VPC Erection, Installation, Commissioning, Operation and Maintenance Procedures For Trunnion Mounted Ball Valves

TANAP
TRANS ANATOLIAN NATURAL GAS PIPELINE

PROJECT
Project Rev Status
Doc.No. VPC-MAN-CST-GEN-003
P3-1 RE-IAA
VDR Code : P05 PO No.
TNP-TPG-BVPC-CNT-001
Document VPC ERECTION, INSTALLATION, COMMISSIONING, OPERATION
Title : AND MAINTENANCE PROCEDURES FOR TRUNNION MOUNTED
BALL VALVES
Equipment BALL-PLUG VALVES
Description :
Tag Nos. SEE DOCUMENT
Vendor:
VALVITALIA S.p.A.
Vendor
Document No. MAN00-2017-039 Rev 2+CRS
Signature &
Date
C1 / APP - Reviewed & accepted. Manufacture may Proceed.For
documents status IFR\IFA, resubmit as IAA at next revision code.
For documents status IAA, no action required.
C2 / AWC - Reviewed & accepted as marked. Manufacture may
proceed. For documents status IFR\IFA, resubmit as IAA at next
revision code.
For documents status IAA, resubmit as Re-IAA at next revision code.
C3 / RWC - Reviewed & returned. Manufacture shall NOT
proceed.For documents status IFR\IFA, resubmit for review Re-
IFR\IFA at next revision code.
For documents status IAA, resubmit as IFA at next revision code.
C4 / IFI -Review not required. Manufacture may proceed
Resubmit for information as IFI at next Revision Code.
C5 / REJ - REJECTED Manufacture shall NOT proceed.
Revise document and resubmit for review.
Remarks:-
VPC ERECTION, INSTALLATION, COMMISSIONING,
OPERATION AND MAINTENANCE PROCEDURES FOR VPC-MAN-CST-GEN-003
TRUNNION MOUNTED BALL VALVES
Revision:P3-1 Status: RE-IAA Date: 30/11/17 Page 3 of 32
DOCUMENT REVISION HISTORY SHEET

Revision
Rev. Date Issued Update / Amendment Details
Description
P3-C IFR 17/01/17 Issued for review
P3-0 IAA 07/08/17 Issued AS APPROVED
P3-1 RE-IAA 30/11/17 Re-Issued AS APPROVED

VPC ERECTION, INSTALLATION,
COMMISSIONING, OPERATION AND
MAINTENANCE PROCEDURES FOR Doc. no. MAN00-2017-039
TRUNNION MOUNTED BALL VALVES rev.2
VPC ERECTION, INSTALLATION, COMMISSIONING,

OPERATION AND MAINTENANCE PROCEDURES FOR
VALVE
TYPE 55
VALVE
TYPE 54
COMMISSIONING, OPERATION AND Doc. no. MAN00-2017-039
MAINTENANCE PROCEDURES FOR rev.2
REVISION SHEET
Rev. Date Prepared Verified Approved

