VPC Erection, Installation, Commissioning, Operation and Maintenance Procedures For Top Entry Ball Valves

TANAP
TRANS ANATOLIAN NATURAL GAS PIPELINE

PROJECT
Project Rev Status
Doc.No. VPC-MAN-CST-GEN-004
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 TOP ENTRY BALL
VALVES
Equipment BALL-PLUG VALVES
Description :
Tag Nos. SEE DOCUMENT
Vendor:
VALVITALIA S.p.A.
Vendor
Document No. MAN00-2017-221 Rev 2+CRS
Signature &
Date
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documents status IFR\IFA, resubmit as IAA at next revision code.
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proceed. For documents status IFR\IFA, resubmit as IAA at next
revision code.
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proceed.For documents status IFR\IFA, resubmit for review Re-
IFR\IFA at next revision code.
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Remarks:-
VPC ERECTION INSTALLATION COMMISSIONING OPERATION
AND MAINTENANCE PROCEDURES FOR TOP ENTRY BALL VPC-MAN-CST-GEN-004
VALVES
Revision:P3-1 Status: Re-IAA Date: 28/05/18 Page 3 of 34
DOCUMENT REVISION HISTORY SHEET

Revision
Rev. Date Issued Update / Amendment Details
Description
P3-C IFR 20/02/17 Issued for review
P3-0 IAA 07/08/17 Issued AS APPROVED
P3-1 Re-IAA 28/05/18 Re-Issued AS APPROVED

VPC ERECTION, INSTALLATION,
COMMISSIONING, OPERATION AND Doc. no. MAN00-2017-221
MAINTENANCE PROCEDURES FOR TOP Rev.2
ENTRY BALL VALVES
VPC ERECTION, INSTALLATION, COMMISSIONING,

OPERATION AND MAINTENANCE PROCEDURES FOR
TOP ENTRY BALL VALVES
Page 1 of 31
ENTRY BALL VALVES
REVISION SHEET
Rev. Date Prepared Verified Approved

0 20-02-17 P.Malchiodi L.Bariani M.Carlini
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ENTRY BALL VALVES
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 NAME PLATE ........................................................................................................................................... 5
2.4. ADDITIONAL NAMEPLATE .............................................................................................................................. 6
3. INSTALLATION .................................................................................................................................................. 7
4. COMMISIONING................................................................................................................................................. 7
5. OPERATING ......................................................................................................................................................... 8
5.1. CHECKS OR REQUIREMENTS......................................................................................................................... 8
5.2. VENT & DRAIN VALVES ................................................................................................................................... 8
6. MAINTENANCE ................................................................................................................................................ 10
6.1. PERIODICAL VERIFICATIONS...................................................................................................................... 10
6.2. VALVE DISASSEMBLY FOR MAINTENACE............................................................................................... 11
6.2.a. Evaluation before valve disassembly.......................................................................................................... 11
6.2.b. Preliminary operations before valve disassembly ..................................................................................... 11
6.2.c. Bonnet assembly removal/disassembly ...................................................................................................... 11
6.2.d. Adapter plate disassembly .......................................................................................................................... 12
6.2.e. Top cover disassembly ................................................................................................................................. 12
6.2.f. Stem disassembly ......................................................................................................................................... 12
6.2.g. Ball disassembly ........................................................................................................................................... 12
6.2.h. Seat disassembly .......................................................................................................................................... 13
6.3. MAINTENANCE ................................................................................................................................................. 13
6.4. LUBRICATION ................................................................................................................................................... 14
6.5. ASSEMBLY .......................................................................................................................................................... 14
6.5.a. Seats assembly .............................................................................................................................................. 14
6.5.b. Ball assembly ................................................................................................................................................ 15
6.5.c. Bonnet assembly placement/assembling .................................................................................................... 15
6.5.d. Stem assembly .............................................................................................................................................. 15
6.5.e. Top cover assembly ..................................................................................................................................... 15
6.5.f. Adapter plate assembly ............................................................................................................................... 16
6.6. FINAL RECOMMENDATION .......................................................................................................................... 16
6.7. SEALANT INJECTION SYSTEM ..................................................................................................................... 17
7. RECOMMENDED SPARE PARTS .................................................................................................................. 17
8. ASSEMBLY DRAWING TYPE 52 ................................................................................................................... 18
9. ASSEMBLY DRAWING TYPE 51 ................................................................................................................... 19
10. ATTACHMENTS: .............................................................................................................................................. 20
10.1. ATTACHMENT 1: LIFTING TOOL DETAIL .............................................................................................. 21
10.2. ATTACHMENT 2: CYLINDER DETAIL ...................................................................................................... 23
10.3. ATTACHMENT 3: BALL MOUNTING ......................................................................................................... 25
10.4. ATTACHMENT 4: SEAT ADJUSTMENT ..................................................................................................... 26
10.5. ATTACHMENT 5: SPACER MOUNTING .................................................................................................... 27
APPENDIX ................................................................................................................................. 28
APPENDIX A) ITEM LIST........................................................................................................................................ 28
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ENTRY BALL VALVES
1. INTRODUCTION
1.1. SCOPE
The purpose of this manual is to furnish the right indications for the installation, use and
maintenance of top entry ball valves.
1.2. REFERENCE DOCUMENTS
Use and maintenance manual for valves conformed to the follow specifications: API 6D.
1.3. SUITABILITY
This document is only for top entry ball valves, installed on pipeline with operating conditions
described on chapter 5.
1.4. VALVE MODELS
The valves covered by this instruction manual are:

