Flowserve 608 User Manual

Installation, Operation
and Maintenance
Instructions

Series 608 Ball Valve

CAUTION: Flowserve recommends that all
product which must be stored prior to installation
be stored indoors, in an environment suitable for
human occupancy. Do not store product in areas
where exposure to relative humidity above 85%,
acid or alkali fumes, radiation above normal
background, ultraviolet light, or temperatures
above 120°F or below 40°F may occur. Do not
store within 50 feet of any source of ozone.

b. With valve open, remove three body bolts,
loosen fourth and swing out body. Remove fourth
bolt and spread pipe ends Close valve, remove
ball, seats, body seals. Return body to its original
position and temporarily secure it with two body
bolts diagonally opposite each other.

c. Weld valve in line.
d. Allow valve to cool, reassemble valve. Install

new body seals, if they were shipped separately
from the valve. Temporary Buna body seals, if
found in the valve as received, are not to be
reused. If coated stainless steel “S” gasket body
seals are used (Code M or G), the wide flange of
the “S” gasket must face the valve body. See
View A-A detail on page 5.

e. Tighten and torque body bolts evenly and
diagonally opposite each other, alternating in a
criss-cross pattern. Use torque figures below:

1.0 INSTALLATION

1. 608 valves may be installed for flow or vacuum
in either direction. Use care to exclude pipe
sealants from the valve cavity. Valves with
upstream relief hole in ball (V3 option) are one­way valves.

2. Weld End Valves (TE, SW, BW): NOTE: Prior
to welding , THOROUGHLY CLEAN ALLJOINT
SURFACES to prevent contamination. Valves with
“PG”, “RG”, “XG”, “AG”, and “GG” seat and body
seal combinations and V67 option code are
compatible with welding temperatures. Therefore,
these valves are weld-as-is and do not have to be
disassembled to be welded in the line. These
valves will have a red welding tag attached. If
these valves are disassembled, the graphite­coated stainless steel gasket body seals and the
seat back seals (used with “A” or “G” seats only)
must be replaced. When welding these valves, the
ball must be open to prevent adhesion of weld
spatter to the ball. Use STICK or MIG welding,
and allow valve and joint to cool to the touch
between passes. For all other weld valves:

a. Tack weld valve in place.

Note: Stainless steel bolts and nuts are generally
used in all three-piece valves with stainless steel
bodies.

CAUTION: The fluoropolymer and UHMWPE
body seals (codes T and U), and the coated
stainless steel gaskets (codes M and G) make
excellent seals. However, some points of
caution in their use need emphasizing.

3.
a. No fluoropolymer or UHMWPE part (except a
seat) or seat back seal is reusable. Coated
stainless steel gaskets are also not reusable and
cannot be used in stainless bodies with cast
surfaces or serrations in body seal area. Upon
disassembly of the valve, these seals or gaskets
should be discarded and replaced with new parts.

b. Care must be taken to avoid scratching the
fluoropolymer or UHMWPE seals or the coating of
the stainless steel gaskets during installation.
Light lubrication of these seals can help to prevent
damage.

c. Care must also be taken when handling
graphite thrust bearing, stem seal, or seat back
seal. These parts can be easily damaged by
squeezing the O.D. of the seal. Parts are to be
handled on the flat surfaces rather than the O.D.

d. The ball used in valves with “A” and “G” (filled
metal) seats is round to special tolerances. To
ensure proper contact with the seat, do not drop,
dent or scratch the ball during handling. These
balls also have an anti-galling coating. DO NOT
use uncoated balls with filled metal seats.

2.0 OPERATION

1. The operation consists of turning the handle
and/or stem 1/4 turn clockwise to close and 1/4
turn counter-clockwise to open. When the handle
and/or stem flats are in line with the pipeline, the
valve is open. These valves may also be
automated.

2. These valves will provide bubble-tight shut-off
when used in accordance with Worcester’s
published pressure/temperature chart. Valves with
“G” seats meet the leakage rates of ANSI B16.104
Class VI.

3. It is not good practice to leave a ball valve
partly open (throttling operation) without
knowledge of the pressure drop and flow at
that position.

