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

TANAP
TRANS ANATOLIAN NATURAL GAS PIPELINE

PROJECT
Project Rev Status
Doc.No. VPC-MAN-CST-GEN-002
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 FLOATING BALL
VALVES
Equipment BALL-PLUG VALVES
Description :
Tag Nos. ALL FLOATING VALVES TAGS
Vendor:
VALVITALIA S.p.A.
Vendor
Document No. MAN00-2017-A88 Rev 1+CRS
Signature &
Date
C1 / APP - Reviewed & accepted. Manufacture may Proceed.For
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.
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
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Revise document and resubmit for review.
Remarks:-
VPC ERECTION INSTALLATION COMMISSIONING OPERATION AND
MAINTENANCE PROCEDURES FOR FLOATING BALL VALVES
VPC-MAN-CST-GEN-002
Revision:P3-1 Status: Re-IAA Date: 05/03/18 Page 3 of 21
DOCUMENT REVISION HISTORY SHEET

Revision
Rev. Date Issued Update / Amendment Details
Description
P3-C IFR 16/12/2016 Issued for review
P3-0 IAA 07/08/2017 Issued as approved
P3-1 Re-IAA 05/03/2018 Re-Issued as approved

VPC ERECTION, INSTALLATION,
COMMISSIONING, OPERATION AND Doc. no. MAN00-2017-A88
MAINTENANCE PROCEDURES FOR rev.1
FLOATING BALL VALVES
VPC ERECTION, INSTALLATION, COMMISSIONING,

OPERATION AND MAINTENANCE PROCEDURES FOR
Sheet 1 of 18
REVISION SHEET
Rev. Date Prepared Verified Approved

0 03-08-17 P.Malchiodi L.Bariani P. Donini
1 05-03-18 P.Malchiodi L.Bariani P. Donini
Sheet 2 of 18
INDEX
1. INTRODUCTION....................................................................................... 5
1.1. SCOPE ..........................................................................................................................5
1.2. REFERENCE DOCUMENTS ...........................................................................................5
1.3. SUITABILITY ................................................................................................................5
2. ERECTION ................................................................................................ 5
2.1. USE ..............................................................................................................................5
2.2. PRECAUTIONS .............................................................................................................6
2.3. NAMEPLATE ................................................................................................................6
2.4. ADDITIONAL NAMEPLATE ..........................................................................................7
3. INSTALLATION ......................................................................................... 7
3.1. DEPRESERVATION ......................................................................................................7
3.2. Handling......................................................................................................................8
3.3. Receipt and storage ...................................................................................................8
3.4. Installation..................................................................................................................8
3.5. Supports......................................................................................................................8
4. COMMISIONING ..................................................................................... 9
5. OPERATION ............................................................................................. 9
CHECKS OR REQUIREMENTS .................................................................................................9
6. MAINTENANCE........................................................................................ 9
6.1. DISASSEMBLY .............................................................................................................9
6.1.1. Adaptor plate disassembly.................................................................................. 10
6.1.2. Top cover disassembly ........................................................................................ 10
6.1.3. Stem disassembly ................................................................................................ 10
Sheet 3 of 18
6.1.4. Body disassembly ................................................................................................ 11

