Spirax Sarco M33 ISO Series, M33F ISO, M33F2 ISO, M33S ISO, M33F3 ISO Installation And Maintenance Instructions Manual

BAC13365

IM-P133-65

CMGT Issue 2

M33F ISO, M33S ISO and M33V ISO

Ball Valves

Installation and Maintenance Instructions

1. Safety information

IM-P133-65 CMGT Issue 2

2. General product information

3. Installation

4. Commissioning

5. Operation

6. Maintenance

7. Spare parts

© Copyright 2018

Printed in GB

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1. Safety information

Safe operation of these products can only be guaranteed if they are properly installed, commissioned,
used and maintained by qualified personnel (see Section 1.11) in compliance with the operating
instructions. General installation and safety instructions for pipeline and plant construction, as
well as the proper use of tools and saf ety equipment must also b e complied with.

1.1 Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet , check that the product is suitable for the intended use/application.
The products listed below comply with the requirements of the Pressure Equipment Directive

(PED) and carr y the mark when so required. The produc ts fall within the following Pre ssure

Equipment Directive categories:

Product Size

DN50 2 1 2 SEP

M33F ISO,
M33S ISO
and
M33V ISO

i) The product has been specifically designed for use on steam, compressed air, water and other

industrial fluids that are in Group 2 of the above mentioned Pressure Equipment Directive.

ii) Check material suitability, pressure and temperature and their maximum and minimum values.

If the maximum operating limi ts of the product are lower t han those of the system in which it
is being fit ted, or if malfunction of the product could result in a dang erous overpressure or
overtemperature occurrence, ensure a safety device is included in the system to prevent such
over-limit situations.

iii) Determine the correct installation situation and direction of fluid flow.

iv) Spira x Sarco products a re not intend ed to wi thst and external stresses that may be induced by

any system to which they are fitted. It is the responsibilit y of the installer to consider these
stresses and take adequate precautions to minimise them.

v) Remove protection covers f rom all connections and protec tive film from all name- plates, whe re

appropriate, before installation on steam or other high temperature applications.

DN65 2 1 2 SEP

DN80 2 1 2 SEP

DN100 2 1 2 SEP

DN150 2 2 2 SEP

DN200 2 2 2 SEP

Group 1

Gases

Group 2

Gases

Group 1

Liquids

Group 2

Liquids

1.2 Access

Ensure safe access and if necessary a safe wor king platform (suitably guarded) b efore attempting
to work on the product. Arrange suitable li fting gear if required.

1.3 Lighting

Ensure adequate lighting, particularly where detailed or intricate work is required.

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IM-P133-65 CMGT Issue 2

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.

1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.
closi ng isolati on valves, el ectric al isolati on) put any othe r part of t he system or any p ersonne l at risk?
Dange rs might in clude isol ation of ven ts or prote ctive devi ces or the re ndering i neffec tive of cont rols
or alar ms. Ensure isolation valves are turned on and off in a gradual way to avoid system shocks.

1.7 Pressure systems

Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume
that the system has depressurised even when the pressure gauge indicat es zero.

1.8 Temperature

Allow time for temperature to normalise after isolation to avoid danger of burns.
If par ts made from PTFE have been subjected to a temperature approaching 260 °C (500 °F) or
higher, they will give off toxic fumes, which if inhaled are likely to cause temporar y discomfort.
It is essential for a no smoking role to be enforced in all areas where PTFE is stored, handled or
processed as persons inhaling t he fum es from burning tabacco contaminated with PTFE particles
can develop 'polymer fume fever'.

1.9 Tools and consumables

Before star ting work ensure that you have suitable tools and/or consumables
available. Use only genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consi der whethe r you and/or oth ers in the vic inity req uire any prote ctive clot hing to prote ct against
the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and
dangers to eyes and face.

1.11 Permits to work

All work must be carr ied out or be super vised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the product according
to the Installation and Maintenance Instructions.
Where a formal 'per mit to work' system is in forc e it must be complied with. Where there is no such
system , it is recomm ended tha t a responsib le person sho uld know what wo rk is going on a nd, where
necessar y, arrange to have an assistant whose primary responsibility is safety.
Post 'warning notices' if necessary.