4. As shipped from the factory, all valves (except
oxygen prepared (V20, V33 or prefix code “X”),
and valves with V38 or V6 options) contain a
silicone-based lubricant. This is for break-in
purposes, and may be removed if it is
objectionable for a particular application by
disassembling and solvent washing. Lacquer
thinner will remove the lubricant. “A” or “G” (filled
metal) seated valves should not be operated
without a break-in lubricant.

5. Media which can solidify, crystallize or
polymerize should not be allowed to stand in ball
valve cavities.

6. Torque Requirements – Operating torque
requirements will vary depending on the length of
time between cycles, line pressure, type of valve
seats, and the media in the system. For a detailed
analysis of valve torque requirements, see
Worcester’s Actuator Sizing Manual.

3.0 OPERATION AND
MAINTENANCE SECTION

.0

1. Valves should be opened and closed slowly to
avoid hammering effect on the valve and pipeline.

2. Valve should be “fully open” or “fully closed” to
prevent damage to the seat and ball caused by
wire drawing.

3. This valve is intended for on-off service and
should not be used in throttling applications.

4. If a stem leak develops, tighten the gland nut
until the leakage has been stopped. If the stem
leak cannot be stopped, replacement stem
packing is available.

CAUTION: For maximum stem seal life, proper stem
adjustment procedure must be followed. Excessive
tightening causes higher torque and shorter stem
seal life.

When replacing the packing, be sure that the
valve is not under pressure. Remove all actuation
to give access to the packing. After loosening and
removing the gland nut, the packing can be
removed by means of a hooked wire or a special
purpose tool.

5. If a through leak occurs, ensure that the valve
is fully closed. If leakage persists, replacement
seats are available.

6. If a body seal leak develops, do not over tighten
the body end cover bolting. This may damage the
valve. Instead a replacement
seal should be installed.

1

SECTION 4.0 DISASSEMBLY

1 Note: If complete disassembly becomes
necessary, replacement of seats, packing, and
bearing material is required. All persons involved
in the removal and disassembly of the valve
should wear the proper protective clothing such as
face shield, gloves, apron, etc.

WARNING: BALL VALVES CAN TRAP

PRESSURIZED FLUIDS INBALL CAVITY WHEN
CLOSED

2. For your safety and protection, it is important
that the following precautions be taken prior to
removing the valve from service or before any
disassembly of the valve:

A. At all times during this entire procedure, keep
hands out of the valve. A remotely actuated valve
could close at any time and result in serious
injury.

B. Know what media is in the line. If there is any
doubt, check with the proper authority.

C. Wear any protective clothing or equipment
normally required when working with the media
involved.

D. Depressurize the line and valve as follows:
Open the valve and drain the line. Close and open
the valve to relieve any residual pressure that may
be in the valve prior to removing the valve from
service. Leave the valve in the open position.
After removal and prior to any disassembly, drain
any remaining media by placing the valve in a
vertical position and carefully closing and
opening the valve several times.

3. Support the valve on a platform.

4. Remove all accessories and adapter or lever
nut and lever.

5. Remove stem nut lock plate. Remove stem nut,
spring washers, ground spring, and packing
gland.

6. Mark the body joint flanges to assure correct
body and tailpiece orientation during reassembly.
Unscrew the body end connection studs and
separate the body and tailpiece(s).

7. Place the body and tailpiece(s) on a clean
wood or cardboard surface. Use care not to
damage the mating surfaces of the body or
tailpiece(s).

8. Rotate the valve to the closed position and
remove the ball. Use care not to damage the
surface of the ball during handling.

9. Take out the seat rings and body seal(s). Use
care not to damage the sealing surfaces of the
seat pocket. Note: on 3-piece valves it may be
necessary to remove the body seals
and seats before the ball.

10. Push the stem into the body cavity and out
through the end port. Remove the stem washer.

11. Clean all parts carefully. If necessary, use a
suitable solvent.

12. Check all sealing surfaces and parts for
damage or uneven wear.

NOTE: The ball and the surfaces against which
the seats and seals are installed should be
undamaged, clean and free of pit marks and
scratches. Light marring from the action of the ball
against the seats is normal and will not affect the
operation of the valve. Flaws which can be seen
but barely detected with fingertips are acceptable.
The stem and body surfaces that the thrust
bearing(s) and stem seal(s) contact must be
undamaged, clean, and free of pit marks and
scratches.