0 12-01-17 P.Malchiodi L.Bariani P. Donini
Page 2 of 29
INDEX
1.INTRODUCTION ................................................................................................................................... 4
1.1.SCOPE ...................................................................................................................................................... 4
1.2.REFERENCE DOCUMENTS ................................................................................................................. 4
1.3.SUITABILITY ......................................................................................................................................... 4
1.4.VALVE MODELS ................................................................................................................................... 4
2.ERECTION............................................................................................................................................ 4
2.1.USE........................................................................................................................................................... 4
2.2.SAFETY PRECAUTIONS....................................................................................................................... 5
2.3.MAIN NAMEPLATE .............................................................................................................................. 5
2.4.ADDITIONAL NAMEPLATE ................................................................................................................ 6
3.INSTALLATION..................................................................................................................................... 6
4.COMMISIONING.................................................................................................................................. 7
5.OPERATION......................................................................................................................................... 8
5.1.CHECKS AND REQUIREMENTS ......................................................................................................... 8
5.2.VENT & DRAIN VALVES FOR TYPE “55” ......................................................................................... 9
5.3.VENT & DRAIN VALVES FOR TYPE “54” ....................................................................................... 10
6.MAINTENANCE.................................................................................................................................. 11
6.1.VALVE DISASSEMBLY ...................................................................................................................... 11
6.1.a.Valve removal from the pipeline ..................................................................................................... 11
6.1.b.Adaptor plate disassembling............................................................................................................ 11
6.1.c.Gland plate disassembling ............................................................................................................... 11
6.1.d.Stem disassembling ......................................................................................................................... 11
6.1.e.Closure disassembling ..................................................................................................................... 11
6.1.f.Seat ring disassembling .................................................................................................................... 12
6.1.g.Ball disassembling ........................................................................................................................... 12
6.1.h.Body and closure control ................................................................................................................. 12
6.2.MAINTENANCE ................................................................................................................................... 13
6.3.LUBRICATION ..................................................................................................................................... 13
6.4.ASSEMBLING ....................................................................................................................................... 13
6.4.a.Closure assembling .......................................................................................................................... 13
6.4.b.Ball assembling ............................................................................................................................... 14
6.4.c.Body assembling.............................................................................................................................. 14
6.4.d.Stem assembling .............................................................................................................................. 15
6.4.e.Gland plate assembling .................................................................................................................... 15
6.4.f. Type “54” lower trunnion assembly assembling............................................................................. 15
6.4.g.Adaptor plate assembling ................................................................................................................ 15
6.5.FINAL RECOMMEDATION ................................................................................................................ 16
7.SPARE PARTS & TOOLING .................................................................................................................. 16
8.ASSEMBLY DRAWING TYPE “55” ........................................................................................................ 17
9.ASSEMBLY DRAWING TYPE “54” ........................................................................................................ 18
10.APPENDIX A) ITEM LIST.................................................................................................................... 19
Page 3 of 29
1. INTRODUCTION
1.1. SCOPE
The purpose of this manual is to furnish the right indications for the installation, use and maintenance of
Side Entry ball valves, with bolted body.
1.2. REFERENCE DOCUMENTS
Use and maintenance manual for valves conformed to the follow specifications:
API 6D / ISO 14313
Directive 97/23/CE (PED)
1.3. SUITABILITY
This document is only for Side Entry ball valves with bolted body, installed on pipeline with operating
conditions described on chapter 4.
1.4. VALVE MODELS
The valves covered by this instruction manual are:

Type “55”: bolted body, trunnion, ball valves 6”full bore and above;
Type “54”: bolted body, trunnion, ball valves up to 6”reduced bore(6”x4”);
The difference between the 2 models are in the ball mounting:
Type “55”: has a ball integral with upper and lower trunnion. The upper trunnion have a “prong”
which is coupled with the stem. Both upper and lower trunnion are housed inside the bearing
retainers(one upper and one lower) which are plates doweled inside the body.
Type “54”: has a lower trunnion which is coupled directly inside the ball lower side. The stem act as a
upper trunnion and is coupled directly in the ball upper side.
The selection between of the above mentioned design is made on a size basis due to economical
reasons.
2. ERECTION
2.1. USE
The VALVITALIA’s Side Entry ball valves are designed for services of flow control in the pipeline
where the valves are in fully open or fully close position. The valves must not be used to regulate the
flow. Improper uses for flow control may invalidate the guarantee.
Page 4 of 29
The valve’s open and close operations shall be done using the instruments furnished and selected for
the valve (wrench, gear, actuator). VALVITALIA refuses any responsibility for manoeuvre done with
different operators.
2.2. SAFETY PRECAUTIONS
Protective clothing and equipment normally required when working with the involved fluid is
recommended.
Depressurize the line and cycle the valve as follows:
Place the valve in the open position and drain the line, cycle the valve to relieve residual pressure in the
body cavity before removal from the line; should the valve be seized in the open or closed position, use
the vent/drain to completely depressurize body cavity. Vent is available only for 6” valves and above. In
case of plug connection, drain and vent shall be used with extreme care and never turned open more than
1/1.5 turns until drain/bleeding occurs through the plug hole. Vent drain plug if completely unscrewed
with valve under pressure may be projected against the operator with danger of injures.
After removal and before any disassembly, cycle the valve again several times.
It is important to refer to the tag fastened on each valve for maximum pressure ratings and material
description.
2.3. MAIN NAME PLATE
The name plate is exposed on VALVITALIA’s valves in accordance to the European
SIZE DN Nominal Diameter Serial N° Serial number

