AVK 854 User Manual

AVK SERIES 854 BALL FLOAT VALVE
FIELD MAINTENANCE AND INSTRUCTION
MANUAL FOR BALL FLOAT VALVES

TABLE OF CONTENTS

GENERAL
SERIES 854(TYPICAL EXPLODED VIEW)
COMPONENT LIST
INTRODUCTION TO AVK/GLENFIELD SERIES 854 VALVE
DESIGN CONSTRAINTS
STORAGE AND HANDING
INSTALLATION & COMMISSIONING
FLANGE COMPARISON
GENERAL MAINTENANCE INSTRUCTIONS
SEAL RENEWAL
SPARE PARTS

AVK GROUP A/S

AVK GROUP A/S
An ISO 9001-2000 registered

Maintenance Manual Series 854
*Subject to change without notice.

General

Instructions for Use

Thank you for selecting a AVK/Glenfield Product, with correct use, it will give long and
reliable service. This manual has been prepared to assist you install, operate and maintain the
valve to the maximum efficiency. For case of reference, it has been divided into sections
covering all aspects of use, and it is in the users best interests to read it and ensure that it is fully
understood.

Health and Safety at Work

It is always recommended that wherever work is being carried out on a valve that the valve
is fully depressurised prior to carrying it out, and for convenience draining of the line may be

It is essential that the user of the valve is aware of the weight of the components and / or
assemblies that must be handled and manipulated during installation and maintenance. It is the
users responsibility to ensure that safe working practices are followed at all times.

that undertake these operations be adequately trained. The hazards of pressurised liquids and
gases can be severe, and it is the responsibility of the users to ensure that trained, competent staff
undertake these duties. This manual has been designed to assist, but it can never fully replace

be covered by this manual.

reliable standard. This provides a safe product with minimum risk to health when used correctly
for the purpose for which it was designed. However, this assumes that the equipment is used and
maintained in accordance with this manual, and the user is advised to study this manual, and to
make it available to all staff that may need to refer to it.

operation or maintenance. The responsibility for this must rest wholly with the user.

Page 1

Series 854 Ball Float Valve

Typical Exploded View

8

9

5

16

2

11

10

14

13

3

4

12

1

7

6

15

Page 2

Series 854 Component List

Item Number Description Material

1 Body Ductile iron

2 Cylinder Ductile iron

3 Fulcrum Bracket Ductile iron

4 Valve Centre Gunmetal

5 Piston Bolt Gunmetal

6 Ball Float Polypropylene

7 Lever Mild steel hot dip galvanized

8 Hinge Pins Stainless steel

9 Links Hot dip galvanized steel

10 Piston Ring synthetic rubber

11 O-Ring Seal synthetic rubber

12 Seat Ring Gunmetal

13 Valve Face synthetic rubber

14 Valve Guide Gunmetal

15 Fasteners (FLoat t

o Lever) zinc steel plated

16 Fasteners (Fulcrum to Cylinder) zinc steel plated

Page 3

Introduction to Series 854 Ball Float Valve

The Series 854 Ball Float Valve controls discharge of water into a tank or

closed

open

Page 4

Design Constraints

Please consider the following points when selecting and installing your valve:

· Consideration should be given at the design stage where valves will be located to give
access for operation, adjustment, maintenance and repair.

· Valves must be provided with adequate support.

· Adjoining pipework must be supported to avoid the imposition of pipeline strains on the body

that may impair its performance.

· Inlet pipe must be well anchored to avoid vibration.

Page 5

Storage and Handling

Storage

· If valves are to be stored in the open for some time, protection should be provided to keep
the valves clear of sand and mud.

· Avoid damaging the protective coating.

· They should not be stored in dust laden or saline environments.

· They should be stored at ambient temperature environments.

· The valve sealing areas must be protected as any ingress of sand or foreign bodies will
cause damage.

Handling

bracket and lever should not be used as lifting or rigging points for valves or serious damage
may occur.

· Avoid damaging the coating protection.

· Sealing faces should be protected throughout.

Page 6

Installation and Commissioning

Before Installing

· All special packaging material must be removed.

