Jag FB2 Installation, Operation & Maintenance Manual

12315 Parc Crest Dr. # 190

Stafford, TX 77477 USA

tel. 1+ 281.933-5775

fax: 1+ 281.933.5779

FB2

Floating

Quarter Turn Soft Seated

Ball Valves

Storage, Installation, Operation

2 Piece Valve

& Maintenance Manual

PUBLICATION No: JAG.FB2-IOM.Rev.0

Issued: 10/2012

JAG flocomponents FB2 IOM

2012

INDEX OF CONTENTS

SECTION 1: STORAGE

SECTION 2: UNPACKING & INSPECTION

SECTION 3: PRE-INSTALLATION

SECTION 4; HANDLING

SECTION 5: INSTALLATION

SECTION 6: OPERATION

SECTION 7: MAINTENANCE

SECTION 8: MAINTENANCE KITS

SECTION 9: SAFETY PRECAUTIONS BEFORE REMOVING VALVE FROM

PIPELINE.

SECTION 10 SAFETY PRECAUTIONS AFTER REMOVING VALVE FROM PIPELINE

SECTION 11 VALVE FASTENERS - APPROX TORQUE VALUES

APPENDIX I TYPICAL VALVE GA

APPENDIX II TYPICAL SEALANT INJECTION

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SECTION 1 - STORAGE

1.1 Pre Despatch

Non corrosion resistant valves shall be

primed and/or painted.

After testing and before shipment, valves

shall be drained of test fluid.

Parts and equipment shall have exposed

bare metallic surfaces protected with a rust
preventative which shall not become fluid
and run at temperatures less than 125°F.

Exposed sealing surfaces shall be protected

from mechanical damage for shipping.

Valves not destined for immediate use will

be adequately prepared and packed before
shipping in such a way as to avoid any
possible damage during transport and
during the subsequent storage period before
use.

Relevant valve certification is always

included in shipment.

1.2 Customer Storage Instruction

If possible it would be advisable to leave the

valves in their own packing cases and/or
pallets during the entire period of storage. In
either case, to prevent damage, the
protective covers on the flanges of every
valve must not be removed. The valves
must always remain in an OPEN position.

It is advisable that storage conditions be

closed and dry. The valves should be stored
in weatherproof conditions in a building with
an adequate roof.

Gearboxes and actuators are supplied and

shipped already assembled with their
relative Valves and fitted with additional
equipment (e.g. Limit Switches / Solenoids)
as required by the customer contract.
Caution must be taken to ensure that all
protective covers on this equipment are not
removed until installation.

2.1 Unpacking and Inspection

Care should be taken during unpacking of

valves.

It is advisable to check valve exterior for

shipping damage and any damage should
be reported to the Quality Assurance
Manager immediately.

All JAG flocomponents valves are supplied

with the ball in the open position and
protective covers on both ends.

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Ensure end covers remain securely in place

until the valve is ready for installation.

This will prevent ingress of dirt and damage

to ball surface and end connection surface
finish.

Please also check that valve certification is

correct to the requirements.

SECTION 3 - PRE-INSTALLATION

3.1 Pre Installation

Before installation check to ensure size,

pressure rating, end connection and material
of construction are suitable for required
service conditions.

Remove dirt/debris that may have

accumulated in the valve during long term
storage and always maintain valve
cleanliness during installation procedure.

In particular weld spatter should be kept

clear of valve seats as this could result in
damage to the soft seats and valve
malfunction.

SECTION 4 - HANDLING

4.1 Handling

On valves with restricted space between the

flanges handling is achieved by slinging the
valve on the neck diameter behind each of
the pipe flanges.

NB. Webbed slings should be used at all

times.

SECTION 5 - INSTALLATION

5.1 Installation

JAG flocomponents valves can be supplied

with various end connections.

Ensure that the pipe work, flanges, etc., are

square, true and that pipes are properly
supported to prevent line buckling, which
could result in excessive stress on the valve.

Dependent on the application, the joint/

gasket selection and bolting torques as
recommended by the joint/gasket
manufacturer[s] should be observed to
maintain sound, tight joints.

