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Worcester Controls
WCAIM2020
(Part 13458)
818/828 Series 150# and 300# Flanged
2" - 8" Two-Piece Ball Valves
Installation, Operation and Maintenance Instructions
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.
A. INSTALLATION
1. Standard valves may be installed for flow or vacuum in either
direction. Valves with upstream relief hole in ball (V3 option) are
one-way valves. Use care to exclude pipe sealants from the valve
cavity.
2. When installing, use standard gaskets suitable for the specific
service. Tighten flange bolts or studs evenly. Follow ANSI
standards for flange bolt torques.
B. OPERATION
1. The operation consists of turning the handle and/or stem
1
/
4 turn
clockwise to close, and
1
/
4 turn counterclockwise to open. The stop
plate has a pointer, and when it points and/or the stem groove
and flats are in line with the pipeline, the valve is open. These
valves may also be automated.
2. These valves will provide bubble-tight shutoff when used in
accordance with Worcester’s published Pressure-Temperature
Chart.
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. These conditions should be checked with
Worcester’s Control Valve Brochure.
4. As shipped from the factory, valves (except oxygen prepared V20,
V33 or prefix code “X”, and valves with V38 or V46 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.
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.
NOTE: Media which contain fine powders (25 microns or less)
will significantly raise ball valve torque requirements.
CAUTION: The fluoropolymer body seal (T) and the graphite
body seal (Z) make excellent seals. However, some points of
caution in their use need emphasizing.
7. a. No fluoropolymer part (except seats) is reusable. Graphite
body seals are also not reusable. Upon disassembly of the
valve, they should be discarded and replaced with new parts.
b. Care must be taken to avoid scratching the fluoropolymer
during installation. Light lubrication of these seals can help to
prevent damage.
C. MAINTENANCE
If seepage is noted at stem, tighten retaining nut
1
/
6 turn at a time until
seepage stops. Caution: For maximum stem seal life, proper stem
adjustment procedure must be followed. Excessive tightening causes
higher torque and shorter stem seal life.
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2 818/828 Series 150# and 300# Flanged 2" - 8" Two-Piece Ball Valves WCAIM2020
Flow Control Division
Worcester Controls
D. REBUILDING
a WARNING: BALL VALVES CAN TRAP PRESSURIZED FLUIDS IN
BALL CAVITY WHEN CLOSED.
If the valve has been used to control hazardous media, it must be
decontaminated before disassembly. It is recommended that the
following steps be taken for safe removal and disassembly:
• Relieve the line pressure. Operate the valve prior to attempting
removal from line.
• Place valve in half-open position and flush the line to remove any
hazardous material from valve.
• All persons involved in the removal and disassembly of the valve
should wear the proper protective clothing such as face shield,
gloves, apron, etc.
CAUTION: If the seats and seals installed differ from those
removed, the valve nameplate or stop must be replaced or
remarked to indicate the altered materials and ratings or valve
tagged to so indicate.
1. A standard repair kit may be ordered for the valve. Specify the
size, series, material of seats and body seal and R# (revision
number) of valve, or for non-standard valves, the “P” number, “T”
number, “C” number, or similar number, as found on the
nameplate. Some series, such as AF and FZ have their own repair
kits, which are ordered by the prefix. (Use Series 818 or 828
designation.)
Examples:
P, T, C
or
Valve Prefix similar
Size (if required) RK Series Material Rev. # #
3" AF RK 818 TZ R3 —
2" RK 828 T R3 —
4" RK 818 RZ — T0914
2. Special handling and cleaning procedures are necessary for
oxygen and vacuum service valves. Refer to industry practices
when overhauling these units.
3. To Disassemble 2"-8" Two-Piece Valves:
a. Valve should be placed with the end connector (smaller body
section) uppermost and on a clean surface, the valve
preferably clamped or bolted down. To disassemble end
connector from body, remove body stud nuts from midflange.
b. Strike end connector with mallet and close the valve. The
mid-flange connection should break open. Repeat if not
successful at first try. The end connector should now be lifted
vertically from the body and placed on the clean surface with
mid-flange end uppermost.
c. With the valve still in the closed position the ball may now be
lifted from the body cavity, and the seats and body seal are
now exposed in either body or end connector. These should
now be removed. Care must be taken to avoid scratching the
machined faces on which they make contact with valve body
and end connector.
General Note: Depending on the valve size and whether a
standard, AF or FZ Series valve is being disassembled, stem
seals may be seven-piece, six-piece, five-piece, two-piece or
one-piece. Also, the 818/828 Series valves have one metal
stem washer under the stem seal(s).
d. Remove handle assembly (if any) by loosening handle screw.
Locking plates, if installed, do not need to be removed.
e. Remove retaining nut. Prevent stem from rotating by holding
stem with wrench.
f. Remove and retain stop (round spacer on 8" valves). Remove
and retain the follower.
g. Push stem into body cavity and remove. Remove and discard
stem seal(s) and thrust bearing. Remove and retain stem
washer.