MONTH/ Pruduction Month/Year CLASS Pressure Class
YEAR
BODY Body material PT Hydrostatic shell test pressure
M.O.P./TminMaximum operating pressure STEM Stem material
at minimum operating
temp.
CATEGORY PED(97/23/EC)’s category. M.O.P./Tmax Maximum operating pressure at
maximum operating temp.
DISC Ball material MODULE Evaluation of adopted
conformity.
SEAT Seat material FLUID Fluid type
TYPE Type of valve
FACE TO FACE / END TO END Face to face / end to end dimension
Table 1
Page 5 of 29
The name plate also shows:

-Company logo and address:
Via Tortona 69
Rivanazzano(PV) ITALY
-API logo and license, CE logo(for European community only), ATEX logo(for E.C. only):
2.4. ADDITIONAL NAMEPLATE
According to project requirement an additional nameplate, reporting all the data required by marking
specification, is fixed below the main nameplate described at point 6.1.
In the following table is possible to find all the fields included in the additional nameplate with a brief
explanation
P.O. Purchase order number TAG N° Valve tag number
Client Client name Project Project name
ITEM Valve item number Max design Valve maximum design pressure
pressure as per data-sheet
Design Maximum differential Hydrostatic Hydrostatic shell test pressure
differential pressure used for actuator test pressure
pressure dimensioning
Weight Valve weight.
Table 2
Both the additional and the main nameplate are in double language English/Turkish as per project
requirement.
3. INSTALLATION
Before the valve’s SET-UP, it should be carefully checked in order to verify that there are not evident
damage due to the shipping and handling. It very important verifying that the inside bore of the valve is
free from any foreign particles that might damage the seats and ball.
Use the appropriate lifting hooks to lift the valve; if these are not available, use a sling rope around the
lateral closures or around the body valve; never use the gear, lever or actuator lifting hooks for valve
Page 6 of 29
assembly handling. During handling of the valve, lateral ports must be always close with plywood or
plastic covers to avoid entry of foreign materials and damage to the flange faces.
The valve can be installed in both flow directions and in vertical or horizontal position. If the valve is
operated by pneumatic, hydraulic or gas over oil actuator the valve shall be installed with the stem in
vertical position only. The mounting with stem in horizontal position is possible only if special
requirements, such as drain positioning & lifting lugs layout are agreed between customer and
VALVITALIA and taken care during engineering phase.
During the SET-UP in the pipeline of the flanged valves, ball shall be in close position.
Remove the end flange’s cover, clean the surfaces treated with antirust.
Before joining the bolts between valve and pipeline flanges, insert the suitable gasket among the contact
faces. Bolting screwing up shall be carried out on diametrically opposite bolts. For bolting torque, see
section 2 in this manual.
After valve set-up, proceed to clear the pipeline to remove any foreign materials. Close and open the
valve at least three times and verify the correct operations.
Lever operated valve is open when lever is in line with the pipeline. Valve is close when the lever is
perpendicular to the flow line.
The gear box is arranged such as the hand-wheel is rotated clockwise to close the valve and anti-
clockwise to open. The gearbox has adjustable stops and these are already set-up and must not be
adjusted. To close the valve, rotate the hand-wheel until the position indicator on the gearbox shows close
and the gearbox hits the close stop. To open, rotate the hand-wheel until the position indicator on the
gearbox shows open and the gearbox hits open stop.
Ball valve can be fitted with pneumatic, hydraulic or electric actuators. Specific instructions should be
followed, as provided by actuator manufacturer.
4. COMMISIONING
After valve set-up, proceed to clear the pipeline to remove any foreign materials. Close and open the
valve at least three times and verify the correct operations.
No specific routine maintenance is necessary except operating the valve periodically, even if only
partially, to verify that the valve operation is satisfactory. Gear operators are grease filled and require no
maintenance.
Page 7 of 29
5. OPERATION
5.1. CHECKS OR REQUIREMENTS
Check there is no visible leak from the valve body, closure or other parts before the valve opening or
closing. If any leak is detected, further inspection shall be done to identify the reason of the leak, before
removing the valve from service.
Check there is no visible leak from the actuator, before the valve opening or closing. If any leak is
detected, further inspection shall be done to identify the reason of the leak, before removing the valve
from service.
Check that the valve line and the body cavity are not under pressure before proceed with any dismounting
