Kerotest WELDBALL Manuale utente

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

1 OF 17

KEROTEST WELDBALL®BALL VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

Table of Contents

1INTRODUCTION .......................................................................................................................................................................................................3

1.1 SCOPE...................................................................................................................................................................................................................3

1.2 REFERENCES .........................................................................................................................................................................................................3

2ENVIRONMENTAL, HEALTH, AND SAFETY...........................................................................................................................................................3

2.1 WARNINGS AND SYMBOLS.......................................................................................................................................................................................3

2.2 RISKS....................................................................................................................................................................................................................3

3PRODUCT DESCRIPTION AND FEATURES............................................................................................................................................................3

4IDENTIFICATION AND MARKINGS..........................................................................................................................................................................4

4.1 CAUTION TAG.........................................................................................................................................................................................................4

4.2 VALVE I.D. TAG (SAMPLE).......................................................................................................................................................................................4

5FACTORY AND FIELD APPLIED COATINGS..........................................................................................................................................................5

6UNLOADING AND STORAGE..................................................................................................................................................................................5

7VALVE INSTALLATION............................................................................................................................................................................................6

7.1 GENERAL CONSIDERATIONS FOR VALVE INSTALLATION..............................................................................................................................................6

7.2 INSTALLATION OF VALVE WITH WELDED CONNECTIONS .............................................................................................................................................6

7.3 INSTALLATION OF VALVE WITH FLANGES...................................................................................................................................................................7

7.4 INSTALLATION OF VALVE WITH SCREWED ENDS ........................................................................................................................................................8

7.5 INSTALLATION AT THE END OF PIPELINE....................................................................................................................................................................8

7.6 PRESSURE TESTING ...............................................................................................................................................................................................9

8OPERATION..............................................................................................................................................................................................................9

8.1 GENERAL VALVE OPERATION ..................................................................................................................................................................................9

8.2 OPERATING TORQUE AND CRITICAL TORQUE............................................................................................................................................................9

9TROUBLESHOOTING.............................................................................................................................................................................................10

9.1 VALVE SHUT-OFF.................................................................................................................................................................................................10

9.2 VALVE PACKING LEAKAGE.....................................................................................................................................................................................10

10 MAINTENANCE ......................................................................................................................................................................................................10

10.1 RECOMMENDED PERIODIC PREVENTATIVE MAINTENANCE........................................................................................................................................10

10.2 GEAR OPERATOR REMOVAL..................................................................................................................................................................................10

10.3 GEAR OPERATOR REINSTALLATION........................................................................................................................................................................11

10.4 GEAR OPERATOR ADJUSTMENT.............................................................................................................................................................................11

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

2 OF 17

10.5 STEM SEAL O-RING REPLACEMENT ......................................................................................................................................................................12

10.6 REPLACING OPERATING SQUARE WITH GEAR OPERATOR ON NPS 6FP /8RP VALVES ............................................................................................13

11 COMPONENTS .......................................................................................................................................................................................................14

12 PHYSICAL SPECIFICATIONS................................................................................................................................................................................15

13 FACTORY TESTING...............................................................................................................................................................................................16

14 DOCUMENT REVISION HISTORY:.........................................................................................................................................................................17

Table of Tables

Table 1 Operating and Critical Torque by Valve Size.......................................................................................................................................................9

Table 2 Stem Seal Repair Kits..........................................................................................................................................................................................12

Table 3 Valve Dimensions, Weight, and Cv.....................................................................................................................................................................15

Table 4 Minimum Test Pressure and Durations..............................................................................................................................................................16

Table of Figures

Figure 1 P-T Chart ..............................................................................................................................................................................................................4

Figure 2 Caution Tag..........................................................................................................................................................................................................4

Figure 3 Valve I.D. Tag .......................................................................................................................................................................................................4

Figure 4 Lifting the Valve...................................................................................................................................................................................................5

Figure 5 Horizontal Installation..........................................................................................................................................................................................6

Figure 6 Vertical Installation..............................................................................................................................................................................................6

Figure 7 Welding in Vertical Position................................................................................................................................................................................7

Figure 8 Welding in Vertical Position................................................................................................................................................................................7

Figure 9 Welding in Horizontal Position............................................................................................................................................................................7

Figure 10 Bolt Torquing Pattern Examples.......................................................................................................................................................................8

Figure 11 Do Not Use at the End of a Pipeline..................................................................................................................................................................8

Figure 12 End of Pipeline Pup and Cap.............................................................................................................................................................................8

Figure 13 Manual Gear Adjustment.................................................................................................................................................................................11

Figure 14 Stem Seal..........................................................................................................................................................................................................12

Figure 15 Operating Square Components ......................................................................................................................................................................13

Figure 16 Weldball Components .....................................................................................................................................................................................14

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

3 OF 17

1 INTRODUCTION

1.1 Scope

This manual defines for gas utility customers the procedures for handling, storage, operation, and common

repairs on the Weldball®line of steel ball valves used in gas distribution or pipeline applications manufactured by

Vexve.