4. Visual Inspection:
a. The ball and the surfaces against which the seats 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.
b. 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.
5. Reassembly: Refer to exploded view illustration on page 4 for
proper reassembly.
NOTE: Care must be used when handling graphite stem seals,
thrust bearings, and body seals. 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. These parts will
not work if they are cracked or broken. Light flaking of the
material is acceptable. If resistance is encountered when
installing stem seals over the stem, use follower to gently push
the stem seal down. Metal stem washer furnished on valve must
be reused.
Valves with a pressure relief hole in the ball (V3) must be
reassembled and installed with the hole upstream (end connector
side) to ensure that cavity relief is upstream when valve is closed.
Any valve with the V3 option will have an arrow on the body
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WCAIM2020 818/828 Series 150# and 300# Flanged 2" - 8" Two-Piece Ball Valves 3
Flow Control Division
Worcester Controls
pointing downstream. This arrow is stamped on the body or on a
metal tag welded to the body.
For all valves, lightly lubricate the ball, seats, body seal, stem
seal(s), and thrust bearing, with a lubricant compatible with the
media being handled, except for valves with V20, V33 or V38
options, which are assembled dry. White petroleum jelly is a good
general purpose lubricant. For oxygen-prepared valves (prefix
code “X”), use a PTFE-based lubricant such as Fluorolube S-30 or
equivalent.
2"-8" Two-Piece Valves:
a. Insert new seat in body. Make sure seat rests firmly on back
surface of recess.
b. Reassemble stem assembly by putting new thrust bearing
onto stem and inserting through body cavity into stem hole.
For 3"-8" sizes the thrust bearing can be distinguished from
the stem seals by the darker color of the 25% filled
fluoropolymer used in the thrust bearing. For the 2" size the
stem seals and thrust bearing are the same size and color,
and are interchangeable. Put metal stem washer, new stem
seal(s), and follower onto stem. Fire-rated valves use graphite
stem seal(s), which are metallic silver gray and thicker than
the graphite thrust bearing.
c. Add stop, pointing in correct direction (or round spacer for 8"
size), and stem nut. Using a wrench to prevent the stem from
turning, tighten the stem nut until stem packing is fully
compressed. Then back off
1
/
6 turn. Excessive tightening
causes higher torque and shortens stem seal life.
d. With valve in closed position (stop pointer and/or stem
groove and flats going across pipeline), carefully insert ball
into body so that stem slot engages tang on stem.
e. Install and make sure body seal rests squarely in seal surface
of body. Insert new seat in cavity of end connector.
CAUTION: If the body seal is installed on the end connector,
it will be damaged.
f. Carefully place the end connector into the body using two or
three body studs to align the mid-flange holes. When
correctly located, strike the end connector with a mallet to
push down the end connector further into the body. Tighten
all body nuts to the following torques:
Torque (Ft-Lbs)
Stainless Steel Studs Carbon Steel Studs
Valve Size 818-150# 828-300# 818-150# 828-300#
2" 33 33 34 34
3" 33 82 34 87
4" 57 82 60 87
6" 82 170 87 178
8" 170 214 178 253
g. Replace handle assembly and tighten hex head screw (manual
valves only).
Pressure checking of valve is desirable if practical.
6. When ordering parts, please provide the part name and the
following information as found on the valve nameplate:
a. Valve Size and Style and Revision Number - Examples:
3" - 818 6 66 T 150 - R3 Stem
6" - AF828 4 66 RZ 300 - R3 Ball
OR
b. Valve Size, Style and 5 Character Code, known as a “P”
Number, “T” Number, “C” Number, or similar number, the
designation for a non-standard product.
Example: 6" 828 6 66 T 300 P2577 Ball
The terminology shown in the part listing on the following
page is standard. Please use them when ordering parts.
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Flow Control Division
Worcester Controls
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: 931 432 4021
Facsimile: 931 432 3105
www.flowserve.com
© 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and Worcester Controls are registered trademarks of Flowserve Corporation. WCAIM2020 9/03 Printed in USA
A 1 Handle Screw
B 1 Handle Assembly
C 1 Retaining Nut
D 1 Stem Follower
E 1 Stem
F 1 Ball
G 1 Body
H 1 End Connector
J 2 Seats
K 1 Body Seal
L 1 Thrust Bearing
M 5 Fluoropolymer Stem Seal (2" 818/828 and 3" 818
uses 6, 6" 828 and 8" 818 uses 7)
N 2 Graphite Stem Seal
- AF/FZ only (2" 818/828 uses 1)
O 1 Stop Screw
P 1 Stop (Round Spacer on 8" Valves)
Q 1 Stem Washer
R 2 Button or Socket Head Screw
S 1 Moving Lock Plate
T 1 Fixed Lock Plate
U 1 Washer
2"-8" 818/828
Two-Piece Valves
ITEM QTY DESCRIPTION
ITEM QTY DESCRIPTION
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