Type “52”: Top entry, bolted body, trunnion, ball valves 6”full bore and above;
Type “51”: Top entry, bolted body, trunnion, ball valves up to 6”reduced bore(6”x4”);
The difference between the 2 models are in the seat mounting:
Type “52”: Has seat housed in a long spring container ring that allows the valve mounting and the centring of
seat on the ball. Cylindrical spring are used for energize the seat;
Type “54”: The seat is housed on a smaller spring container ring that allow the seat centring, but energize the
seat with “belleville springs”.
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 top 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.
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.
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2.2. SAFETY PRECAUTIONS
Protective clothing and equipment normally required when working with the fluid involved 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 plug to completely depressurize body cavity. Drain vent plug shall be
used with extreme care and never turned open more than 1/1.5 turns until drain/bleeding occurs
through the drain hole. Vent drain plug if completely unscrewed with valve under pressure may be
ejected against the operator with danger of injures. For Drain and Vent with flanged connection the
drain/vent procedure is at customer care.
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.
General notes:
This instruction manual is prepared to be used for installation maintenance and repair of valves
only.
Any other equipment/accessories mounted on the valve will not be covered by this manual.
It is highly recommended to read carefully the instructions related to other equipment mounted on
the valve before starting any of the following operations.
2.3. MAIN NAME PLATE
The name plate is exposed on VALVITALIA’s valves in accordance to the European directive
certificate, where applicable.
Here below you can find an explanation table of what you will find on the name plates applied on
the valves.
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
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ENTRY BALL VALVES
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.
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ENTRY BALL VALVES
3. INSTALLATION
At valve receipt it should be carefully checked in order to verify that there are not evident damage
due to the shipping and handling.
Store the valve properly before installation. Keep it in a covered and dry ambient before moving to
the erection site. Do not remove the protection plates before installing the valve into the pipeline.
The valve is always delivered in the open position.
Before the valve’s SET-UP it is very important verifying that the inside bore of the valve is free from
any foreign particles that might damage the seats and ball.
Depreserve the valve in accordance to depreservation procedures. Please note that certain valves may
not be preserved but only cleaned. These are clearly marked by means of special tags.
Use the appropriate lifting hooks to lift the valve. On small valves(type “51”) where lifting hooks are
not available, use a sling rope around the lateral closures or around the body valve; never use the
gear or the lever for valve 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 shall be installed according to the flow directions marked on the valve body, in horizontal
position with the stem in vertical position. Flush or blow the pipeline clean before installing the
valve.
Not to install it with the stem downwards, as in case of leakage through the gland packing, the flow
media would run over the actuator
Ball valve with WE ends, welding connection to pipeline should be carefully carried out with ball in
open position and avoid an overheating of the body that can damage seals, gasket and seat ring
(concerning to the Interpass temperature, refer to the WPS/PQR supplied for each job)
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.
Ball valve can be fitted with pneumatic, hydraulic or electric actuators. Specific instructions should
be followed, as provided by actuator manufacturer.
No specific routine maintenance is necessary except operating the valve periodically, even if only
partially, to verify that the valve operation is satisfactory.
When installing the valve, please consider carefully the following points:
• Disassemble the actuator without removing the cables;