procedures.
Grease fitting(where injection devices are provided)maybe carried out also when the valve line is under
pressure, due to the presence of security check valves.
Since valves are double piston effect design check that the valve is periodically vented in order to
depressurize the valve body cavity. The pressure maybe relieved by the special vent and drain bleeder or
DBB valves provided.
It’s required to have sealant and Sealant injection pumps always available for maintenance or operational
purposes;
A batch of standard spare parts are always required for “routine”maintenance. If those particulars are not
included in the original scope of supply have to be requested to VALVITALIA through a service order.
Page 8 of 29
5.2. VENT & DRAIN VALVES FOR TYPE “55”
Side entry ball valves have been provided with drain and vent double block & bleed valves, used to
relieve the built up pressure, which is retained inside the valve body by the double piston effect seats.
Both drain and vent valve could relieve the pressure while open since the main valve is gas service.
The drain is also used to dump the test water after hydro-testing, in order to facilitate the liquid bleed,
the drain is located at the lowest point of the valve body. The vent instead is located at the highest
possible point therefore could relieve only gas.
The discharge of fluid could be dangerous since high pressure is involved, due to this reason both
drain and vent connection facing the rear side of the valve.
Since the valve body is bolted the vent & drain are connected to the valve by means of flanges.
Figure 1
Since drain and vent valves are floating the DBB feature is granted by the twin ball that allow to stop
the flow on each direction. A needle valve is provided between the 2 balls to internal pressure when
the 2 balls are closed.
The valve is open while the lever is parallel to the pipe and closed when the lever is perpendicular to
the pipe.
Page 9 of 29
5.3. VENT & DRAIN VALVES FOR TYPE “54”
Due to the small dimensions of valve types “54” drain and vent are combined in a single hole, located at
the lowest point of the lower trunnion. This point has been selected since will facilitate the complete
emptying of the valve body from the liquids(during test phase), the same connection can be used to vent
the valve body from pressured gas.
The discharge of fluid could be dangerous since high pressure is involved, due to this reason drain-
vent connection is faced on the rear side of the valve.
Differently for valve type”55” the connection with DBB valve is possible only by NPT threaded
connection for size 6” reduced bore(6”x4”), since there is not enough space to machine a flanged
connection on the body.
Figure 2
On smaller valves 1 ½” up to 4” (full bore) the use of DBB floating valve is not applicable due to its large
dimensions. It has been agreed that the connection shall be done using a NPT bleeder plug:
Figure 3
Page 10 of 29
6. MAINTENANCE
6.1. VALVE DISASSEMBLY
6.1.a. Valve removal from the pipeline
Isolate the pipeline and make sure that the valve is not under pressure, rotate the ball in open
position. Unscrew the drain plug (type”54”)or open the DBB valve(type “55”) (particular 028 of the
BOM) and drain the fluid thought the drain hole in the bottom of the valve.
Rotate the ball in close position, remove the valve from the pipeline and put the valve in a position
simple to disassembly the top part
6.1.b. Adaptor plate disassembling
Unscrew the key’s capscrew if it is present and remove the key (021) from the stem (004).
Unscrew the adaptor plate’s cap-screws(010)and pull up the adaptor plate (020) from its position.
6.1.c. Gland plate disassembling
Remove the gland bushing(006). If present, unscrew the grease fitting (030) from the gland plate
(005), pull the adaptor plate pins(036) off and unscrew the gland plate’s cap-screws (009). Now the
gland plate can be removed from its housing. Pull up the gland plate helping with two opposite
screwdrivers to lever, pay attention to score the stem during the operation.
Remove the gland plate (005), remove the stem’s fire safe seal (019), stem’s O-rings (012) and clean
it with a degreasing fluid and verify the integrity of the O-rings. Make the same operation for the
gland plate O-ring/graphite (015 & 018). In case of o-ring’s damages, it should be substituted.
6.1.d. Stem disassembling
Screw on the top of the stem a lifting hook and pull up the stem (004).
Remove the upper thrust washer (022) and degrease, verify the integrity and in case of damages, it
should be substituted.
6.1.e. Closure disassembling
Put the valve in vertical position with a closure (002) turned to the ground.
Unscrew and remove the body’s nuts (008) and the bolts (007). Pull up the closure (002) in order to
avoid sudden movements follow the vertical axes.
Remove body-closure’s O-ring and graphite (011-016) from the closure.