Butt Weld End Valves - during welding all

possible efforts should be taken to stop the
ingress of weld slag into the pipeline.

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5.2 In-Line Testing

Do not leave valves in the half open position

as this could result in damage to the soft
seat.

Ensure that after welding (if applicable) all

valves are flushed out and left in the fully
open or fully closed position.

The valve is now ready for line testing.

Ensure that after testing all valves are

flushed out and left in the fully open or fully
closed position.

SECTION 6 - OPERATION

6.1 Operation

JAG flocomponents (manual operation)

floating ball valves are operated by a simple
quarter turn of the stem to the fully open or
fully closed positions against the stops.

The valve position is indicated by the stem

flats and / or handle.

When the stem flats and/or handle is in line

with the pipeline the valve is in the fully
open position. When stem flats and/or

handle are at right angles to the pipeline
the valve is in the fully closed position.

Floating Ball Valves contain two seats.

Each seat is made of RTFE or similar
material.

The valve seals by pressure in the line

pushing the ball into the opposite seat
ensuring a positive seal on the outlet sides
of the valve.

As more pressure is applied a tighter seal is

formed.

If the valve is provided with a gear, the

position stops that are located in the manual
gearbox are adjusted and factory set to give
true alignment in both the open and closed
positions.

JAG flocomponents recommends that the

position stops should not be tampered with
as it may affect the operational efficiency of
the valve.

The valve closes in a clockwise direction.

Where manual operation is not required an

actuator may control the valves.

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Actuator operation shall be in accordance

with the actuator manufacturers
Installation, Operation and Maintenance
Instruction.

Note: Like any other piece of precision

machinery, JAG flocomponents ball valves
should not be immobilised for long periods of
time. Where possible, the valve should be
cycled at periodic intervals to ensure
continued correct operation.

Tight closure valves are intended to be

either FULLY OPEN or FULLY CLOSED.
Leaving the ball in some intermediate
position can rapidly cause severe damage
and / or failure.

SECTION 7 - MAINTENANCE

7.1 Maintenance

All JAG flocomponents floating ball valves

are designed with an anti-blow out stem.

JAG flocomponents floating ball valves do

not require lubrication.

Maintenance is seldom required.

If necessary, the valves may be refurbished

by relatively unskilled labour using a small
number of parts, none of which require
matching on site.

The only parts likely to require attention are

Ball, Seats, Stem, 'O' Rings and Fire Safe
Seals.

JAG valves are designed for ease of service

and assembly in the field. The only
preventative maintenance recommended is
to periodically inspect the valve for leaks
around the stem. Should a leak be noticed,
the following procedure is for adjusting the
packing.

Stem Packing Adjustment ­ Remove the nut and handle from valve.

Bend up the lock washer and snug up the
nut in a clockwise direction. Once complete
bend back lock washer and replace handle
and nut.

Leakage at Body Joint: This is invariably due

to damage to the cap seal and it will be
necessary to dismantle the valve.

In-Line Leakage: Check that the valve is fully

fully closed. If the valve is fully closed, then
leakage will be due to damaged seat or ball
sealing surface. Further maintenance on

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seat or ball necessitates dismantling the
valve.

Leakage at Pipeline Joint: Test for tightness

of flange bolting. If slack, tighten bolting to
gasket/bolting manufacturer's recommended
torque. Ensure pipe work flanges etc., are
square, true and that piping is properly
supported to prevent line buckling.

Note: Over tightened bolts can cause flange

leaks as excessive force can cause flanges
to bow.

7.2 Dismantling the Valve

Remove the gland nut (14) and handle
(22) (or gear box if applicable);

Remove stopper (16), gland nut (14), lock
washer (18), locking plate (17), belleville
washers (21) and packing ring (6);

Remove nuts (13);

Remove cap (2);

Place Valve in closed position and
remove Ball (3);

Push stem (4) through body (1) from
the outside in;

Remove seats (5) from body (1) and cap
(2)

Remove old packing (10) from body (1)

The valve has now been dismantled. It can

be cleaned and checked for wear and
damage. Damaged seats must be replaced
and therefore a new set of seats should be
fitted into body of cap. New sets of 'O' Rings
and firesafe seals should be fitted and any
other defective parts replaced.