• That the bleed and vent connections are properly located;
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ENTRY BALL VALVES
• That the sealant injection connections are properly located;

• Any further instruction mentioned in the instruction manual for the actuator;
• When tightening the flange bolts, please follow the recommendation of the gasket
manufacturer;
• Ensure that the gaskets are suitable for the operating conditions;
• Do not attempt to correct pipe misalignments by means of flange bolts;
• Whenever possible, try to support properly the valve. This would minimise pipeline induced
stress and vibrations into the valve body. It is recommended to support the valve by means of
connected pipes welded or flanged to the valve and to put the valve supports on a basement,
but not by the valve body itself. Do not use, in any case, the flange or body bolts or parts of
the actuator as supports, unless clearly mentioned in design documents.
5. OPERATING
5.1. CHECKS OR REQUIREMENTS
With the valve mounted on the pipeline please follow the following precaution before removal.
Check there is no visible leak from the valve body, bonnet 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 maybe carried out also when the valve line is under pressure, due to the presence of
security check valves.
In case of 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 valves provided.
It’s required to have sealant and Sealant injection devices 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.
5.2. VENT & DRAIN VALVES
Top 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.
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ENTRY BALL VALVES
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.
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 valve is open while the lever is parallel to the pipe and closed when the lever is perpendicular to
the pipe.
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ENTRY BALL VALVES
6. MAINTENANCE
6.1. PERIODICAL VERIFICATIONS
Good operation procedure requires periodic control to ensure the correct functioning of the
valve. The frequency of these controls has to be established in relation to the type of service.
Two main points must be observed:
• STEM LEAKAGE
• SEAT LEAKAGE
STEM LEAKAGE
Stem leakage could occur if stem seals (012) have been damaged.
On this type of valve, complete dismounting of the stem while the valve is pressurized is not
possible due to safety reasons.
Partial dismounting of the adaptor plate, in order to replace the packing, while the valve is
pressurized is possible, but for safety reasons not suggest.
SEAT LEAKAGE
In order to check the proper sealing action of the seats, put the valve in closed position and
bleed it through an appropriate connection downstream.
No leakage should occur after the body cavity pressure and temperature should be stable.
In case of leakage from one of the seats, this type of valve will not seal properly in both
directions.
Whenever a seal fails is discovered, ensure that suitable spare are available in stock to carry
out the replacement. In case such spare parts are not available at site, it should be
commissioned through a service order to VALVITALIA.
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ENTRY BALL VALVES
6.2. VALVE DISASSEMBLY FOR MAINTENACE
Before disassembling the valve, ensure that the relevant spare parts available.
Always follow carefully the instructions given in the PRECAUTIONS section.
6.2.a. Evaluation before valve disassembly
Top entry design allow the removal of the internals while the valve is kept on the line. It is
anyway possible to remove the valve with its actuator from the pipeline.
If the medium is TOXIC or CORROSIVE, flush the valve TO AVOID ANY ACCIDENTS.
In case that the valve should be returned to the manufacturer for repair works, please DO NOT
disassemble it.
6.2.b. Preliminary operations before valve disassembly
Operate the valve to remove all flow media trapped in the body cavity.
The valve should be placed in the closed position, use the vent/drain connection to completely
depressurize body cavity. Drain vent plug (if provided), 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 ejected against the operator with
danger of injures. In case of flanged connection the drain procedure is at customer care.
When disassembling the valve, please use a clean surface such as cardboard, plastic or wood to
support the disassembled components.
Disassemble the actuator from the coupling flange following the instructions given by the actuator
manufacturer in the relevant manual.
Check that the valve cavity and connected lines are fully depressurized.
Purge the valve and the connected line from explosive gas using inert gas.
For valve part numbers refer to typical assembly drawings provided in sections 8 and 9.
6.2.c. Bonnet assembly removal/disassembly
Unscrew the body stud nut (008) and remove them. The nut have to be untighten operating on
diametrical opposite studs.
Lift vertically the bonnet (002a) using lifting eyes in threaded holes provided on the top of the
bonnet itself (while lifting the bonnet be careful to support the stem (004) properly) and place the
assembly on a solid and clean surface. During the lifting pay attention to not damage the soft seals