· Check that all sealing faces are free from damage. (See Spare Parts Section P15)

· Check that the pipeline is free from debris.

· To ensure adequate sealing it is important to select the correct type of gasket for the medium
concerned.

Installation

· Use the correct bolt diameter, length and material for the particular pipeline system being used.

For details refer to Flange Comparison Page 12.

· Tighten bolts loosely.

· Finally tighten bolts to correct torque.

· Assemble Lever and Float

· Check for freedom of movement and alignment.

· The valve sealing areas must be clean and lubricated throughout.

running strips.

Once the Valve is Installed (Commissioning)

· When the pipeline has been charged, inspect the valve for any leaks and adjust as necessary

in accordance with the maintenance instructions.

· If permissable operate valve over full stroke and check for free movement.

· Lubricat all hinge pins and linkages.

· All external debris and foreign matter should be cleaned off from the external surface of the
valve.

· Touch up any paint that may have been damaged during installation.(See Spare Parts Section
P15).

· It is a must that series 854 float valves are installed in a suitable valve chamber with sufficient

overhead coverage, if installed outdoors or in an environment with dust, debris etc.

Page 7

British Metric
Flange Comparison

Dk d2

Nom Flange Pitch Circle No. and dia. Of Dia. Of Flange Raised Face Raised Face Nom

Pipe Diameter Diameter Bolts Bolt Holes T hickness Diameter Height Pipe

Dia. 4504/4772 4504/4772 4504/4772 4504/4772 G1 D1 4504/4772 4504/4772 Dia

80 200 160 8 M16 19 22 19 132 3 80

100 220 180 8 M16 19 24 19 156 3 100

150 285 240 8 M20 23 26 19 211 3 150

200 340 295 8 M20 23 26 20 266 3 200

250 395 350 12 M20 23 28 22 319 3 250

300 445 400 12 M20 23 28 24.5 370 4 300

350 505 460 16 M20 23 30 24.5 429 4 350

400 565 515 16 M24 28 32 24.5 480 4 400

450 615 565 20 M24 28 32 25.5 530 4 450

500 670 620 20 M24 28 34 26.5 582 4 500

600 780 725 20 M27 31 34 30 682 5 600

700 895 840 24 M27 31 40 32.5 794 5 700

800 1015 950 24 M30 34 44 35 901 5 800

900 1115 1050 28 M30 34 46 37.5 1001 5 900

1000 1230 1160 28 M33 37 50 40 1112 5 1000

1100 1340 1270 32 M33 37 53 42.5 1218 5 1100

1200 1455 1380 32 M36 31 56 45 1328 5 1200

d2

b

f

d4

K
D

b

d4 f

Nom Flange Pitch Circle No. and dia. Of Dia. Of Flange Raised Face Raised f ace Nom

Pipe Diameter Diameter Bolts Bolt Holes Thickness Diameter Height Pipe

Dia. 4504/ 4722 4504/4772 4504/4772 4504/4772 G1 D1 4504/4772 4504/4772 Dia.

80 200 160 8 M16 19 22 19 132 3 80

100 220 180 8 M16 19 24 19 156 3 100

150 285 240 8 M20 23 26 19 211 3 150

200 340 295 12 M20 23 30 20 266 3 200

250 405 355 12 M24 28 32 22 319 3 250

300 460 410 12 M24 28 32 24.5 370 4 300

350 520 470 16 M20 28 36 26.5 429 4 350

400 580 525 16 M27 31 38 28 480 4 400

450 640 585 20 M27 31 40 30 548 4 450

500 715 650 20 M30 34 42 31.5 609 4 500

600 840 770 20 M33 37 48 36 720 5 600

700 910 840 24 M33 37 54 39.5 794 5 700

800 1025 950 24 M36 41 58 43 901 5 800

900 1125 1050 28 M36 41 62 46.5 1001 5 900

1000 1255 1170 28 M39 44 66 50 1112 5 1000

1100 1355 1270 32 M39 44 - 53.5 1218 5 1100

1200 1485 1390 32 M45 50 - 57 1328 5 1200

Nom. Flange Pitch Circle No. and dia. Of Dia. Of Flange Raised Face R aised Face Nom

Pipe Di ameter Diam eter Bolt s Bolt Holes Thick ness Diamet er Diameter Pi pe

Dia 4504/4772 4504/4772 4504/4772 4504/4772 G1 D1 4504/4772 4504/4772 Dia.

