Flowserve F53 Series Flanged DIN Reduced Bore Ball Valve User Manual

User instructions

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1

STORAGE AND PRESERVATION

All valves are despatched in the open position and it is recommended that they are left in this position during
storage. All protective packaging should remain in position until the valve is to be installed. Valves should be stored
in a clean, dry environment. Carbon steel valves are manganese phosphated and coated with a de-watering oil. This
coating is non-toxic and is quite safe on edible or potable products.

2 VALVE

MARKINGS

Each valve has the following identification information plate attached to the side of the body:

2.1

Pressure Equipment Directive: If the identity plate carries the Pressure Equipment Directive number '97/23/EC' and
the Notified Body identity number '0086' beside the 'CE' mark, the product complies with the Pressure Equipment
Directive 97/23/EC and the Pressure Equipment Regulations 1999 (SI 1999/2001). Without these numbers, the
product is classified as 'SEP' (Sound Engineering Practice) and may only be used within the limitations defined in
tables 6, 7, 8 & 9 of Schedule 3 of the Pressure Equipment Regulations.

2.2

ATEX Directive: If the identity plate carries the ATEX Directive number '94/9/EC' followed by the Explosion
Protection Symbol and codes identifying the equipment group and category, the zone suitability and protection type
beside the CE mark, the product complies with the ATEX Directive and The Equipment and Protective Systems for
Use in Potentially Explosive Atmospheres Regulations 1996.
Definition of identity plate marking above:
'II' = Equipment Group; '2' = Equipment Category; 'G' = Gas Zone suitability (Zones 1 & 2);
'D' = Dust Zone suitability (Zones 21 & 22); 'c' = type of protection i.e. constructional safety
(BS EN 13463-5).
'X' = Special temperature reference (Surface Temperature: As per BS EN 13463-1:2001 paragraph 14.2g, the tem
perature class or maximum surface temperature cannot be marked on the product as it is dependant on the
operating conditions. However, the maximum/minimum allowable operating temperatures for the product are
marked on the identification plate.

2.3

Should the valve soft trim materials be changed during the course of its operational life it is necessary for this
change to be reflected on the identification plate i.e. material change may impact pressure and temperature
limitations.Refer to Flowserve Flow Control Technical Sales for details.

2.4

Material traceability markings are hard marked on the valve body and connector.

3

HEALTH AND SAFETY

When installing or maintaining valves:

a)

Conduct a risk assessment and eliminate or reduce hazards to an acceptable level.

b)

Work in accordance with Safe Systems of Work.

c)

Observe all site Health and Safety Rules in particular Permit to Work and Hot Work procedures.

d)

Wear all necessary Personal Protective Equipment.

e)

Never remove or maintain a valve or joint unless the line has been fully de-pressurised, drained and where
necessary, purged of toxic / explosive / flammable media. Always operate the valve to the open position to
ensure that no trapped pressure exists within the cavity.

f)

Never handle valves that have been used on harmful substances unless they have been completely
decontaminated and certified safe to handle.

g)

Never use a valve on a duty which exceeds its prescribed operating parameters. Refer to Flowserve Flow
Control Technical Sales for performance curves or further information.

h)

Never modify or alter valves unless the manufacturer has been consulted or recommends such changes.

i)

The valves wrenches are only designed for use in operating the valves and must not be used to carry
them by. Failure to observe this warning may result in operator injury.

j)

Due to the large physical size and weight of some sizes of this product, always use correct lifting methods
and equipment when installing, removing and maintaining the product, and that it is correctly supported in its
final operating location.

k)

Due to the variety of duties on which this product can be employed, it is the end users responsibility to
ensure the compatibility of the media with the materials of construction of the product for each specific
application (i.e.corrosion and erosion which may affect the integrity of the pressure-containing envelope).

l)

Before equipment is installed in areas which may be subject to seismic activity or extreme climatic conditions
consult Flowserve Flow Control Technical Sales.

m) End Flanges: The end flange design of this product has been verified by either 2001(2003 addenda) ASME

Boiler and Pressure Vessel Code Section VIII Division 1 calculation method, by Finite Element Analysis in
accordance 2001(2003 addenda) ASME Boiler and Pressure Vessel Code Section VIII Division 2 - Alternative
Rules, or by experimental testing as defined in BS EN 12516-3 Valves Design Strength - Part 3 Experimental
Method.