1.2 References

•API Std 1104 Welding of Pipelines and Related Facilities

•ASME Boiler and Pressure Vessel Code

•ASME B1.20.1 Pipe Threads, General Purpose, Inch

•ASME B16.5 Pipe Flanges and Flanged Fittings: NPS ½ through NPS 24, Metric/Inch Standard

•ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves

•ASME B16.34 Valves Flanged, Threaded, and Welding End

•ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly

2 ENVIRONMENTAL, HEALTH, AND SAFETY

2.1 Warnings and Symbols

Within this document, you will see the following symbols:

General Advisory Marking - for information or operational procedures, order of operation, etc.

Caution Marking –note designates an action or step that may result in personal injury or

death or equipment/property damage. Personnel performing activities should be fully aware of

the hazards and take necessary steps to prevent any injuries, damage, or unsafe operating/repair

condition.

2.2 Risks

NOTE: Failure to follow the instructions in this manual when installing, operating, and/or

performing maintenance on the valve could lead to loss of life and/or damage to the environment.

3 PRODUCT DESCRIPTION AND FEATURES

Weldball ball valves are welded steel valves used in natural/fuel gas distribution pipelines and are available in

NPS 3/4 through NPS 12, Full Port (FP) / Reduced Port (RP), and in ASME/ANSI Pressure Classes 150 and

300, and 500 CWP.

The valve end connections are welded, flanged (raised and flat face), weld-by-flange, and some threaded

configurations. Other configurations or options are available upon request.

The intent of this manual is to acquaint our customers with installation, operation, and maintenance/service

repair techniques for Weldball ball valves.

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

4 OF 17

Below are some of the features of the Kerotest Weldball steel ball valves:

•Low maintenance

•No gland tightening

•No lubrication required

•Polished 304 stainless steel ball

•Sealed-for-life welded steel construction

•Double O-ring stem seal

•Weather sealed operating square

•Lightweight

•Low operating torque

•Bidirectional installation and operation

•Ultra-Stop* feature for excessive limit torques

•Locking mechanism available on NPS 6 RP and smaller

•Gear Operator option for NPS 6 FP and larger

*The Kerotest Ultra-Stop feature is a heavy duty operating square limit stop designed to accommodate applied

excessive torque during field operation. It can be identified by a notched plate welded to the valve neck and a

pin on the operating square within the notch or as an integral collar and pin. This feature is available on sizes

NPS 3/4 through NPS 8 RP.

4 IDENTIFICATION AND MARKINGS

4.1 Caution Tag

Caution tags are attached to valves with a butt weld end.

4.2 Valve I.D. Tag (Sample)

I.D. tags are attached to valve body. Each valve will have an

identification label attached with the following information:

•Manufacturing company

•Valve Size (NPS)

•ASME/ANSI Pressure Class

•Pressure/Temperature Ratings

•Body and Stem Materials

•Valve Length

•Serial Number

•Date of Manufacture

Figure 1 P-T Chart

Figure 2 Caution Tag

Figure 3 Valve I.D. Tag

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

5 OF 17

5 FACTORY AND FIELD APPLIED COATINGS

The standard factory coating supplied on Weldball is a gray epoxy powder coat not suitable for outdoor or buried

service. It is recommended the customer apply an appropriate coating to the entire valve exterior.

Additionally, the valve may be ordered from the factory with a two-component, high solids epoxy coating rated

for outdoor or buried service.

If a valve appears corroded prior to installation, particularly on the internal components, contact Kerotest to

determine if the valve can be installed.

Fusion Bonded Epoxy (FBE) and/or coatings that require applied heat should not be used. These restrictions

also apply to supplied gear operators. Coatings should be applied per the coating manufacturer's requirements

and specifications for preparation and environmental conditions.

6 UNLOADING AND STORAGE

General Considerations for Unloading and Storage

•Check that the contents of the delivery are as ordered. Check that the valve and related equipment have not

been damaged during transportation.

•Store the valve carefully before installation, preferably in a well-ventilated, dry place, on a shelf or a wooden

grid to protect it from moisture.

•The valve must be transported to the installation site in a sturdy package. Do not remove the flow port or

flange protectors before installation. Protect the valve from sand, dust, and other impurities.

•Use lifting ropes when lifting the large size valves. Do not lift the valve by its operating square or stem (see

Figure 4). Valves are top-heavy and can shift or rotate in the sling.

•The valve is shipped in the open position and should remain open while in storage

•When stored in the original packaging in a well ventilated, clean, dry environment the shelf life is unlimited.