and the bonnet pin (190).
Remove the bonnet fire safe seal (016a) from the valve body (001). Clean the components with a
degreasing fluid and verify the integrity.
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6.2.d. Adapter plate disassembly
Unscrew the key’s capscrew if it is present and remove the stem key (021) from the stem (004).
Unscrew the adapter plate (020) capscrew (010) and pull up the adapter plate (020) from its
position. The capscrews have to be untighten operating on diametrical opposite screws.
6.2.e. Top cover disassembly
Unscrew the stem grease fitting (030) from its weldolet, then unscrew the top cover capscrews
(009), and remove them from its housing. Pull up the top cover (005) helping with two opposite
screwdrivers to lever, paying attention to score the stem (004) during the pull out of the top cover.
Pay attention to do not loose the top cover pins (088).
Remove from the top cover (005) the gland bushing (006), the stem fire safe seal (019) and the
stem O-ring (012). Clean the components with a degreasing fluid and verify the integrity of the O-
ring. In case of O-ring damages, it should be substituted.
The top cover O-ring (015) and the top cover fire safe seal (018) may stick to the top cover (005)
or valve bonnet (002). Remove and clean them and verify the integrity of the O-ring. In case of O-
ring damages, it should be substituted.
6.2.f. Stem disassembly
Lift vertically the bonnet (002a) using lifting eyes on the top of the bonnet itself and the stem will
remain on the work surface (if stem have difficult to pull out from the bonnet a rubber hummer
may be used to help the extraction).
Remove the upper thrust washer (022) from the stem.
Remove from the bonnet the lower stem O-ring (012).
Clean the components with a degreasing fluid and verify the integrity of the O-ring. In case of O-
ring damages, it should be substituted.
6.2.g. Ball disassembly
With the ball (003) in the closed position insert the cylinder (attachment 2) into the set clamps
provided in the spring holder rings (097). In order to do it may be necessary to reduce the width of
the piston shaft to the minimum. Insert the cylinder in the space between the opening of the ball
and the body and release them again to a length suitable to clamp the seats.
After clamping the spring holder rings, the piston shall be actioned in order to pull the seat
assemblies (025 & 026) against the ball (003).
Continue to pull seats against the ball until a gap of 1-2 mm is achieved between the spring holder
(097) and the spacer chain (096). The spacer chain can now be removed from around the seats
pulling them out and lifting each segment as it becomes free (attachment 5).
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ENTRY BALL VALVES
Using a manual pump or a compressor, push liquid solvent (e.g. petroleum, gasoline, kerosene,…)
through sealant injection points (if available) on the back seat cavity (direction: top-down) in
order to wash the area and to allow the seat an easier backing.
Operate the piston vice-versa and push seats (025 & 026) completely inwards inside the body.
Release until the cylinder can be removed from the seats clamps and taken out to the valve body
(001).
Turn the ball (003) into the fully open position (attachment 3).
Lift the ball (003) out of the body (001) using the appropriate screwed holes on the top trunnion.
While doing that, avoid contact between the ball and the seats or the body as it is lifted and
becomes free.
6.2.h. Seat disassembly
Use the piston to pull the seats (025 & 026) out of the valve body with a similar operation used
before (attachment 2).
When the seats (025 & 026) are sufficiently pulled out, the seats are no longer subject to the
springs (027) force. When the seat gaskets are come out from the body pocket, the cylinder can be
disengaged.
Lift each seat using the proper lifting tool (attachment 1).
The seat O-rings (014 & 048) may be removed from the seat rings by removing the spring holder
rings (097).
The spring holder O-rings(048a & 048b) can be now removed from the spring holder.
6.3. MAINTENANCE
Regardless to the reason of taking the valve apart we highly recommend all steps mentioned
hereinafter to be followed.
Clean ball surface with a soft cloth and a solvent, if required.
Check ball surface for major scratches, pitting or erosion particularly in the seat sealing area. If
scratches or other damages are found on the ball it must be changed, NO REPAIR IN ANY WAY
ARE ALLOWED, refer immediately to VALVITALIA since the ball is not included in the spare
parts kit.
Check ball bearing surfaces (033) for scratches and unusual wear. If scratches in ball bearing are
found, immediately refer to VALVITALIA since, unless especially requested, bearings are not
included in the spare parts kits.
Check the stem lip seals sealing area. There must be no evident scratches or wear on the surface. In
case of minor scratches it is recommended to polish or grind that surface.
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ENTRY BALL VALVES
Check the seal areas of seats for any damage or deformation. No scratches or deformations are
allowed on the seal of seat. In case damages are found on the seal of seat change the complete seat
holder.
Check status of the springs (027);