6.1.5. Ball & seat disassembly ....................................................................................... 11
6.2. MAINTENANCE ........................................................................................................ 11
6.3. INSPECTION ............................................................................................................. 12
6.4. ASSEMBLY ................................................................................................................ 12
6.4.1. Seat assembly ...................................................................................................... 13
6.4.2. Ball & stem assembly .......................................................................................... 13
6.4.3. Body assembly ..................................................................................................... 13
6.4.4. Top cover assembly ............................................................................................. 13
6.4.5. Adaptor plate disassembly.................................................................................. 13
6.5. FINAL RACCOMANDATION ..................................................................................... 14
7. SPARE PARTS AND TOOLING ................................................................ 14
8. ASSEMBLY DRAWING FOR TYPE 86 ...................................................... 15
9. ASSEMBLY DRAWING FOR TYPE 86 WITH METAL SEAT........................ 15
10. ASSEMBLY DRAWING FOR CRYOGENIC VALVE .................................. 16
11. APPENDIX A) ...................................................................................... 17
Sheet 4 of 18
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 floating ball valves, with bolted body. It is highly recommended to read
carefully the instructions related to other equipment fitted to the valve before starting any of the
following operations.
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 floating ball valves with bolted body, installed on pipeline
with operating conditions described on chapter 5.
2. ERECTION
2.1. USE
The VALVITALIA’s Side Entry floating 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.
Sheet 5 of 18
2.2. PRECAUTIONS
Protective clothing and equipment normally required when working with the fluid involved is
recommended.
Depressurise 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. After removal and before any disassembly, cycle the
valve again several times.
2.3. NAMEPLATE
The name plate is exposed on VALVITALIA’s valves in accordance to the European

regulation
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
The name plate also shows:

-Company logo and address:
Via Tortona 69
Rivanazzano(PV) ITALY
Sheet 6 of 18
-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
3.1. DEPRESERVATION
Depreserve the valve in accordance to depreservation procedures.

Please note that certain valves may not be preserved but only clean-built. These are
clearly marked by means of special tags.
Sheet 7 of 18
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.
3.2. Handling
Floating ball valves are supplied without lifting lugs due to the low weight. Place the lifting
ropes around the valve body. Never lift the valve placing the ropes around the actuator.
3.3. Receipt and storage
Check that the valve was not damaged before installation and store the valve properly.
Keep it at covered and dry ambient before need on 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.
3.4. Installation
Flush or blow the pipes clean before installing the valve.

Impurities, sand or welding rags might damage the ball surface and the seats.
Manual valve can be installed in the most convenient position. Anyhow, we would
recommend not to install it with the stem downwards, as in case of leakage through the
gland packing, the flow media would run over the operator.
When installing the valve, please consider carefully the following points:
• disassemble the actuator without removing the cables
• any further instruction mentioned in the instruction manual for the actuator
• when tightening the flange bolts, please follow the recommendation practice 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.
3.5. Supports
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 and not by the valve
body itself.
Do not use, in any case, the flange or body bolts or parts of the actuator.
Sheet 8 of 18
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, to

verify that the valve operation is satisfactory. Floating valves are not provided with seat
lubrication so does not require this type of maintenance.
5. OPERATION
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(injection devices are provided only for stem and on larger diameter)maybe
carried out also when the valve line is under pressure, due to the presence of security check
valves.
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.
6. MAINTENANCE
6.1. DISASSEMBLY
Before disassembling the valve, ensure you have the relevant spare parts available.
Observe carefully always the instructions given in the PRECAUTIONS section 2.2.
Before starting valve disassembly the following operation shall be carried out:
• Remove the valve with its actuator from the pipeline then operate the valve to remove all
flow media trapped in the body cavity.
Sheet 9 of 18
If the media 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.
• When disassembling the valve, please use a clean surface such as cardboard, plastic or
wood
• disassemble the actuator from the coupling flange following the instructions given by the
actuator manufacturer in the relevant manual
• place the valve in the vertical position keeping the ball in the OPEN position
6.1.1. Adaptor plate disassembly

Unscrew the key’s capscrew if it is present and remove the key (21) from the stem (04).
Unscrew the adaptor plate’s cap-screws(10)and pull up the adaptor plate (20) from its
position.
If the valve is cryogenic: adaptor plate is not present.
6.1.2. Top cover disassembly

Remove the gland bushing(06). If present, unscrew the grease fitting (30) from the
top cover (05) and unscrew the gland plate’s cap-screws (09). Now the top cover can
be removed from its housing. Pull up the top cover helping with two opposite
screwdrivers to lever, pay attention to score the stem during the operation.
Remove the gland plate (05), remove the stem’s fire safe seal (19), 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 top cover O-ring/graphite (15 & 18). In case of o-
ring’s damages, it should be substituted.
If the valve is cryogenic: unscrew the stop collar(061) by removing its screws. The
screwed bushing(94) could be unscrewed using the profile in the top part and taken
away so the packing is free.
Remove the top cover bolts(55) and nuts(56). The top cover is free and can be
removed. Remove the packing: fire safe gasket (19) lantern(37) and stem lip seal
gasket(12a). Also the stem bearing (53) shall be removed.
Make the same operation for the top cover graphite (18).
6.1.3. Stem disassembly

