

operating device

4. Leaky ball valve in

seats

- Incorrect adjustment

of the ball valve and

incorrect position of the

obturator

- Change of pressure in

downstream piping

- Inspection and

adjustment (if

necessary) of position

of the obturator * - Installed ball valve –

on site

- Impurities on the ball

or in the seat


flushed with diesel oil

with simultaneous

cycling**

- Defective body, seat

or ball

- Small defects can be

removed by injection of

sealing paste Sealant

#5050 made by

Sealweld or another

equivalent product***

- Installed ball valve –

on site

- Replacement or repair

of existing components


removed from piping

and repaired at the

manufacturing plant

5. Improper function of

actuator - Defective actuator

- Impossibility to open

or close the valve

- For troubleshooting

see operating

- Replacement or repair

of actuator, gearbox –

mailto:[email protected]

MPP-AG-K92-08/2015 /36


instructions and

directions applicable to

the actuator

on site

* - Adjustment shall be performed by the Manufacturer or duly trained personnel. Position of the obturator

shall be checked regularly as an incorrect position can damage the seats. Position of the obturator shall be

checked visually according to the position of the indicator located on the actuator. An incorrect position can

be a consequence of a shift of flanges of the joint between the actuator and the ball valve as well. Therefore

it is also necessary to retighten the bolts of this joint regularly.

** - Diesel oil can be used if diesel oil in the piping is not a hindrance to its subsequent use. Cleaning can be

also done by using VALVE CLEANER PLUS made by SEALWELD or another equivalent product. Only the

Manufacturer or duly trained personnel may do this activity.

*** - Grease guns generating a pressure of three times the nominal pressure shall be used for sealant

injection purposes. When injecting the sealing paste to the seats, it is necessary to turn the ball three or four

times to distribute the paste on the entire circumference of the seats uniformly. The fluid flow pushes the

paste to the place of damage and makes it tight. Due to the high viscosity of the paste it is not recommended

to inject the paste at a temperature lower than 0°C. If this operation is to be done at lower temperatures, it is

allowed to warm up both the paste and the sealant injection line.

Table No. 5

EXTERNAL LEAKAGE

Defect characteristics Possible cause Symptoms Remedy

Place of repair

1. Leakage through the

joint between body and

body cap

- Insufficiently

tightened joint between

body and body cap

- Escape of fluid

from this joint

- Retightening of the joint

between body and body

cap with torque shown in

Table No. 3


on site

- Damaged gasket - Gasket replacement


removed from piping

and repaired at the

manufacturing plant

2. Leakage around the

stem

- Damaged cylindrical

surface of the stem

(mechanical, due to

corrosion)

- Escape of fluid

around the stem

- Repair of cylindrical

surface (repolishing,

regrinding)


removed from piping

and repaired at the

manufacturing plant

- Damaged stem seal

- Replacement of upper

sealing ring

(Caution, proceed acc. to

”Replacement of sealing

components of the stem“)

- Ball valve with sealant

injection feature: injection

of sealing paste Sealant

#5050 made by Sealweld

or another equivalent

product **


on site

3. Leakage through the

joint between stem

flange and body

- Insufficiently

tightened joint

- Escape of fluid

from this joint

- Retightening of the joint

with torque shown in

Table No. 3


on site

- Damaged gasket

- Gasket replacement


removed from piping

and repaired at the

manufacturing plant

4. Leakage of drain,

vent and gas supply

lines

- Insufficiently

tightened joint - Escape of fluid

from this joint

- Retightening of plugs or

cap nuts


on site *

- Damaged gasket - Gasket replacement

- Disassembly and

replacement of gaskets

– on site *

MPP-AG-K92-08/2015 /36


- Leaky weld in the

joint

- Repair of weld and non-

destructive examination of

the weld


on site ***

5. Leakage of drain,

vent, pressure relief and

gas supply valves

- Leaky valve after

removal of cover plug

- Leakage around the

valve stem

- Escape of fluid

from this joint - Valve replacement


on site ***

* - Regular retightening shall be a part of routine maintenance as the bolted joints may get loose as a result

of valve vibration. If this does not help, the relevant gasket shall be replaced. Gasket replacement has to be

done only with the installed ball valve containing no pressure.