80 200 160 8 M16 19 26 19 132 3 80

100 235 190 8 M20 23 28 19 156 3 100

150 300 250 8 M24 28 34 20 211 3 150

200 360 310 12 M24 28 34 22 274 3 200

250 425 370 12 M27 31 36 24.5 330 3 250

300 485 430 16 M27 31 40 27.5 389 4 300

350 555 490 16 M30 34 44 30 448 4 350

400 620 550 16 M33 37 48 32 503 4 400

450 670 600 20 M33 37 50 34.5 548 4 450

500 730 660 20 M33 37 52 36.5 609 4 500

600 845 770 20 M36 41 56 42 720 5 600

Dk d2 b d4 f

Dk d2 b d4 f

Page 8

Operation and Maintenance Instructions

Operation

also that all pin joints and linkages are greased and checked for freedom of movement.

Maintenance

It is always recommended that wherever work is being carried out on a valve that may involve the
release of any internal pressure, the valve is fully isolated and depressurised prior to carrying it out,

It is essential that the user of the valve is aware of the weight of the components and / or
assemblies that must be handled and manipulated during installation and maintenance. It is the
users responsibility to ensure that safe working practices are followed at all times.

· Regularly lubricate cylinder and all pin joints and linkages.

· Check for freedom of operation and/ or movement.

If tight:
External Check

1. Ensure all pin joints and linkages are free from bending and are lubricated.

Internal Check

2. Remove the piston assembly

4. Inspect piston seal and face seal for wear, damage or cuts etc. (to replace seal see P12)

6. Inspect valve guide and seat ring for damage/ scoring due to grit, stones or other debris

8. Reassemble piston components and use correct torque on piston bolt (50-100) and bolts
(150mm to 300mm) diameter

10. Ensure that piston is free moving vertically and rotates freely through 360 degrees

13. Touch up any coating or damage

· After re-commissioning check for leaks

· Periodically check

1. Freedom of movement (lubricate)

3. All bolts and fasteners for tightness

4. Coating and touch up as required

Damage in Rubber Seal

Page 9

Operation and Maintenance Instructions cont.

11

10

4

13
12

14

Cut away view to show assembled
component positions

Grit/ Stone/ Debris in valve

Page 10

Seal Renewal

It is always recommended that wherever work is being carried out on a valve that may involve the
release of any internal pressure, the valve is fully depressurised prior to carrying it out, and for

It is essential that the user of the valve is aware of the weight of the components and / or
assemblies that must be handled and manipulated during installation and maintenance. It is the
users responsibility to ensure that safe working practices are followed at all times.

Piston Ring/Seal Replacement

To replace the piston seal it is necessary to do the following:

· Remove the piston assembly

· Remove piston seal

· Clean/ lubricate seal groove

· Fit new piston seal

· Reassemble and replace piston assembly

Face seal Replacement

To replace the face seal it is necessary to do the following:

· Remove the piston assembly

· Remove face seal

· Clean/ lubricate seal groove

· Fit new face seal

· Reassemble and replace piston assembly

5

10

4

13

12

14

Exploded piston assembly

Page 11

Recommended Spare Parts

The use of inferior materials or parts in a valve can have serious consequences. It is
policy therefore, to use only materials of the highest quality, manufactured to our own designs and
thoroughly checked and tested in accordance with our internal Quality.
Assurance system that is approved to ISO 9001:2000. It is absolutely essential therefore, that in
order to guarantee the highest level of safety and performance, only genuine
parts are used.
AVK/Glenfield can accept no responsibility whatsoever for the fitting and subsequent failure of any
non-AVK/Glenfield or non-approved parts.

AVK/Glenfield recommend that these spare parts are purchased when ordering Series 854 Ball
Float valves.

· Seals/ gaskets

· Lubricants

· Touch up paint

For more information contact AVK/Glenfield Technical Department.

Page 12