The stem(04) is free and shall be pulled off together with thrust washer(22). Since the
stem is inserted in the ball may require small effort to came free. Make sure to collect
the antistatic device after this operation(31).
Sheet 10 of 18
6.1.4. Body disassembly

Proceed to remove the fastening bolts(07) and nuts(08) between the two body
sections(01, 02). Lift the male body(01) being sure that the seat doesn’t pop out.
Place the male body (01) standing on its flange. Body gaskets (11-16) shall been
taken out now. If the valve is cryogenic: the body O-ring is not present.
If the body is in 3 pieces: remove the bolting on both sides, pull out the closures(02)
an put them standing on their flanges.
6.1.5. Ball & seat disassembly

Turn the ball(03) into the closed position, clamp it by means of a nylon or rubber
strip, lift it carefully and place it with the vertical bore on a soft surface
Take the bottom seat(25)out of the closure(02). If the seat is metal: shall be taken out
togheter with its spring(27) retainer ring(26) and O-ring(14)
6.2. MAINTENANCE
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 ‘O’ rings have been damaged.
On this type of valve, external stem packing may be replaced while the valve is under
pressure. Stem thrust washer is capable of generating a reasonable tight seal while the valve
is under pressure for the period of time required to change stem packing. Should a under
pressure repair be chosen, every precaution and procedures required to operate with the used
fluid shall be adopted.
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 are stabilised.
In case of leakage of one of the seats, this type of valve will not seal properly in both
directions.
Sheet 11 of 18
Whenever you discover that a seal fails, ensure you have available in stock the suitable spare
parts to prevent any further damages.
6.3. INSPECTION
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 in ball bearing are found, immediately refer to the manufacturer since, unless
especially requested, bearings are not included in the spare parts kits
• if scratches or other damages are found on the ball it must be changed, NO REPAIR IN
ANY WAY IS ALLOWED, refer immediately to the manufacturer since the ball is not
included in the spare parts kit
• check the stem packing and 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
• check the seal of seat for any damage or deformation
• no scratches or deformations are allowed on the seal of seat. In case you find a damaged
seat change the complete seat.
After having inspected all items and replaced the fault ones, clean down all parts for
assembly. All ‘O’ rings and sealing rings must be replaced at any time a valve becomes
disassembled.
6.4. ASSEMBLY
A good lubricant compatible with the flow media should be applied seats, seals, ball and
stem to facilitate assembly and for ease of initial operation.
Clean seats and seals areas and all other parts before assembly.
Assembling requires a certain skill from the operator. Before starting any assembly, please
become familiar with the procedure lay down afterwards.
Firesafe valves have grafoil seal rings throughout.
Handling and installation of these seals requires a great amount of precautions since they are
very fragile and can not be repaired.
Sheet 12 of 18
6.4.1. Seat assembly

With the closure(02) and male body(01) rest on their flanges, install the seat(025) in
their housing. If the seat is metal: all the seat shall be ressembled adding component
in the rear side in this order spring(27), retainer ring(26) and O-ring(14).
6.4.2. Ball & stem assembly

Lift the ball(03) and carefully place it in the closure (02) over the bottom seat assembly.
Turn it to the closed position in order to insert, by gently hammering, the stem(04) in the
ball slot. Ensure that antistatic device(31), has not pop out. Insert the thrust washer(22).
6.4.3. Body assembly