7.3 Assembling the Valve

Replace seats in body (1) and caps (2);

After replacing thrust washer (7) and O-ring
(11) push stem (4) internally through the
body (1)

When fully located turn stem one complete

revolution to ensure smooth action;

Line up stem (4) and replace ball (3) into
body (1);

Replace body seals (8) (9)

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Fit cap (2) over studs (12) and replace and
tighten nuts (13). (See Section 11.1 for
tightening torques);

Replace packing (10) over Stem (2) and into
body (1);

Replace packing ring (6) over stem (2) and
onto packing (10);

Replace belleville washers (6) over stem (2);

Replace gland nut (14) and torque nut to
30ft/lbs of torque;

Replace lock washer (18) and bend over
gland nut (14)

Replace stopper (16) and locking plate (17),

Replace Handle (22) and gland nut (14)

Check stem action. (4)

Check Open and closed position.

Always maintain valve cleanliness during
assembly procedure.

The valve has now been assembled ready
for test.

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In Service

SECTION 8 - MAINTENANCE KITS

8.1 Maintenance Kits

Maintenance kits are available from JAG flocomponents and consist of the following:
2 off Seats

1 set of O Rings and
1 set of Fire Safe Seals.

RECOMMENDED SPARES FOR ONE-YEAR OPERATION

No. Of Valves

Spare Kits 1 2 3 6

In event of valves requiring repair rather than maintenance, additional spare parts are available from JAG
flocomponents.

These parts are typical recommended spares.

If additional parts other than this list are required it may be recommended that the complete valve is replaced.

IMPORTANT

Spare parts from different valve types should not be interchanged. This will ensure that the valve remains capable
of being used for its original design and construction purpose. There can be no risk to health and safety when the
valve is properly used.

JAG flocomponents shall not be liable for any Failure/Damage/Injury where valve parts are not of the Company's
original design or specification.

SECTION 9 - SAFETY PRECAUTIONS

BEFORE REMOVING VALVE FROM PIPELINE

9.1 Safety Precautions - Before removing

valve from Pipeline

Media flowing through a valve may be

corrosive, toxic, inflammable or of a
contaminant nature.

Where there is evidence of harmful fluids in

the valve pipeline the utmost care must be
taken.

It is suggested that the following safety

precautions should be taken when handling
valves of this nature.

Always wear eye protectors.
Always wear gloves and overalls.
Always wear protective footwear.
Always wear protective headgear.

Ensure that running water is readily
available.
Ensure suitable fire extinguisher is readily
available.

Ensure that no pressure exists on either the

upstream or downstream sides of the valve;
ask responsible pipeline personnel, to check
pipeline pressure gauges to ascertain
pressure is zero before handling valves.

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JAG flocomponents FB2 IOM

1 - 10 11 - 25 26 - 50 51 - 100

Ensure that any trapped media is released

by slowly operating the valve to the half
open position. Leave valve in the fully open
position before removing from the pipeline.

SECTION 10 - SAFETY PRECAUTIONS AFTER
REMOVING VALVE FROM PIPELINE

10.1 Safety Precautions - After removing valve

from Pipeline

If, after removing the valve from pipeline, it is

discovered the valve is closed and not in the
fully open position, ensure that any trapped
media is released by slowly operating the
valve to the half open position.

The safest place to stand when opening the

valve is away from the end of the stem, and
to one side of the valve.

Leave valve in the fully open position prior to

dismantling.

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Bolt Size

Material B7/L7

Material B7M/L7M

SECTION 11 - VALVE FASTENERS

11.1 Valve Fasteners - Approximate Torque Values

3/8” 16 UNC 33.50 ft/lbs 25.50 ft/lbs

1/2” 13 UNC 73.80 ft/lbs 36.40 ft/lbs

5/8” 11 UNC 149.00 ft/lbs 110.75 ft/lbs

3/4” 10 UNC 279.00 ft/lbs 210.00 ft/lbs

7/8” 9 UNC 414.74 ft/lbs 317.00 ft/lbs

1” 8 UN 614.00 ft/lbs 469.00 ft/lbs

2012

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