API 6D Two - Piece Cast Trunnion
Mounted Ball Valve
Atlas Series
Document Number:
Revision:
Release Date:
EDC 506
0
01/03/2018
Installation, Operation, and Maintenance Manual
API 6D Two - Piece Cast Trunnion Mounted Ball Valve – Atlas Series
IOM: Installation, Operation and Maintenance Manual 1/17
API 6D Two - Piece Cast Trunnion
Mounted Ball Valve
Atlas Series
Document Number:
Revision:
Release Date:
EDC 506
0
01/03/2018
TABLE OF CONTENTS
1 SCOPE ............................................................................................................................................................................................. 3
1.1 RESPONSIBILITY FOR VALVE APPLICATION ................................................................................................................... 3
1.2 RECEIVING INSPECTION, HANDLING AND STORAGE .................................................................................................. 3
2 BILL OF MATERIAL ....................................................................................................................................................................... 5
3 INSTALLATION .............................................................................................................................................................................. 7
3.1 NAMEPLATE .............................................................................................................................................................................. 8
3.2 HIGH TEMPERATURE SERVICE ........................................................................................................................................... 8
3.3 LOW TEMPERATURE SERVICE ........................................................................................................................................... 8
4 OPERATION ................................................................................................................................................................................... 8
4.1 INITIAL START-UP/COMMISSIONING .................................................................................................................................. 8
4.2 NORMAL OPERATING ACTIVITY .......................................................................................................................................... 8
4.3 DOUBLE BLOCK AND BLEED OPERATION ....................................................................................................................... 8
4.4 BODY CAVITY RELIEVING SYSTEM .................................................................................................................................... 9
5 MAINTENANCE .............................................................................................................................................................................. 9
5.1 VALVE MAINTENANCE IN OPERATION .............................................................................................................................. 9
5.1.1 STEM LEAKAGE ................................................................................................................................................................... 9
5.1.2 SEAT LEAKAGE .................................................................................................................................................................. 10
5.2 SCHEDULE OF ROUTINE MAINTENANCE ....................................................................................................................... 10
5.3 VALVE CLEANING .................................................................................................................................................................. 10
5.4 EMERGENCY REPAIR ........................................................................................................................................................... 10
6 DISASSEMBLY AND REASSEMBLY INSTRUCTIONS ........................................................................................................ 11
6.1 DISASSEMBLY ........................................................................................................................................................................ 11
6.2 RECONDITIONING ................................................................................................................................................................. 13
6.3 REASSEMBLY ......................................................................................................................................................................... 13
7 PROPER VALVE TESTING ........................................................................................................................................................ 14
7.1 SHELL TEST ............................................................................................................................................................................ 14
7.2 HYDROSTATIC SEAT TEST ................................................................................................................................................. 14
7.3 DOUBLE BLOCK AND BLEED (DBB) TEST ...................................................................................................................... 14
7.4 SUPPLEMENTAL AIR SEAT TEST ...................................................................................................................................... 15
8 BOLTS TIGHTENING TORQUE ................................................................................................................................................ 15
9 TROUBLESHOOTING ................................................................................................................................................................. 15
IOM: Installation, Operation and Maintenance Manual 2/17
API 6D Two - Piece Cast Trunnion
Mounted Ball Valve
Atlas Series
Document Number:
Revision:
Release Date:
EDC 506
0
01/03/2018
We recommend that this entire document be read prior to proceeding
with any installation or repair.
Do not use any valve in applications where either the pressure or
temperature is higher than the allowable working values. Also, valves
should not be used in service media if not compatible with the valve
material of construction, as this may cause premature failure.
1 SCOPE
The following instructions are very important for the maintenance, disassembling and assembling of C&C
Atlas series end entry two-piece trunnion ball valves.
The instructions make references to valves with emergency sealant injectors and with back up rings for
high pressure service. As the above-mentioned features are not standard, in some cases these parts may
not be found, or may be found partially during the disassembling of the valves.
1.1 RESPONSIBILITY FOR VALVE APPLICATION
The End User is responsible for ordering the correct valves for the intended application. C&C Valves are to
be installed in observance of the pressure rating and design temperature. Prior to installation, the valves
and nameplates should be checked for proper identification to be sure the valve is of the proper type,
material, and is of a suitable pressure class and temperature limit to satisfy the application requirements.
1.2 RECEIVING INSPECTION, HANDLING AND STORAGE
On arrival at site, an accurate checking must be carried out in order to verify if any damage has occurred
during transportation.
Compliance to purchase order requirements.
Correct type, pressure class, size, body, trim & seal material and end connections
(This information may be found on the nameplate or may be stamped on the body of the valve)
Each C&C valve has unique serial number hard stamped on the closure of the valve.