Put the body O-ring(011)inside the closures(02) and also the body fire sae gasket(16).
Body stud(07) shall be installed and screwed up to the end
Turn the male body (01)upside down, lift it by the flange. Install it on the closure(02)
avoiding shocks that can make the seat assembly slipping out.
If the body is in 3 pieces: the closures shall be left rest on is flange lift the body(01)
and fit it in such a way that the protruding studs get into the closure(02). The second
closure(02) shall be lifted with ropes by the flange and assembled on the second side of
the body(01).
Tighten completely the body and closures, with the nuts(08). Use table 3 for bolt torque.
6.4.4. Top cover assembly

Place the top cover O-ring/graphite (15 & 18) in their place. If the valve is
cryogenic: only the graphite(018)is present.
Assemble the top cover with all the stem gaskets(012-019) and fit it in its place over
the body(01). The stem greas fitting(30)shall be screwed. If the valve is cryogenic:
the assembly include also stem bearing(53) stem lip seal(12a-in place of the O-ring),
lantern(037), fire safe gasket(19) and the screwed bushing(94) which has to be
tighten to provde the right load for the packing.
To fasten the top cover use the apposite capscrews(09) and the gland bushing(06)
shall be fitted on top of stem graphite(18). For cryogenic valves: bolts(55)and
nuts(56) shall be used.
6.4.5. Adaptor plate disassembly

Put the adaptor plate(020) over the top cover and fix it with its capscrews(10).
Screw the key’s capscrew if it is present to fix the key (21) on the stem (04).
Sheet 13 of 18
If the valve is cryogenic: adaptor plate is not present and stop collar(061)shall be
tighten on top of top cover.
6.5. FINAL RACCOMANDATION
After assembly operate several times the valve to be sure that there are no sticks or
interference.
Install all accessories in accordance to their own instruction manual, test the valve in
accordance to the approved procedures.
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
BOLT SIZE TORQUE TORQUE

diam. mm Nm Nm
B7/L7 B8M/B8
10 56.00 30.22
14 151.86 82.00
16 231.38 124.95
7. SPARE PARTS AND TOOLING
Please refer to documents VPC-SCH-OPR-GEN-004.
Sheet 14 of 18
8. ASSEMBLY DRAWING FOR TYPE 86
9. ASSEMBLY DRAWING FOR TYPE 86 WITH METAL SEAT
Sheet 15 of 18
10. ASSEMBLY DRAWING FOR CRYOGENIC VALVE
Sheet 16 of 18
11. APPENDIX A)
APPENDIX A) ITEM LIST
Sheet 17 of 18
Sheet 18 of 18

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

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

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TANAP

TRANS ANATOLIAN NATURAL GAS PIPELINE

DOCUMENT REVISION HISTORY SHEET

P3-C IFR 16/12/2016 Issued for review

P3-0 IAA 07/08/2017 Issued as approved

P3-1 Re-IAA 05/03/2018 Re-Issued as approved

VPC ERECTION, INSTALLATION, COMMISSIONING,

Rev. Date Prepared Verified Approved

6.1.4. Body disassembly ................................................................................................ 11

1.2. REFERENCE DOCUMENTS

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

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

Depreserve the valve in accordance to depreservation procedures.

Flush or blow the pipes clean before installing the valve.

No specific routine maintenance is necessary except operating the valve periodically, to

6.1.1. Adaptor plate disassembly

6.1.2. Top cover disassembly

6.1.3. Stem disassembly

6.1.4. Body disassembly

6.1.5. Ball & seat disassembly

6.4.1. Seat assembly

6.4.2. Ball & stem assembly

6.4.3. Body assembly

6.4.4. Top cover assembly

6.4.5. Adaptor plate disassembly

6.5. FINAL RACCOMANDATION

BOLT SIZE TORQUE TORQUE

7. SPARE PARTS AND TOOLING

Please refer to documents VPC-SCH-OPR-GEN-004.

8. ASSEMBLY DRAWING FOR TYPE 86

9. ASSEMBLY DRAWING FOR TYPE 86 WITH METAL SEAT

10. ASSEMBLY DRAWING FOR CRYOGENIC VALVE

APPENDIX A) ITEM LIST

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