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1.12 Handling

Manual handling of large and /or heav y products may present a risk of injury. Lifting, pushing,
pulling, car rying or suppor ting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, t he individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.

1.13 Residual hazards

In normal use the external surface of the product may be ver y hot. If used at the maximum
permitted operating conditions the surface temperature of these products may reach temperatures
of 260 °C (500 °F).
These produc ts are not self-draining. Take due care when dismantling or removing the product
from an installation (refer to 'Maintenance instructions').

1.14 Freezing

Provision must b e made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.

1.15 Disposal

Unles s otherwi se stated in t he Install ation and Ma intenance I nstruct ions, this p roduct is rec yclable
and no ecological ha zard is anticipated wi th its disposal providing due care is taken, with the
exception of PTFE.

PTFE:

Can only be disposed of by approved methods, not incineration.

-

Keep PTFE waste in a separate container, do not mix it with other rubbish, and consign it to

-

a landf ill site.

1.16 Returning products

Custom ers and stockists are reminded that under EC Health, Saf ety and Environment Law, when
retur ning produ cts to Spi rax Sarco t hey must prov ide infor mation on a ny hazard s and the pre caution s
to be taken due to contamination residues or mechanical damage which may present a health,
safety or environmental risk. This information must be provided in writing including Health and
Safet y data sheets relating to any substances identified as hazardous or potentially hazardous.

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IM-P133-65 CMGT Issue 2

2. General product information

2.1 General description

The full bore two-piece body ball valves that are covered in this document have a f loating ball as standard
and are produced in accordance with API 6D. They have been designed for use as isolating valves, not
control valves.

ISO mounting

As standard, all the valves in this document have an integral ISO body mounting which allows the valve to
be automated without losing seal integrity, as the body does not require disassembly. Manual to remote
control may therefore be easily accomplished by fitting a BVA300 series pneumatic actuator available from
Spirax Sarco. For further details contact Spirax Sarco.

Available types and applications

M33F2 ISO

M33F3 ISO

M33S2 ISO Zinc plated carbon steel body and PDR 0.8 seats (for high temperatures)

M33S3 ISO Stainless steel body and PDR 0.8 seats (for high temperatures)

Applications

M33V2 ISO Zinc plated carbon steel body and PTFE seats

M33V3 ISO Stainless steel body and PTFE seats

Applications

Has an API 607 firesafe design, zinc plated carbon steel body and PDR 0.8 seats (for
high temperatures)

Has an API 607 firesafe design, stainless steel body and PDR 0.8 seats (for high
temperatures)

API 607 firesafe design - In normal working c onditions, the ball rests against two PDR

0.8 seats ensuring total closure. When the valve is submitted to temperature above the
limits the seats can withstand, the seat bec omes deformed and renders to extrusion. When
the seats have been totally destroyed, the ball will come to rest fir mly against the metal
seat in the c ap, producing a metal-to-metal closing. This secondar y seat in the valve cap
ensures the valve will operate to international API 607 standards.

Applications

Designed for use with the majority of industrial fluids on applications,
which include steam, condensate, water, oil, gases, and other fluids
within its operating range.

Designed for use with the majority of industrial fluids on applications,
which include steam, condensate, water, oil, gases, and other fluids
within its operating range.

Designed for use on applic ations at low temperatures which use natural
gas and most of the hydrocarbon fluids in the OPC refinery sites.

Standards

This product fully complies with the requirements of the Pressure Equipment Directive (PED) and carries

the mark when so required.

Certification

These products are available with material certification to EN 10204 3.1.
Note: All cer tification/inspection requirements must be stated at the time of order plac ement.

IM-P133-65 CMGT Issue 2

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2.2 Sizes and pipe connections

DN50, DN65, DN80, DN100, DN150 and DN200.

Standard flange ASME B 16.5 Class 150 and 300 with face -to-face dimensions acc ording to B 16.10.