** - Grease guns generating a pressure of three times the nominal pressure shall be used for sealant

injection purposes. When injecting the sealing paste to the seats, it is necessary to turn the ball three or four

times to distribute the paste on the entire circumference of the seats uniformly. The fluid flow pushes the

paste to the place of damage and makes it tight. Due to the high viscosity of the paste it is not recommended

to inject the paste at a temperature lower than 0°C. If this operation is to be done at lower temperatures, it is

allowed to warm up both the paste and the sealant injection line.

*** - Repair can be done if allowed by safety regulations of the User of the ball valve and only with the valve

containing no pressure. Otherwise the ball valve shall be removed from the piping and repaired at the

manufacturing plant.

11. Spare parts

Recommended spare parts for two years of service:

- set of sealant injection check valves

- set of sealing components and plugs for drain and vent lines

- spare seals for the stem

The quantity of spare parts is 10% maximum of the purchase order volume, but 1 piece minimum and 10

pieces maximum.

Spare parts are delivered on the basis of a separate purchase order of the Buyer or requirements of the

project.

When ordering spare parts, the serial number of the valve and the spare part numbers or item numbers

according to Annexes hereto shall be specified always.

Storage time of sealing components makes 5 years maximum if stored correctly. Service life of metallic

parts is identical to that of the entire valve.

12. Basic criteria of operational reliability of ball valves under service

conditions

All relevant regulations and rules were observed when designing and sizing the valves and when selecting

the materials in order to provide for safety, operational reliability and long service life of the ball valves

under service conditions. Nevertheless, it is necessary to mention some aspects and criteria which have to

be respected in order to achieve the required properties.

Especially:

a) Ball valves are industrial valves intended for full opening or full closing of the service fluid flow in

the piping only. If used for flow regulation or throttling purposes, the subsequent tightness of the

obturator cannot be guaranteed. It is strictly forbidden to fill the piping system with gas or liquid

with the obturator in intermediate position.

b) For safe handling during the installation, it is necessary to provide for stability of the valve and to

prevent its overturning.

c) The installation shall be made in a way which will guarantee that minimum forces and bending

moments act on the valve body. The valves shall never be used to support the piping!

MPP-AG-K92-08/2015 /36


d) The Manufacturer recommends to drain the ball valves once a year or during planned shutdowns in

order to avoid clogging of the drain line with impurities. The Manufacturer recommends also to

move the obturator from one end position to the other end position (cycle of opening and closing)

whenever allowed by the technological modes of operation of the system or during the shutdown.

The purpose of this operation is to prevent “freezing” of the obturator and to eliminate formation of

deposits on the spherical surface.

e) The Manufacturer bears no responsibility for valve untightness caused by removal of the operating

system and its unprofessional adjustment or by unprofessional installation of the operating system.

f) If the ball valves are used in systems transporting hot fluids, protective gloves have to be worn

always when handling the valve or the manual operating device.

g) Prior to any operation, check the position of the ball valve obturator and then turn the lever or

handwheel in the correct direction. Values of the force Fs for unseating (breakaway), seating, and

operation in intermediate position are in compliance with ČSN EN 12570.

h) Take special care when performing venting or draining of the ball valve. No humans shall be

exposed to the flow of the escaping fluid that could be injured by the flow, and no objects shall be

exposed to the flow of the escaping fluid that could be damaged or destroyed by the flow. The jet

of the discharged fluid shall not strike against a solid obstacle from which it could bounce off and

injure the operator. To do this, loosen the plug slightly first for the fluid to escape through the

relieving hole in the plug. The plug can be removed completely only after reduction of

pressure!!

i) When transporting the ball valve by slinging, the general safety rules applicable to operation of

lifting equipment shall be followed.

j) For correct delivery and subsequent operation, it is always necessary to specify exactly all

necessary data when ordering the ball valve from the Manufacturer.