Verify the O-rings integrity after cleaning and degreasing and if they are damaged, they should be
substituted.
Page 11 of 29
6.1.f. Seat ring disassembling
Remove the seat rings (025& 026 for valve type 55 or only 025 for valve type “54”) from the
closures by using two opposite screwdrivers to lever.
After cleaning and degreasing them, verify that seat rings are not scored. If there are some damages,
they may be removed by using rubbing paper.
For valve type 55, in case of damages of the seat’s seal O-ring (013), it must be replaced. For valve
type 54, control the insert and, if it is damaged, substitute the entire seat ring with insert (025-065).
Extract the inner seat ring (025), remove the grease U-cup packing (only for valve type 55 position
048) and seat seal o-ring (014) and execute the cleaning operation, with a wet cloth. Verify by
flexion that the radial surface have no laceration that requires the complete replacement of the rings.
Clean the seat seal housing and the closure seal housing before replacing the seal in position.
Extract the seat’s spring (027) from their housing and then clean well. Moreover verify that they are
not flattened or compressed, in this case they need to be replaced.
6.1.g. Ball disassembling
For the valve type “55”, extract the ball (003) with the relative supports (032), for this operation use
a non metallic rope through the ball bore and the side of the ball.
Remove the centering pins (046) and rest the ball and the support assembly on a clean place, in order
to clean the ball’s surface and remove the supports from the ball’s hubs; pay attention to the two
bearings (033) and to the lower trust washer (023). Clean and control the bearing (033) and the lower
trust washer (023); if they are damaged they should be substituted.
For the valve type 54, unscrew the cap-screws (052) and remove the lower trunnion; (051) pay
attention to the bearing on the lower trunnion (058), at this point you can pull up the ball.
Disassemble the closure still bolted on the body(that is the one where the valve was resting),
following the same procedure described at section 9.5.
6.1.h. Body and closure control
Clean the body in every part with an appropriate solvent.
If the valve has been extracted from the line, it will be possible to check it accurately. Particularly,
it will be possible to check the closures in the seal areas in order to verify the existence of corrosions
or frictional pick-up.
Page 12 of 29
6.2. MAINTENANCE
The ball valves don’t require periodic lubrications.
The ball valve’s maintenance should be made only with the valve removed from the pipeline.
Clean accurately the metallic parts using an oil wet cloth. Do not clean elastomers with solvents. In case
of damage of soft parts, replace them.
Check accurately the external surface of the ball and the seats to find damages, if any. If the ball and the
seats are slightly scratched, it is possible to remove the damages by wiping them lightly with sand paper
roughness maximum 1200. This operation should be executed from technical staff. In doubt and for better
results, we suggest to substitute the damaged parts with new ones.
Verify the functionality of the valve making one manoeuvre cycle per year.
6.3. LUBRICATION
Every metallic surface in contact with the ball during the ball movement, should be lubricated with
MACON GREASE C2 or equivalent grease.
The thrust washer (022&023) and bearing (033) are auto-lubricated, so them not require any lubrication.
Lubricate the screw thread with anti - frictional pick up
The emergency seal should be made using grease NORDSTROM 555.
6.4. ASSEMBLING
Before starting to reassemble the valve, control that every parts are accurately cleaned and free from any
external materials. Ensure that the assembly will be made in a clean area and also that every packaged
parts are kept as cleanest as possible. Substitute all the fire safe gaskets since they can not be utilized after
the disassembling. The assembling instructions are opposite to the disassembling instructions. For a
correct screwing of the bolting, see the table 3 closing torque.
For valve part numbers refer to typical assembly drawing provided in sections 8(type 55)& 9(type54).
6.4.a. Closure assembling