Gaskets: The gaskets used in all methods are Spiral Wound to BS4865 for PN rated flanges, and ASME B16.20 for
Class rated flanges. These have Gasket Factors and Design Stresses of 2.5 and 10000psi respectively for Carbon
Steel gaskets, and 3.0 and 10000psi for Stainless Steel gaskets as defined in the 2001(2003 addenda) ASME
Boiler and Pressure Vessel Code Section VIII Division 1.

If gaskets are used with higher Gasket Factors and Design Stresses than those stated above, please consult
Flowserve Flow Control Technical Sales.

5

INSTALLATION INSTRUCTIONS

a)

Standard valves may be installed in either direction. Valves with a upstream relief hole (Q190) are
unidirectional and must be fitted with the flow arrow pointing downstream.

b)

Installation of flanged valves should follow prevailing site standards. Where such standards do not exist the
following should be used as a guideline.

i)

Flanged joints require compressive loading onto the gasket material as the normal line pressure forces
tend to separate the joint. There should be no misalignment between the valve and mating faces.

ii)

Pipework should have the correct gap to allow for the valve face to face length plus assembled gasket
material thickness.

iii) Ensure the pipeline and flange faces are clean and free of any debris which may be detrimental to flange

sealing.

iv) Bolting should be of the correct size, length and material for the duty.

v)

Locate the valve between the pipe ends and slide in the gaskets. It may be necessary to lever the mating
flanges gently apart to allow for easy fitting of the gasket. Care should be taken to prevent damage to the
sealing surfaces. Correct lifting equipment must be used when handling valves for operator safety.

vi) Assemble all bolts and loosely tighten. Diametrically and evenly tighten the bolts to the correct torque

required for the specific gasket material.

c)

It is recommended that the valves are left in the open position during fitting.

6

OPERATION

6.1

USE

Worcester ball valves provide bubble tight shut off when used in accordance with the published pressure/
temperature chart.

It is not good practice to leave a standard ball valve in the partially (throttled) position as this may cause damage
and seat life may be reduced. Flow control ball valves which contain seats designed for this purpose are available
from Flowserve Flow Control.

Any media which may solidify, crystallise or polymerise should not be allowed to stand in the ball cavity since this
is detrimental to valve performance and life.

6.2

MANUAL OPERATION

The basic type of wrench which is fitted to 15-50mm (½”-2”) valves is of sheet steel with integral stop. The larger
sizes of valves have a cast wrench head and tubular handle secured to the stem by a wrench bolt.

Worcester valves have ¼ turn operation, closing in a clockwise direction. It is possible to see when the valve is
open or closed by the position of the wrench: When the wrench is in line with the pipeline, the valve is open; when
the wrench is across the pipeline, the valve is closed. Similarly, if the wrench is removed the flats of the stem will
also indicate valve position.

When operating the valve the use of excessive side loading on the wrench should be avoided.

6.3

REMOTE OPERATION

Where automation of valves is required, Flowserve Flow Control (UK) Ltd. can supply pneumatic and electric
actuators to cover a wide range of operating torques.

Operation will be in accordance with installation, operation and maintenance instructions for the relevant actuator.

7

MAINTENANCE

7.1

GENERAL

With self wipe ball / seats and patented pressure equalising slots, Worcester valves have long, trouble free lives
and maintenance is seldom needed. The following checks will help extend life further and reduce plant problems:
Routine checks / maintenance:

i)

Every 25000 cycles or 3 months: Check for any signs of leakage (see 7.2, 7.3 & 7.4 below) and that all fasten
ers (including the gland nut) and joints are tightened to their correct torque value (see Section 10).

ii)

Infrequent operation: The valve should not be left standing without operation for more than 1 month. After
this period the valve should be operated through three full cycles.

7.2

IN-LINE LEAKAGE

Check that the valve is fully closed. If it is, then any leakage will be due to damage to the body, connector, insert,
seat or ball sealing surfaces and it will be necessary to dismantle the valve to repair it (see Section 9 & 10).