MPP-AG-K92-08/2015 /36


Annex No. 1 Ball valve identification – type designation

Sheet 1/1

Manufacturer (Supplier)

Body material

Operation

Connection

K92.24 DN 100 PN 16 114 AG

NPS 4“ Class 150

Nominal pressure

Valve size

Body design

Seating surfaces

Valve type

Valve type K92 – ball valve with trunnion mounted ball, with full or reduced bore

Body design 1 – forged body, bolted design with plates

(TRUNNION – PLATE) 2 – forged body, fully welded design with plates

(TRUNNION – PLATE) 3 – forged body, bolted design on stems

(TRUNNION – STEM) 4 – forged body, fully welded design on stems

(TRUNNION – STEM) C – forged body, cryogenic construction Seating surfaces 1 – soft-seated (PMSS with thermoplast) 2 – metal-to-metal seated 3 – special (on request) 4 – combined (PMSS with elastomer and thermoplast) Nominal size DN – according to ČSN EN Standards NPS – according to ANSI Standards

Nominal pressure PN – according to ČSN EN Standards CLASS – according to ANSI Standards

Type of connection 1 – flanged ends 2 – welding ends Method of operation 1 – manual (lever) 2 – gear operator 3 – electric actuator 4 – pneumatic, hydraulic, electrohydraulic or hydropneumatic

actuator 5 – bare stem (ready for operator/actuator installation) 6 – other Body material 0 – corrosion resistant steel 3 – wrought alloy steel 4 – wrought carbon steel Manufacturer (Supplier) AG – ARMATURY Group a.s.

MPP-AG-K92-08/2015 /36


Annex No. 2 Typical design of ball valves K92.3x, DN 40 to 50 (NPS 1 ½“ to NPS 2")

Sheet 1/2

Sectional view drawing of ball valve DN 40 to 50 (NPS 1 ½“ to NPS 2")

MPP-AG-K92-08/2015 /36


Annex No. 2 Typical design of ball valves K92.3x, DN 40 to 50 (NPS 1 ½“ to NPS 2")

Sheet 2/2

Material specification of ball valves DN 40 to 50 (NPS 1 ½“ to NPS 2")

CS = CARBON STEEL

SS = STAINLESS STEEL

Number Component Material Certificate EN 10204

1 BODY A105, A350 LF2 3.1

2 BODY CAP

3 BALL A182 F316 3.1

4 STEM A182 F316 3.1

5 SEAT – COMPLETE A182 F316 2.1

6 FLANGE A 350 LF2 3.1

7 TRUNNION A182 F316 2.1

12,17 THRUST BEARING SS+PTFE, PTFE 2.1

14,15,16 PLAIN BEARING

30 STUD BOLT A320 L7 + Zn 2.2

31 NUT A194 Gr.7 + Zn 2.2

33,34 SCREW A320 L7 + Zn 2.2

42 PIN SS 2.1

52 PACKING RING EXP. GRAPHITE 2.1

55,57,58 O-RING HNBR + ED 2.1

56 SEALING RING PTFE 2.1

60,62,63 GASKET GRAPHITE + SS 2.1

91 SMALL BALL SS 2.1

93 KEY CS 2.1

90 SPRING SS 2.1

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Annex No. 3 Typical design of ball valves K92.2x, DN 80 to 100 (NPS 3“ to NPS 4")

Sheet 1/2

Sectional view drawing of ball valve DN 80 to 100 (NPS 3“ to NPS 4")

SECTION L-L

MPP-AG-K92-08/2015 /36


Annex No. 3 Typical design of ball valves K92.2x, DN 80 to 100 (NPS 3“ to NPS 4")

Sheet 2/2

Material specification of ball valves DN 80 to 100 (NPS 3“ to NPS 4")

CS = CARBON STEEL



1 BODY A 350 LF2 3.1

2 BODY CAP

3 BALL A350 LF2 + ENP – 900 HV 3.1

4 STEM AISI 4140+ ENP

or 1.4021 (QT700) 3.1

5 SEAT – COMPLETE A350 LF2+ENP+HNBR-ED 2.1


8 BEARING BODY 1.0577 2.1

12, 17 THRUST BEARING CS+PTFE 2.1

14, 16 PLAIN BEARING

33 SCREW A320 L7+ Zn 2.2

40,42 PIN CS 2.1

52 PACKING RING EXP. GRAPHITE 2.1

55,57,58 O-RING HNBR90 ED 2.1

62 GASKET GRAPHITE + SS 2.1


91, 99 SPRING SS 2.1

MPP-AG-K92-08/2015 /36


Annex No. 4 Typical design of ball valves K92.1x and K92.2x for DN 150 (NPS 6") and larger