NOTE: Take the weight of the valve into account when handling it.

Figure 4 Lifting the Valve

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

6 OF 17

7 VALVE INSTALLATION

7.1 General Considerations for Valve Installation

CAUTION: Incorrect installation may result in serious personal injury and damage equipment or

facilities. These instructions must be followed carefully when installing the valve.

These general instructions do not cover all possible operating scenarios. For more specific guidance on

the use of the valve or its suitability for an intended use, please contact Kerotest.

•Do not remove the flow port protectors before installation. Keep the valve protected from sand, dust, and

other impurities.

•If the valve was delivered with a gear operator installed, avoid removing it during installation.

•Incorrect re-installation or adjustment of the gear operator can result in leakage.

•Exercise extreme caution when testing the valve before installation in the pipeline.

•The valve or valve assembly must not be lifted with the operating square or the gear operator input shaft

(See Figure 4). Dropping or incorrect lifting of the valve can result in personal injury or equipment damage.

•Use one of the allowed lifting methods shown in Figure 4.

•Prior to installation remove the flow port protectors and check that the inside of the valve is clean.

•Recommended installation position for the valve is with the input shaft facing up or in the horizontal position.

See Figure 5 and Figure 6.

CAUTION: The pipeline and valve shall be cleaned prior to installation as any welding debris or

other impurities can damage the valve.

Figure 5 Horizontal Installation

Figure 6 Vertical Installation

7.2 Installation of Valve with Welded Connections

During welding the ground must be connected to the pipe of the valve body or the pipeline.

Ground cable should be connected to the pipe on the same side as the welding seam. As current may

damage the valve seal, never connect the ground to the valve neck, operating square flange, or

operating square.

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

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•The welder must be qualified in accordance with relevant sections of API 1104, section IX of the ASME

Boiler and Pressure Vessel Code (ASME BPVC), or company approved and qualified welding standard.

•Recommended welding method is manual metal arc welding. Valve pipe end material is carbon steel with a

34ksi tensile strength.

•Do not overheat the valve. Use cooling during the welding such as a wet fabric to protect the valve seat from

excessive heat. Cool down the valve after welding before normal operation. After welding, the valve may not

be opened and/or closed before it has cooled down.

•The valve can first be bridged to the pipeline using spot welding, with 4–8 seams alternately on opposite

sides of the valve.

•The valve must remain open during installation and welding to ensure the seal surfaces are not damaged.

•The ends of the pipes must be parallel to the valve and correctly aligned.

•The length of the valve must be the same as the distance between the pipe ends, taking into consideration

the welding gaps.

•Diameter and wall thickness of the pipes must be compatible with welding ends of valve.

When installed in a horizontal position:

When welding the valve, it must be in the open position to protect the surface of the ball from welding

contamination (See Figure 9).

When installed in a vertical position:

When making the upper seam welding, the valve must be open to protect the surface of the ball from welding

contamination (See Figure 7). When making the lower welding seam the valve must be closed to avoid the

overheating of the valve (See Figure 8).

Figure 7 Welding in Vertical

Position

Figure 8 Welding in Vertical

Position

Figure 9 Welding in Horizontal

Position

When welding the upper seam the

valve must be in open position.

When welding the lower seam the

valve must be in closed position.

The valve must be in open position.

7.3 Installation of Valve with Flanges

•Valve may be installed only by a qualified operator.

•The valve must remain open during installation to ensure that any residue or dirt does not damage the

sealing faces.

•The sealing faces of the pipe flanges must be parallel to the valve sealing faces and correctly aligned.

•The length of the valve must be the same as the distance between the flanges in the pipeline, taking into

consideration the gasket.

•The valve flanges conform to standard ASME B16.5.

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

8 OF 17

•Bolting and gasketing practice conforming to ASME B16.5 is suggested. Bolts and gaskets used on

installation (not included with the valve) must be selected to match operating conditions, temperature,

pressure and medium. Gasket dimensions must be compatible with sealing faces of the flanges.

•Standard end flange facing is 1/16" raised face with phonographic finish. Some valves may be ordered with

a flat face finish. Contact Kerotest or your distributor for further information and availability of flat face

finished valves. Flat face finished valves are slightly shorter than standard faced valves, as allowed per

ASME B16.10.

•End flange bolts should not be fastened in consecutive order. Bolts should be tightened in a cross pattern

similar to Figure 10. Two passes should be made, one pass for half tightness and a final pass for full

tightness. ASME PCC-1 can provide guidelines for assembly of bolted flanges.

Figure 10 Bolt Torquing Pattern Examples

7.4 Installation of Valve with Screwed Ends

•Screwed End Valves are only available on valves ≤ NPS 2 with class 300 ratings.