Position the closure (002) which will situated downwards with the area of seat lodging facing
upwards.
Page 13 of 29
Insert the seat’s springs (027) in the housing hole in the closure(type”55”) or in the bottom of the
seat groove(type 54), helped by a grease if necessary. Depending on the valve diameter the spring
housing can be machined directly inside the seat ring.
Put the seat seal in the right position, U-cup packing (48 only for valve 55) and seat gasket O-ring
(014). During this operation pay attention to pinch the O-rings.
Put the body-closures O-ring and graphite (011-016) in the closure using lubricant if
necessary.
6.4.b. Ball assembling
The following procedure is applicable only for valve type “55”. The type “54” ball can be directly
fitted once the body is fitted on the laying closure.
Put the upper and lower bearings (033) on the ball hubs.
Put the lower thrust washer (023) on the lower ball hub.
Put the supports (032) on the ball hubs.
Put the centring pins (046) in the hole on the supports lateral surfaces
Insert the assembly of ball and two supports on the closure. Pay attention that the pins on the support
must be centred with the closure pins holes.
Put the ball in close position.
6.4.c. Body assembling
Put the body (001) vertically on the closure so that the bolts (007) enter through their hole in the
closure.
Verify that the gland plate’s hole in the body is aligned with the upper ball trunnion.
Assembly with the body the other closure completed with the seat ring, following the procedure
described in the precedent points.
Screws the nuts (008) on the bolt (007) stating with the bolts positioned in the lower part of the
valve.
Screw the drain connection (028) on the body. In case of valve type 54, the drain is directly screwed
in the lower trunnion(see section 12.6).
Page 14 of 29
6.4.d. Stem assembling
Position the stem (004) on the ball (003) with the key (021) in axes with the flow axe.
For valve type 54, the bearing(033) shall be fitted in the lower stem part and the stem shall be
centred using the apposite pin (053).
Add the upper thrust washer (022) on the stem.
6.4.e. Gland plate assembling
Place the gland plate’s O-ring/graphite (015&018) in their housing at the end of the gland plate, at
the top of the body hole.
Place the stem o-rings (012), in their housing inside the gland plate.
Screw the check valve(044 if any) and grease fittings (030) at the gland plate.
Place the gland plate (005) on the body (001), using a pin hole between the body and the gland plate,
center the gland plate in the correct position; pay attention to scratch the stem during this operation.
Fix the gland plate to body screwing well the capscrews (009) to have correct seal.
Put the pin (036) in their hole in the gland plate.
6.4.f. Type “54” lower trunnion assembling
Place the lower trunnion graphite (050) in its housing at the end of the body.
Place the lower trunnion O-rings (059), in their housing inside the lower trunnion.
Insert the bearing (058) on thelower trunnion top.
Fit the completed lower trunnion assembly in the body(001)bottom hole and tight all the cap-
screws(052) to fix it.
Screw the drain plug (028) on the lower hole.
6.4.g. Adaptor plate assembly
Insert the graphite (019), place the gland bushing (006) in its housing on the top of the gland
plate(005).
Page 15 of 29
Place the adaptor plate (020) on the gland plate, centring the adaptor flange pin’s hole position (020)
with the gland plate pin’s hole position (005).
Place the capscrews (010) in their hole on the adaptor flange, screwing them.
Place the key (021) on its stem housing and fix it screwing the capscrew.
6.5. FINAL RECOMMENDATION
After assembling the valve, move the valve from close position to open position twice in order to
assets the parts.
With the valve in open position, verify that the key position is in axes with the flow, and when the valve
is in close position, the key position should be perpendicular to the flow axe.
For a correct screwing of the bolts, refer to Table 3 – torque wrench settings. The table is applicable only
to the body to closure bolting and not cover line flange bolting.
Table 3 – TORQUE WRENCH SETTINGS [Nm ± 5%]
BOLT SIZE A 193 B7 A 193 B8