Sheet 1/2

Sectional view drawing of ball valve DN 150 to 1400 (NPS 6“ to 56“)

MPP-AG-K92-08/2015 /36


Annex No. 4 Typical design of ball valves K92.1x and K92.2x for DN 150 (NPS 6") and larger

Sheet 2/2

Material specification of ball valves DN 150 to 1400 (NPS 6“ to 56“)

CS = CARBON STEEL


* - BOLTED DESIGN ONLY


1 BODY (WELDMENT) A 350 LF2, A694 F52, A694 F60, A694 F65

3.1 2 BODY CAP

3 BALL A350 LF2 + ENP – 900 HV 3.1

4 STEM AISI 4140+ENP

or 1.4021 (QT700) 3.1

5 SEAT – COMPLETE A350 LF2+ENP+HNBR-ED 2.1


8 BEARING BODY 1.0577 2.1

9 BEARING RING 1.0577

12, 17 THRUST BEARING CS+PTFE 2.1

15, 16, 18 PLAIN BEARING CS+PTFE 2.1

19 ISO FLANGE 1.0566 2.1

30* STUD BOLT A320 L7+Zn 2.2

31* NUT A194Gr.7+Zn 2.2

33, 35 SCREW A320 L7+Zn 2.2

40, 41, 42 PIN CS 2.1

51 LIP SEAL RPTFE 2.1

52, 53, 60* SEAL GRAPHITE 2.1

55, 57*, 58 O-RING HNBR + ED 2.1

56 RING PTFE 2.1


92 SPRING SS 2.1

94 SUSPENSION CS + Zn 2.1

95 FOOT CS + Zn 2.1

MPP-AG-K92-08/2015 /36


Annex No. 5 Typical design of ball valves K92.3x

Sheet 1/2

Sectional view drawing of ball valve

DETAIL G – bolted design DETAIL G – fully welded design

MPP-AG-K92-08/2015 /36


Annex No. 5 Typical design of ball valves K92.3x

Sheet 2/2

Material specification

CS = CARBON STEEL



1 BODY A 350 LF2 3.1

2 BODY CAP

3 BALL A182 F316, F51 3.1

4 STEM A182 F316 3.1

5 SEAT – COMPLETE 2.1

5/1 SEAT A182 F316+PEEK

5/2,5/3 O-RING HNBR + ED

5/4 BK-RING PTFE

5/5 SPRING SS



10 PLUG OR BALL VALVE A350 LF2 + HNBR + ED 2.1

12,17 THRUST PLAIN BEARING SS + PTFE 2.1

16,18 RADIAL PLAIN BEARING SS + PTFE 2.1

19 ISO FLANGE 1.0566 2.1

20 NOZZLE CS 2.1

21 SEALANT INJECTION VALVE

CS 2.1

22 CHECK VALVE SS 2.1

30 STUD BOLT A320 L7+Zn 2.2

31 NUT A194 Gr.4+ Zn 2.2

33,34,35 SCREW A320 L7+Zn 2.2

52,60,62 SEAL GRAPHITE 2.1

55,57,58 SEAL HNBR + ED 2.1

90,91 SMALL BALL, SPRING SS 2.1

94,95 SUSPENSION, FOOT CS+Zn 2,1

MPP-AG-K92-08/2015 /36


Annex No. 6 Typical design of ball valves K92.3х for higher temperatures

Sheet 1/2

DETAIL G – bolted design

MPP-AG-K92-08/2015 /36


Annex No. 6 Typical design of ball valves K92.3х for higher temperatures

Sheet 2/2

Material specification


1 BODY A 350 LF2 3.1

2 BODY CAP

3 BALL A182 F316, F51 3.1

4 STEM A182 F316 3.1

5 SEAT – COMPLETE 2.1

5/1 SEAT A182 F316+PEEK

5/2,5/3 O-RING HNBR + ED

5/4 BK-RING PTFE

5/5 SPRING SS

6 STUFFING BOX A 350 LF2 3.1


10 PLUG OR BALL VALVE A350 LF2 + HNBR + ED 2.1

12,17 THRUST PLAIN BEARING SS + PTFE 2.1

16,18 RADIAL PLAIN BEARING SS + PTFE 2.1

19 ACTUATOR FLANGE 1.0566 2.1

20 NOZZLE CS 2.1

21 SEALANT INJECTION VALVE

CS 2.1

22 CHECK VALVE SS 2.1

30 STUD BOLT A320 L7+Zn 2.2

31 NUT A194 Gr.4+ Zn 2.2

33,34,35 SCREW A320 L7+Zn 2.2

58,60,62 SEAL GRAPHITE 2.1

55 SEAL HNBR + ED 2.1

64 ADAPTER CS+Zn 2.1

65 PACKING GLAND CS+Zn 2.1

66 GLAND FLANGE CS+Zn 2,1

67,68 STUD BOLT, NUT A320 L7+Zn, A194 Gr.4+Zn 2.1

90,91 SMALL BALL, SPRING SS 2.1

94,95 SUSPENSION, FOOT CS+Zn 2.1

MPP-AG-K92-08/2015 /36