After having inspected all the items and replaced the fault ones, clean accurately all parts for
assembly. Clean the metallic parts using an oil wet cloth, and if present, do not clean elastomers with
solvents. All soft seals, fire safe seals, back-up rings and sealing rings must be replaced at any time a
valve becomes disassembled.
6.4. LUBRICATION
The thrust washer (022&023) and bearing (033) are auto-lubricated, so they do not require any
lubrication.
Lubricate the screw thread with anti - frictional pick up.
The emergency seal should be made using grease NORDSTROM (BTR) 555.
6.5. ASSEMBLY
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. A good lubricant compatible with the flow media
should be applied on seats, seals, ball and stem to facilitate assembly and for ease of initial operation.
Assembling requires a certain skill from the operator. Before starting any assembly, please become
familiar with the procedure lay down afterwards. Handling and installation of fire safe seals requires
a great amount of precautions since they are very fragile and cannot be repaired. The assembling
instructions are opposite to the disassembling instructions. For a correct screwing of the bolting, see
the table 2 closing torque.
6.5.a. Seats assembly
Verify that spring holder rings (097) together with the O-rings(048a &048b) and the related
springs (027) are correctly positioned in their housing into the valve body (001).
Place the O-rings (013, 014 & 048a) on the seat rings (025 & 026), in order to complete the seats
assembly.
Insert each seat assembly in the body pocket using the proper lifting tool (attachment1), until the
seat gaskets starts to engage into the body.
Use the lifting tool to pull completely the seats into their pocket and install the seat clamps
(attachment 2).
Take the lifting tools out of the body.
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6.5.b. Ball assembly
Insert the ball (003) in the fully open position between the seats taking care not to scratch the ball
surface during the operation (attachment 3).
Turn the ball in the fully closed position (attachment 3).
Insert the cylinder on the seats clamps. Use the cylinder to push the seats against the body. After
doing that the seats will be in the exactly same position (attachment 4).
Use the cylinder to pull the seats against the ball. When a sufficient space between the spring
holder (097) and body is achieved, insert the spacer chain (096) in both seats (attachment 5).
Move the seats assembly with the cylinders against the spacer (96).
Release the cylinders pressure and take them out of the valve.
6.5.c. Bonnet assembly placement/assembling
Place bonnet body O-ring(039) and the bonnet containing ring (47b) on the upper side of the body
(001).
Place also the bonnet fire safe seal (016a) into its recess on the lower side of the bonnet(002a).
6.5.d. Stem assembly
Place the stem (004) on a solid and clean surface and place the upper thrust washer (022) on the
shoulder upper side.
Lift vertically the bonnet using lifting eyes on the top of the bonnet itself. Let down the bonnet on
the stem, paying attention to not damage the contact surface.
6.5.e. Top cover assembly
Place the top cover O-ring (015) in their position on the upper side of the bonnet.
Place the top cover fire safe seal (18) in its housing on the lower side of the top cover (005).
Place the stem O-ring (012) in their housing inside the top cover (005).
Place the top cover (005) on the bonnet (002a), using the pin holes between the bonnet and the top
cover, centre the top cover in the correct position, and then place the top cover pins (088) in their
hole; pay attention to do not scratch the stem and damage the O-rings during this operation.
Fix the top cover to the body screwing the capscrews (009) to have a correct seal.
Place the stem grease fittings (30) on the weldolet in the front of top cover (005).
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ENTRY BALL VALVES
6.5.f. Adapter plate assembly
Insert the stem fire safe seal (019), place the gland bushing (006) in its housing on the top of the
top cover (005).
Place the adapter flange (020) on the top cover, centring the adapter plate position with the top
cover pins (088).
Place the capscrews (010) in their hole on the adapter plate, and screw them.
Place the stem key (021) on its stem housing and fix it screwing its capscrew if provided.
Lift vertically the bonnet (002a) using lifting eyes in threaded holes provided on the top of the
bonnet itself (while lifting the bonnet be careful to support the stem (004) properly) and let down
the assembly on the valve body (001) using as reference for the correct alignment the bonnet pin
(190). During the positioning pay attention to not damage the soft seals.
Screw the body stud nut (008) on the body stud (007). The nut have to be tighten operating on
diametrical opposite studs.
Install all the drain/vent connections and, if present, all accessories in accordance to their own
instruction manual.
6.6. 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 axis.
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.
Test the valve in accordance to the approved procedures.
Page 16 of 31
ENTRY BALL VALVES
Table 3 – TIGHTENING TORQUES [Nm ± 5%]
Bolt size A 193 B7