(This shall be always be quoted for any enquiry related to a particular valve)
Condition of valve paint and location of required Mylar tags.
End protectors on valve end are in place with a nonporous moisture barrier between the cover and
the metal flange or welding end.
Valve are shipped in the fully open position with wooden or plastic covers to protect the ends from
ingress of foreign materials.
It is recommended that lifting devices that are rated for the valve weight should be used when lifting any
C&C Valves. C&C Atlas series ball valves 6” full bore and larger are provided with lifting lugs integral to the
valve body. Operators like gearboxes or actuators may have their own lifting points that are intended and
designed to bear the load of the operator only. Operator lifting points shall not be used to lift the
valve/operator assembly.
IOM: Installation, Operation and Maintenance Manual 3/17
API 6D Two - Piece Cast Trunnion
Mounted Ball Valve
Atlas Series
Document Number:
Revision:
Release Date:
EDC 506
0
01/03/2018
Do not store valve without end protection to prevent from ingress of foreign
materials
Recommended handling procedure when lifting with slings is shown in figure 1.
Pallets, boxes, crates are provided with lifting/piling indications that shall be followed at all times.
Operator lifting points shall not be used to lift the valve.
Other lifting equipment provided with hooks can be used instead.
Chains shall not be used instead of slings using procedures in figure 1.
Lifting equipment’s safe working load (SWL) shall always be double checked prior to any lift.
During lifting/handling always keep valve flange protection in place to avoid foreign material from
entering the valve bore
Pay attention, as not to damage the valve paint during lifting/handling procedures.
Special care to the marking applied on the crates, and particularly to piling instructions, must be taken during
storage/stowage of the box containing the valves. Unless otherwise agreed, CNC wooden boxes are not
suitable for storage/stowage one on top of the other. Non-observance of crate handling markings could result
in the serious injury of people and damages to the goods.
IOM: Installation, Operation and Maintenance Manual 4/17
API 6D Two - Piece Cast Trunnion
Mounted Ball Valve
Atlas Series
Document Number:
Revision:
Release Date:
EDC 506
0
01/03/2018
ITEM
Component
ITEM
Component
1
Body
24
Segment Ring Retainer
2
Closure
25
Stem Keys
3
Ball
26
Stem Pins
4
Stem
27
Stem Retaining Pin
5
Trunnion Support
28
Stem Fire Safe Seal
6
Seat Rings
29
Gland Flange
7
Seat Inserts
30
Gland Pin
8
Fire Safe Seat Seal
31
Cap Screws, Gland Flange
9
Seat O-Rings
32
Trunnion O-Ring
10
Seat Back up Rings
33
Trunnion Gasket
11
Springs
34
Trunnion Thrust Washer
12
Body O-Ring
35
Trunnion Bearing
13
Body Gasket
36
Cap Screws, Trunnion
14
Body Studs
37
Seat Injection Fittings
15
Body Nuts
38
Stem Injection Fitting
16
Antistatic Plunger/Ball
39
Check Valve
17
Antistatic Spring
40
Bleed Fitting
18
Stem Thrust Washer
41
Gear Stud
19
Stem Bearing
42
Gear Nut
20
Lantern Ring
43
Gear
21
Stem O-Rings
44
Lever
22
Stem Back up Rings
45
T-Lever
23
Segment Ring
46
Cap Screw, T-Lever
Whenever possible valve shall be stored indoors and out of weather. When stored without wooden
box, care must be taken not to put stainless steel valves and/or components in contact with any
carbon steel components and/or structures to avoid cross contamination. Also, grinding of carbon
steel components near stainless steel valves shall be avoided.
For open air storage, special precaution should be taken to avoid both package and valve damage
by environmental factors. Wooden boxes shall have minimum protection, using cellophane or
similar sheets without tears/holes adequately fixed and the boxes lifted from the ground. Box
condition shall be checked maximum every two months.
For storage periods over two months in un-covered areas, CNC does not take any responsibility
unless this requirement has been agreed on the purchase order.
Lubrication during storage is not recommended.
2 BILL OF MATERIAL
NOTE: Quantities of the valve components depend on valve sizes and classes. Valve sales drawing available upon
request shall specify quantities.
IOM: Installation, Operation and Maintenance Manual 5/17
API 6D Two - Piece Cast Trunnion
Mounted Ball Valve
Atlas Series
Document Number:
Revision:
Release Date:
EDC 506
0
01/03/2018
Sizes 2” – 4”
IOM: Installation, Operation and Maintenance Manual 6/17
Figure 2: Atlas Series Ball Valve
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