SECTION 5.0 ASSEMBLY – 3­PIECE VALVES

1. Place the stem washer on the stem with the
chamfered I.D. side to be against the blow-out
collar. Apply a light coat of silicone lubricant to the
stem washer and insert the stem through the body
into the stem bore.

NOTE: For valves having graphite stem
seal(s), care must be taken when installing the
graphite parts because they are easily
damaged by squeezing the O.D. of the seals.
Handle gently by holding seal(s) on flat
surfaces rather than on the O.D. If resistance
is encountered when installing seal(s) over the
stem, use follower to gently push the stem
seal(s) down.

2. Install the stem packing into the packing bore.
Be careful not to scratch the I.D. of the packing
rings on the threaded section of the stem.

3. Apply a light coat of silicone lubricant on the top
packing ring and then place the packing gland,
ground spring and spring washers, stem nut lock
plate and the stem nut on the stem. Finger
tighten the stem nut. Spring washers must be
oriented cup to cup.

4. Rotate the stem to align with the ball in the
closed position. Carefully install the ball into the
body. Gently rock the ball to make sure the stem
is centered in the ball slot.

5. Apply a light coat of silicone lubricant on the
ball side of the seat and place it into the seat
pocket of one tailpiece.

6. Place the body gasket into the machined
recess of the body and place the tailpiece
assembly on the body. Press firmly
and evenly on the tailpiece.

Refer to view AA for proper orientation of
metal “S” gasket

Valves with a pressure relief hole in the ball
(V3 option and chlorine valves) must be
assembled and installed with the hole
upstream when the valve is closed, to insure
that cavity relief is upstream. Any valve with a
relief hole will have an arrow on the body
pointing downstream. This arrow is stamped
on the body or on a metal tag welded to the
body.

Note: Metal G seats and special ball come
coated with a Molycoat and should not be
lubricated with silicone

For valves with “A” or “G” seats, before
putting the center section back between the
pipe ends make sure that the seat back seal is
located on the seat correctly. If it is not, it
could be damaged or cause the valve to leak

CAUTION: Do not scratch body seals when
replacing valve body.

8. Insert the four long bolts through the bolt holes
on the top and bottom holes. The hex nuts must
be torqued sequentially as shown in Figure 1

9. Torque the stem nut to the values listed in
Table 1.

TABLE 1

View AA

Rotate the valve stem several times and re-torque
the stem nut.

10. Place the stem nut lock plate over the stem
nut making sure it fits securely over the stem nut.
It may be necessary to rotate the stem nut slightly
(tightening only) for the lock plate to fit.

11. Place the wrench on the stem and secure it
using the wrench bolt. Be sure to position the
wrench so that it rotates clockwise to close and
counterclockwise to open. Also make sure that the
locking device locks properly between the tabs of
the body casting.

Flowserve Corporation has established industry leadership in the
design and manufacture of its products. When properly selected, this
Flowserve product is designed to perform its intended function
safely during its useful life. However, the purchaser or user of
Flowserve products should be aware that Flowserve products might be
used in numerous applications under a wide variety of industrial
service conditions. Although Flowserve can (and often does) provide
general guidelines, it cannot provide specific data and warnings for all
possible applications. The purchaser/user must therefore
assume the ultimate responsibility for the proper sizing and selection,
installation, operation, and maintenance of Flowserve products. The
purchaser/user should read and understand the Installation
Operation Maintenance (IOM) instructions included with the product,
and train its employees and contractors in the safe use of Flowserve
products in connection with the specific application.
While the information and specifications contained in this literature are
believed to be accurate, they are supplied for informative purposes only
and should not be considered certified or as a guarantee of
satisfactory results by reliance thereon. Nothing contained herein is to
be construed as a warranty or guarantee, express or implied, regarding
any matter with respect to this product. Because Flowserve
is continually improving and upgrading its product design, the
specifications, dimensions and information contained herein are subject
to change without notice. Should any question arise concerning
these provisions, the purchaser/user should contact Flowserve
Corporation at any one of its worldwide operations or offices.

For more information about Flowserve Corporation, contact
www.flowserve.com or call USA 1-800-225-6989.

FLOWSERVE CORPORATION
FLOW CONTROL DIVISION

1978 Foreman Drive
Cookeville, Tennessee 38501 USA
Phone: [phone]
Facsimile: 931 432 3105
www.flowserve.com
© 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and
Worcester Controls are registered trademarks of Flowserve
Corporation.