Annex No. 7 Examples of ball valves with accessories

Sheet 1/4

Typical ball valve design for above-ground installation

with seat sealant injection device, with venting and draining by means of plugs

MPP-AG-K92-08/2015 /36



Sheet 2/4


with seat sealant injection device, with venting and draining by means of ball valves

MPP-AG-K92-08/2015 /36



Sheet 3/4


with seat sealant injection device, with venting and draining by means of ball valves

MPP-AG-K92-08/2015 /36



Sheet 4/4

Typical ball valve design for underground installation with underground set,

bypass, seat sealant injection device, with venting and draining by means of ball valves

MPP-AG-K92-08/2015 /36


Annex No. 8 Recommended method of ball valve slinging

Sheet 1/1

1. Slinging with utilization of four eyes

2. Diagonal slinging with utilization of

two eyes

LEGEND:

1. Recommended methods of slinging are shown. Other methods of slinging at the User’s risk only!

2. It is not allowed to use the operating device for slinging purposes!

MPP-AG-K92-08/2015 /36


Annex No. 9 List of applicable standards Sheet 1/1

API Spec 6D Specification for Pipeline and Piping Valves

API 598 Valve Inspection and Testing API 607 Fire Test for Quarter-Turn Valves and Valves Equipped with Nonmetallic Seats API 608 Metal Ball Valves – Flanged, Threaded, and Welding Ends API 6FA Specification for Fire Test for Valves API 5L Specification for Line Pipe

ANSI B16.10 Face-to-Face and End-to-End Dimensions of Valves ANSI B16.25 Buttwelding Ends ANSI B16.34 Valves – Flanged, Threaded, and Welding End ANSI B16.47 Large Diameter Steel Flanges ANSI B16.5 Pipe Flanges and Flanged Fittings

ČSN EN 558-1,2 Industrial valves – Face-to-face and centre-to-face dimensions of metal valves for use

in flanged pipe systems

ČSN EN 1092-1 Flanges and their joints – Circular flanges for pipes, valves, fittings and accessories,

PN-designated – Part 1: Steel flanges

ČSN EN 10204 Metallic products – Types of inspection documents

ČSN EN 12266-1 Industrial valves – Testing of valves – Part 1: Pressure tests, test procedures and

acceptance criteria – Mandatory requirements

ČSN EN 12266-2 Industrial valves – Testing of valves – Part 2: Pressure tests, test procedures and

acceptance criteria – Supplementary requirements

ČSN EN 12570 Industrial valves – Method for sizing the operating element

ČSN EN 14141 Valves for natural gas transportation in pipelines – Performance requirements and

tests

ČSN EN ISO 5211 Industrial valves – Part-turn valve actuator attachment

ISO 5208 Industrial valves – Pressure testing of metallic valves

PED 2014/68/EU Directive 2014/68/EU of the European Parliament and of the Council on the

harmonisation of the laws of the Member States relating to the making available on

the market of pressure equipment

STEEL BALL V K92 WITH TRUNNION MOUNTED BALL · The Directions for Installation and Operation apply...

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