Fig. 1 M33 _ ISO

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2.3 Pressure/temperature limits

Pressure psi g

0 100 200 300 400 500 600 700

M33F ISO

and

M33S ISO

M33V ISO

A - B Flanged

ASME 300

A - C Flanged

ASM E 150

Body design conditions ASME B 16.34

Maximum allowable

PMA

pressure

Maximum allowable

TMA

temperature

Minimum allowable temperature -29 °C -20 °F

Maximum operating

PMO

pressure for saturated
steam service

Maximum operating

TMO

temperature

Minimum operating temperature -29 °C -20 °F

Maximum differential pressure is limited to the PMO

PMX

Designed for a maximum cold hydraulic test pressure of:

260

A

200

150

100

Temperature °C

230
200

150

100

Temperature °C

-29

Steam
saturation

50

curve

0

-29
0 10 20 30

0 100 200 300 400 500 600 700

A

Steam
saturation
curve

50

0

0 10 20 30

M33V ISO ASME 30 0 51 bar g @ 45 °C 740 psi g @ 113 °F

M33F ISO and M33S ISO

M33V ISO 230 °C @ 0 bar g 446 °F @ 0 psi g

M33F ISO and M33S ISO 260 °C @ 0 bar g 500 °F @ 0 psi g

M33V ISO 10 bar g 145 psi g

M33F and M33S ISO 17.5 bar g 254 psi g

M33V ISO 230 °C @ 0 bar g 446 °F @ 0 psi g

M33F ISO and M33S ISO 260 °C @ 0 bar g 500 °F @ 0 psi g

C

Pressure bar g

Pressure psi g

C

Pressure bar g

ASM E 150 19 bar g @ 38 °C 275 psi g @ 100 °F

ASM E 150 20 bar g @ 38 °C 290 psi g @ 100 °F

ASM E 300 51 bar g @ 38 °C 740 psi g @ 100 °F

ASM E 150 28.5 bar g 413 psi g

ASM E 300 76.5 bar g 1109 psi g

The product must not be

used in this region.

40 51

The product must not be

used in this region.

40 51

500

400

300

200

100

B

0

400

300

200

100

0

B

Temperature °F

Temperature °F

IM-P133-65 CMGT Issue 2

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3. Installation

Note: Before ac tioning any installation observe the 'Safet y information' in Section 1.

Although the valve has great structural integrity, severe misalignment and/or the pulling ef fect of incor rect
pipe length will have a detrimental ef fect on the valve and must be avoided. Par ticular attention should be
paid to correct pipe alignment such that the inlet pipework and valve are all on the same axis.
Valves are for on/off applications and may be operated manually.
Wherever practicable, valves should be installed where there is adequate space available so that they can
be conveniently operated and maintained.
Before installing a valve, check to ensure that size, pressure rating, materials of construction, end c onnections,
etc. are suitable for the ser vice conditions of the particular applic ation.
Care must be taken to ensure that all dirt which may have ac cumulated in the valve during storage is removed
before installation, maintain cleanliness during installation since the introduction of dirt can result in damage
to the valve seats and operating mechanism.
To minimise the danger of abrasive particles damaging the seats, pipeline strainers should be fitted upstream
of the valves.
Install the valve with the handle in a suit able position. The preferred position is with the spindle vertical. The
valve can be installed in any position for gas ser vice (see Figure 3 below).

When used on steam ser vices:

1. Fit a trapped drain pocket upstream of the valve.

2. Open valve slowly to prevent the risk of waterhammer damage.

Do not mount the valve upside down
for liquid ser vic e (Figure 2).

Fig. 2 Incorrect installation for
liquid service

Valves should be installed into the
pipeline in the fully closed position.

Always open valves slowly to avoid
system shocks.

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Fig. 3 Cor rect installation for gas ser vice

IM-P133-65 CMGT Issue 2

4. Commissioning

After installation or maintenance ensure that the system is fully functioning. Carry out tests on any alarms
or protective devices.

5. Operation

The valve is operated manually by a handle. Special care must be taken to ensure that the movement is
made in the c orrect direction.
The valve can be used as an on/off valve, and c an be operated fully open, or fully closed.

IM-P133-65 CMGT Issue 2

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6. Maintenance

Note: Before ac tioning any maintenanc e programme observe the 'Safety information' in Section 1.