A 320 L7
M 24 666
M 27 988
M 33 1568
M 48 5429
M 56 8431
M 80 26027
6.7. SEALANT INJECTION SYSTEM
It’s possible to reduce the leakage on line if the sealant injection is applied on the seat or stem.
Unless required by customer metal seated valves are not provided with sealant injection.
Sealant injection shall be used only to solve emergency function and shall not be used during normal
operation.
To inject the sealant grease a high pressure pump shall be used. After the connection of the pump
with the sealant injection device and after the removal of the closing tap, fill the injection system to
reach a pressure higher than the maximum rating pressure of the valve.
When the sealant injection is performed on the seats ball valve shall be fully closed.
Depending on the type of grease used different sealant quality and sometimes the fully sealant shall
be reached. If the surface of the ball or of the seats is very damaged it is not possible to avoid leakage
but it is only possible to reduce it.
7. RECOMMENDED SPARE PARTS

Please refer to documents VPC-SCH-OPR-GEN-004.
Page 17 of 31
ENTRY BALL VALVES
8. ASSEMBLY DRAWING TYPE 52
Page 18 of 31
ENTRY BALL VALVES
9. ASSEMBLY DRAWING TYPE 51
Page 19 of 31
ENTRY BALL VALVES
10.ATTACHMENTS:
• ATTACHMENT 1: Lifting tools detail
• ATTACHMENT 2: Cylinder detail
• ATTACHMENT 3: Ball mounting
• ATTACHMENT 4: Seat adjustment
• ATTACHMENT 5: Spacer mounting
Page 20 of 31
ENTRY BALL VALVES
10.1. ATTACHMENT 1: LIFTING TOOL DETAIL
SPECIAL TOOL LIST