A 320 L7
M 10 51 -
M 12 90 -
M 16 197 189
M 18 270 -
M 20 - 295
M 33 - 951
M 36 2168 -
M 39 2807 -
M 42 3547
Only bolt size used on the valves are included in the table.
7. SPARE PARTS & TOOLING

Please refer to documents VPC-SCH-OPR-GEN-004.
Page 16 of 29
8. ASSEMBLY DRAWING TYPE 55
20 ADAPTOR FLANGE 149 DRAIN PLUG

19 STEM FIRE SAFE GASKET 48 “U” CUP RING
18 GLAND PLATE F.S. GASKET 46 SUPPORT PIN
16 CLOSURE F.S. GASKET 44 CHECK VALVE
15 GLAND PLATE O-RING 41 GREASE FITTING
14 SEAT GASKET O-RING 40b DRAIN CONNECTION
13 SEAL O-RING 36c STOP PIN
12 STEM O-RING 35 LIFTING LUG
11 CLOSURE O-RING 33 SUPPORT BEARING
10 ADAPTOR FLANGE CAPSCREW 34 LEG
9 GLAND PLATE CAPSCREW 32 SUPPORT
8 NUT 30 STEM GRASE FITTING
7 BODY BOLT 27 SEAT SPRING
6 GLAND BUSHING 26 SEAT ESTERNAL RING
5 GLAND PLATE 25b SEAT INNER RING
4 STEM 23 LOWER THRUST WASHER
3 BALL 22 UPPER THRUST WASHER
2 CLOSURE 21a KEY CAPSCREW
1 BODY 21 STEM KEY
Pos. Description Pos. Description
10
35
20
36c 27
6
9
30 5
12 19
33
12 22
21 4
21a 149
18
36c
15
16
7
8 11
44 48
14
41
26
2 3 25
23
13
33
32
2 46
1
40b
34
Page 17 of 29
9. ASSEMBLY DRAWING TYPE 54
Page 18 of 29
APPENDIX
10. APPENDIX A) ITEM LIST
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VPC Erection, Installation, Commissioning, Operation and Maintenance Procedures For Trunnion Mounted Ball Valves

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VPC Erection, Installation, Commissioning, Operation and Maintenance Procedures For Trunnion Mounted Ball Valves

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TANAP

TRANS ANATOLIAN NATURAL GAS PIPELINE

DOCUMENT REVISION HISTORY SHEET

P3-C IFR 17/01/17 Issued for review

P3-0 IAA 07/08/17 Issued AS APPROVED

P3-1 RE-IAA 30/11/17 Re-Issued AS APPROVED

VPC ERECTION, INSTALLATION, COMMISSIONING,

Rev. Date Prepared Verified Approved

1.2. REFERENCE DOCUMENTS

1.4. VALVE MODELS

The valves covered by this instruction manual are:

The difference between the 2 models are in the ball mounting:

2.2. SAFETY PRECAUTIONS

2.3. MAIN NAME PLATE

The name plate is exposed on VALVITALIA’s valves in accordance to the European

SIZE DN Nominal Diameter Serial N° Serial number

The name plate also shows:

2.4. ADDITIONAL NAMEPLATE

5.1. CHECKS OR REQUIREMENTS

5.2. VENT & DRAIN VALVES FOR TYPE “55”

5.3. VENT & DRAIN VALVES FOR TYPE “54”

6.1. VALVE DISASSEMBLY

6.1.a. Valve removal from the pipeline

6.1.b. Adaptor plate disassembling

6.1.c. Gland plate disassembling

6.1.d. Stem disassembling

6.1.e. Closure disassembling

Remove body-closure’s O-ring and graphite (011-016) from the closure.

6.1.f. Seat ring disassembling

6.1.g. Ball disassembling

6.1.h. Body and closure control

Clean the body in every part with an appropriate solvent.

The ball valves don’t require periodic lubrications.

Lubricate the screw thread with anti - frictional pick up

The emergency seal should be made using grease NORDSTROM 555.

6.4.a. Closure assembling

6.4.b. Ball assembling

Put the supports (032) on the ball hubs.

Put the ball in close position.

6.4.c. Body assembling

6.4.d. Stem assembling

Add the upper thrust washer (022) on the stem.

6.4.e. Gland plate assembling

Put the pin (036) in their hole in the gland plate.

6.4.f. Type “54” lower trunnion assembling

Insert the bearing (058) on thelower trunnion top.

Screw the drain plug (028) on the lower hole.

6.4.g. Adaptor plate assembly

6.5. FINAL RECOMMENDATION

Table 3 – TORQUE WRENCH SETTINGS [Nm ± 5%]

BOLT SIZE A 193 B7 A 193 B8

7. SPARE PARTS & TOOLING

8. ASSEMBLY DRAWING TYPE 55

20 ADAPTOR FLANGE 149 DRAIN PLUG

9. ASSEMBLY DRAWING TYPE 54

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