6.1 General information

As with all mechanical devices, regular maintenance is the most efficient means of ensuring continued
operational efficiency.
Regular scheduled inspection of all valves is essential, especially on valves which are operated only
occasionally.

6.2 General maintenance

Isolate the unit - Before removing the M33 ISO ball valve from the pipeline to action any maintenance work,
isolate it both upstream and downstream and wait for the unit to reach ambient temperature before handling.
The complete body assembly can then be removed and any new parts f itted - See Section 7.

6.3 How to replace the stem seats:

Remove the ball valve from the pipeline observing the 'Safety information' in Section 1.

-

Warning: Isolate the ball valve both upstream and downstream and wait for the unit to reach ambient

temperature before handling.

Remove the nuts (20) from the studs (19) and split the main body (1) from the insert (2).

-

Remove the seats (4) and the ball (3).

-

Withdraw the stem (6) and replace the lower stem seal (7) and the 'O' ring (8).

-

Reassemble the unit using a new body gasket (5). The nuts and studs (19, 20) and gland nut (13) sh ould

-

be tightened to the recommended torque, see Table 1, page 12.

Please note - When the seats and lower stem seal have been replaced and the valve has been reassembled
it is advisable to conduct a cold hydraulic test to the valve body as follows:

ASM E 150 28.5 bar g (410 psi g)

-

ASME 300 76.5 bar g (1010 psi g)

-

It is also advisable to conduct a seat leakage test using c ompressed air at 7 bar g (101 psi g).

After 24 hours in ser vic e, retighten nuts (20 and 13) and check for leaks.

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IM-P133-65 CMGT Issue 2

Locking plate

DN65 to DN200

Screw

DN50 shown for the main illustration

Fig. 4 M33 _ ISO

8

7

6

2 x Belville washers

13

Stop screw

Separator

Screw

Locking plate

13

Belville stem

washers

Stop plate

Separator

9

2

IM-P133-65 CMGT Issue 2

520

28

1

19

28

4

3

4

11

6.4 How to replace the upper stem packing:

Obser ve the 'Safety information' in Section 1.

-

Warning: Isolate the ball valve both upstream and downstream and wait for the unit to reach ambient

temperature before handling.

Remove the gland nut (13).

-

Replace the upper stem packing (9).

-

Reassemble the unit and tighten the gland nut (13) to the recommended torque, see Table 1.

-

Please note - If leakage is observed through the stem, after 24 hours in service, it may be stopped by
retightening the gland nut (13) to the recommended torque, see Table 1.

Table 1 Recommended tightening torques

Part Size

DN50 60 140 44 10 3

DN65 60 220 44 162

Studs (19) and
Nuts (20)

Gland nut (13)

DN80 60 220 44 162

DN100 140 140 103 103

DN150 140 220 103 162

DN200 350 350 258 258

DN50 30 - 40 22 - 30

DN65 54 - 61 40 - 45

DN80 54 - 61 40 - 45

DN100 76 - 90 56 - 66

DN150 196 - 216 145 - 159

DN200 196 - 216 145 - 159

ASM E 150 ASME 300 ASM E 150 ASME 3 00

N m (lbf ft)

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IM-P133-65 CMGT Issue 2

Locking plate

DN65 to DN200

Screw

DN50 shown for the main illustration

Fig. 5 M33 _ ISO

8

7

6

2 x Belville washers

13

Stop screw

Separator

Screw

Locking plate

13

Belville stem

washers

Stop plate

Separator

9

2

IM-P133-65 CMGT Issue 2

520

28

1

19

28

4

3

4

13

7. Spare parts

The spare parts available are shown in solid outline. Parts drawn in a grey line are not supplied as spares:

Seats, body gasket, stem seals, stem 'O' ring and seat 'O' ring set 4, 5, 7, 8, 9, 28

How to order spares

Always order spares by using the descr iption given in the column headed 'Available spares' and state the
size and type of ball valve.

Example: 1 - Seats, body gasket, stem seals and stem 'O' ring set for a Spirax Sarco DN80 flanged
ASME 150 M3 3SV2 ISO ball valve.

8

7

Fig. 6 M33 _ ISO

14

9

428

28

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