Lifting jack for
Quantity
valve size
30” 1
30”x24” 1
48”x42” 1
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ENTRY BALL VALVES
Page 22 of 31
ENTRY BALL VALVES
10.2. ATTACHMENT 2: CYLINDER DETAIL
SPECIAL TOOL LIST

Cylinder for
Quantity
valve size
10”x8” 2
10” 2
30” 2
30”x24” 2
48”x42” 2
Page 23 of 31
ENTRY BALL VALVES
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ENTRY BALL VALVES
10.3. ATTACHMENT 3: BALL MOUNTING
Page 25 of 31
ENTRY BALL VALVES
10.4. ATTACHMENT 4: SEAT ADJUSTMENT
Page 26 of 31
ENTRY BALL VALVES
10.5. ATTACHMENT 5: SPACER MOUNTING
Page 27 of 31
ENTRY BALL VALVES
APPENDIX
APPENDIX A) ITEM LIST
Page 28 of 31
ENTRY BALL VALVES
Page 29 of 31
ENTRY BALL VALVES
Page 30 of 31
ENTRY BALL VALVES
Page 31 of 31

VPC Erection, Installation, Commissioning, Operation and Maintenance Procedures For Top Entry Ball Valves

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VPC Erection, Installation, Commissioning, Operation and Maintenance Procedures For Top Entry Ball Valves

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TANAP

TRANS ANATOLIAN NATURAL GAS PIPELINE

DOCUMENT REVISION HISTORY SHEET

P3-C IFR 20/02/17 Issued for review

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

P3-1 Re-IAA 28/05/18 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 seat mounting:

2.2. SAFETY PRECAUTIONS

2.3. MAIN NAME PLATE

SIZE DN Nominal Diameter Serial N° Serial number

The name plate also shows:

2.4. ADDITIONAL NAMEPLATE

P.O. Purchase order number TAG N° Valve tag number

• Disassemble the actuator without removing the cables;

• That the sealant injection connections are properly located;

5.2. VENT & DRAIN VALVES

6.2. VALVE DISASSEMBLY FOR MAINTENACE

6.2.a. Evaluation before valve disassembly

6.2.b. Preliminary operations before valve disassembly

6.2.c. Bonnet assembly removal/disassembly

6.2.d. Adapter plate disassembly

6.2.e. Top cover disassembly

6.2.f. Stem disassembly

Remove the upper thrust washer (022) from the stem.

Remove from the bonnet the lower stem O-ring (012).

6.2.g. Ball disassembly

6.2.h. Seat disassembly

Clean ball surface with a soft cloth and a solvent, if required.

Check status of the springs (027);

Lubricate the screw thread with anti - frictional pick up.

6.5.a. Seats assembly

Take the lifting tools out of the body.

6.5.b. Ball assembly

Turn the ball in the fully closed position (attachment 3).

6.5.c. Bonnet assembly placement/assembling

6.5.d. Stem assembly

6.5.e. Top cover assembly

6.5.f. Adapter plate assembly

6.6. FINAL RECOMMENDATION

Table 3 – TIGHTENING TORQUES [Nm ± 5%]

Bolt size A 193 B7

6.7. SEALANT INJECTION SYSTEM

7. RECOMMENDED SPARE PARTS

8. ASSEMBLY DRAWING TYPE 52

9. ASSEMBLY DRAWING TYPE 51

10.1. ATTACHMENT 1: LIFTING TOOL DETAIL

SPECIAL TOOL LIST

10.2. ATTACHMENT 2: CYLINDER DETAIL

SPECIAL TOOL LIST

10.3. ATTACHMENT 3: BALL MOUNTING

10.4. ATTACHMENT 4: SEAT ADJUSTMENT

10.5. ATTACHMENT 5: SPACER MOUNTING

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