•Valve ends have NPT pipe threads machined per ASME B1.20.1

•Apply (sparingly) a suitable threading compound to the threads on the pipe.

•Start threading by hand, use wrench to tighten. Do not cross-thread.

7.5 Installation at the End of Pipeline

NOTE: For valves located at the end of a pipeline, it is recommended to install a short pipe pup with a

pressure rated cap to the valve outlet to reduce potential corrosion issues and gas leaks caused by unintended

operation. Following installation, the pup and cap section should be pressurized to match the main pipeline.

(See Figure 11 and Figure 12)

Figure 11 Do Not Use at the End of a Pipeline

Figure 12 End of Pipeline Pup and Cap

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

9 OF 17

7.6 Pressure Testing

During installed valve testing, maximum allowable test pressure is 1.1x the marked rating when the valve is

closed and 1.5x the marked rating when the valve is open.

8 OPERATION

During closing, the valve ball is rotated against the elastomeric seat seals until the solid portion of the valve ball

contacts the seat seals. Positive contact pressure is maintained between the ball and the seat seals by Belleville

springs behind each seat seal. On valves without gear operators, a stop on the operating square provides a

positive stop against the locking plate in the full open and full closed position.

8.1 General Valve Operation

Do not use excessive torque to operate the valve which may damage the valve or the gear

operator!

•Standard valves are equipped with a 2” operating square and can be operated with an adaptor tool or

wrench.

•Standard valves operate clockwise to close, and counterclockwise to open.

•Valve should not be operated as a throttling valve between full open and full close.

•Valves with gear operators will take multiple turns to open or close.

8.2 Operating Torque and Critical Torque

Excessive or unlimited operating torque will ultimately cause failure of the stop pin or Ultra-Stop. The chart

below indicates the minimum torque value where a failure will occur.

Table 1 Operating and Critical Torque by Valve Size

Nominal Valve

Size

(NPS)

Maximum Operating

Torque

(ft-lbs)

Minimum Shear Pin

Failure Torque

(Valves without Ultra-Stop)

(ft-lbs)

Nominal Ultra-Stop

Failure Torque

(ft-lbs)

3/4

1-1/4

150

800

150

800

100

150

1000

200 (Class 150)

300 (Class 300)

500

1500

350 Without Gear

Operator

The stop failure mechanism is

designed into the gear operator

N/A

Only supplied with gear

operator

The stop failure mechanism is

designed into the gear operator

N/A

Only supplied with gear

operator

The stop failure mechanism is

designed into the gear operator

N/A

KEROTEST WELDBALL BALL VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1484

REV.:

DATE:

03MAR2022

PAGE:

10 OF 17

9 TROUBLESHOOTING

9.1 Valve Shut-Off

If seat shut-off is unattainable, there may be some debris trapped between the valve ball and the seat seals.

Reopen the valve full and cycle until desired shut-off has been obtained. If positive shutoff is still not obtained,

please contact Kerotest.

9.2 Valve Packing Leakage

Valve stem leakage may occur if the stem or stem seal O-rings are worn, damaged, or operated outside the

valve temperature limitations. See section 10.5 for replacement of the stem seal O-ring.

10 MAINTENANCE

10.1 Recommended Periodic Preventative Maintenance

The following is recommended periodically:

•Check that the valve is free from surface damage and shaft leaks and repair any damage.

•Fully cycle the valve annually to clear any buildup of debris on the ball and seat surfaces.

•To ensure long-term operational reliability, even when seldom used (around ten times a year or less), the

following is recommended:

Approximately six months after installation and then once a year, inspect the valve for shaft leaks, check

the gear operator / operating square, and ensure the tightness of the screws between valves.

10.2 Gear Operator Removal

The gear operator can be removed when the valve is under pressure.

NOTE: Avoid removing the gear operator from the valve. The gear operator has been adjusted at the

factory to ensure that the valve is leak-free. If the gear operator is removed, it may have to be re-adjusted.

Kerotest does not accept responsibility for adjustments of customer installed gear operators. Refer to section

10.4 for adjustment instructions.

CAUTION: Incorrect disassembly may cause serious personal injuries as well as malfunctions and

damage to the equipment. Extreme caution must be exercised during the disassembly!

Part numbers mentioned in this section refer to Figure 13.

1. Turn the valve to the open position before removing the gear. Valve opens when you turn the operating

square of the gear counterclockwise.

2. Turn the operating square towards the close position (clockwise) to release forces between the valve and

the gear to make it easier to remove the gear. To do this, turn the operating square only until it rotates easily.

3. Remove the bolts (2) of the position indicator plate and remove the position indicator plate (3). Mark the

position of the valve stem to the gear to make it easier to reinstall the gear back into the right position.

4. Remove the attachment bolts of the gear and then remove the gear.

Indice

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