7.3

STEM LEAKAGE

Remove the wrench assembly as detailed in section 9 or the actuator as detailed in the relevant actuator I.O.M.,
followed by the gland nut locking clip (valves up to and including 65mm), and retighten to the recommended
torque. If the leakage persists then it will be necessary to dismantle the valve to establish the cause and/or replace
gland packings and thrust seals (see Section 9 & 10).

7.4

BODY/INSERT/CONNECTOR JOINT LEAKAGE

BODY/CONNECTOR:
Check the interface bolting is tightened to the recommended torque values and tighten if necessary. If leakage still
occurs it will be necessary to remove the valve from line and split the valve at the interface joint to replace the body
seal and to establish whether the seal faces of the body and connector have been damaged (see Section 9 & 10).

BODY/INSERT:
If leakage occurs here, it will be necessary to remove the valve from line. Remove the insert and establish whether
the body and insert seal faces have been damaged. Replace the body seal, refit and tighten the insert to to the
recommended torque value (see Section 9 & 10).

8

REPAIR KITS

Repair kits are available for all Worcester valves. Details of their contents are found in the Instruction sheet
supplied with the kit.

If other parts are required, it is usually recommended that the complete valve is replaced, although piece parts are
available. Parts from different sized / rated valves must not be interchanged.

Only Worcester authorised spare parts should be used. This includes basic components such as fastenings.
Flowserve Flow Control will accept no responsibility if the valve is altered in any way without the consent
of Flowserve Flow Control.

3

HEALTH AND SAFETY (cont.)

Bolting: End flanges have been verified by the methods stated above, using bolt design stress values
based on those for ASTM A193 B8 Cl.2 (i.e. 25000/20000psi - dependant on the bolt size) for
Stainless Steel valves, and ASTM A320 L7 (25000psi) for Carbon Steel valves as defined in 2001(2003
addenda) ASME Boiler and Pressure Vessel Code Section II - Materials - Part D - Properties.

n)

Lethal Service. In accordance with the design verification code (2001 (2003 addenda) ASME Boiler
and Pressure Vessel Code Section VIII Division 1) a casting quality factor of 1.0 is allowable for
all products. Those intended for 'lethal service' must have had non-destructive examination carried out
in accordance with Appendix 7 of the code. Refer to Flowserve Flow Control Technical Sales.

o)

If the processes or environments that the products are used in are likely to cause temperatures
(high or low) that may cause injury to personnel if touched, then adequate insulation/protection must
be fitted.

p)

If the equipment is to be used on unstable gas duty, ensure that the operational parameters as
indicated on the product identification plate cannot be exceeded.

q)

This equipment should be protected by other devices to prevent over-pressurisation.
(i.e. caused by external fire etc).

r)

This equipment must be installed in a system that is designed to prevent excessive forces acting on
the flanges, connections, etc.

4

PREPARATION FOR INSTALLATION

When dispatched, valves contain a mineral oil which aids the bedding in of the valve. This may
be removed if found unsuitable. Special variants may contain other lubricants or be dry built.

Some valves contain a Silica gel bag inside the ball cavity to absorb humidity during storage.
These must be removed before installation, as must all other protective packaging.

For valves up to and including 65mm it is important to ensure that the gland nut locking clip is
retained at all times. If, during installation, it is noted that the locking clip is not in place, the gland nut
must be adjusted to the correct torque and a new locking clip fitted.

Significant problems can arise with any valve installed in an unclean pipleline.
Ensure that the pipeline has been flushed free of dirt, weld spatter, etc. before installation.
The working area should be clean and clear of any debris which could contaminate the valve.

User Instructions

Worcester Reduced Bore 53/54 Series

Installation

Operation

Maintenance

WCEIM0010-01

Flowserve Flow Control

A Division of Flowserve GB Ltd.
Burrell Road,
Haywards Heath,
West Sussex
RH16 1TL
England
Telephone: +44 (0)1444 314400
Telefax: +44(0)1444 314401

Published and Printed by
Flowserve Flow Control

Information given in this leaflet is
made in good faith and based
upon specific testing but does not,
however constitute a guarantee.

© Copyright Flowserve Flow Control

WCEIM0010-01 Replaces PB 53/54 IOM Iss. 5/04

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