Manual-Trunnion Ball Valves
Manual-Trunnion Ball Valves
1. GENERAL
This manual covers the 3-PC trunnion mounted ball valves with trunnion plate design. This type of valves is selected as
open-close device in gas & oil pipelines and has adequate strength to withstand pipeline stress. They characterize
advanced design, low flowing resistance, fast & flexible open and closing, long service life and high reliability.
1.1 General Rules
1) Prepare for preliminary plans and the necessary tools.
2) Rule out the direct dangerous source.
3) Carry out the following necessary inspection before installation.
- Open the valve packing, carefully check the products' logo, notice the warning marks that be attached in valve or with
the valve, and take the appropriate action.
- Check whether the valve has flow indicating mark. If so, the installation place must be match with it.
- Carefully disassemble the protective cover in the end of valve. If available, the inspection to valve from inside to end
needs to be carried out, to check whether has other objects and harmful corrosion.
- After passing the inspection, carefully clean the oil and dirt that attached in the valve flange seal face or weld end.
- Before installation, inspection of dirt and other objects that attached in the pipe that connects with valve. If it is
necessary, it needs to be cleaned.
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- Carefully clean the oil and dirt that attached in the butt connection flange seal surface and weld end of pipe, and check
its surface condition, alignment degree(parallel, concentric), should meet the pipeline specification.
- As to the power operated valve, relevant inspection needs to be carried out according to the instruction of actuating
mechanism before installation.
4) After all the relevant inspection work is ready, valves should be installed at once.
5) During the installation process, ensure that there is no dirt or other external objects in the pipe or valves.
6) In the whole installation process of valves, the closure element should be in fully open situation.
7) Put valves in the right installation place, and it's important that ensure the alignment (parallel, concentric) of
connecting flange and butt ends.
8) Valves are installed in the pipeline, and try not letting it not
7) After finishing welding, make corrosion protection for welding sew as soon as possible.
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2. APPLICABLE STANDARD
(1) Design and manufacturing as per API 6D.
(2) Temp. and Pressure Rating as per ANSI B16.34.
(3) Face-to-Face as per ANSI B16.10.
(4) Flange as per ANSI B16.5 or MSS SP-44.
(5) Test and inspection as per API6D or API 598.
(6) Marking to API 6D.
3. FEATURES
Valve consists of body, body cap, ball, seat and stem etc. Stem may be extended on request; Extension dimension is to
be specified by customer. Operators may be manual, pneumatic, electric and gas over oil etc.
(1) Upstream Seal & Bi-directional Valve (Trunnion Ball Valve)
Superior spring-loaded seat module is employed for seat seal, it characterizes self-tighten function, and thus
upstream seal is achieved. Each valve incorporates two seats, both of which can be sealed. There’s no direction limit
in installation, inlet sealing is possible regardless of the fluid flowing direction. Thorough sealing is well assured under
high pressure, low pressure and vacuum.
(2) Double Block and Bleed (Trunnion Ball Valve)
As upstream seal & bi-directional valve, both of its two seats are able to block fluid. When the valve is in fully open or
closed position, the fluid or dirt entrapped in valve cavity can
Horizontal pipeline and the gear or actuator is above the pipeline. Withstand the mechanical forces.
9) Take appropriate methods to eliminate the external tensile, pressure and bending or reduce to minimum (such as
build the suitable basis).
8) Maintain the valve in fully open situation until the dirt, especially the dirt around the seat ring in pipe or valves need
to be cleaned completely.
9) After finishing the installation, pipeline needs to be cleaned correctly, and all the dirt needs to be cleaned completely
The way to clean is watering pipe/ flushing.
10) After watering the pipe, fully closed the valve and then turn to the fully open, to carry out the whole inspection, it
needs to be no breakdown.
4. INSTALLATION
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(1) For trunnion ball valve, either end of the valve can be installed in the upstream. Valves operated with handle or lever
could be installed anywhere in the pipeline. However, for gear-operated or pneumatic actuated ball valves, the valve
shall always be erectly installed, e.g. installed in horizontal pipeline and the gear or actuator is above the pipeline.
(2) Between the flanges of the valve and pipeline, there shall be gaskets in accordance with the design spec of the
pipeline.
(3) The bolts of the flanges shall be fastened symmetrically and equably.
(4) To connect pneumatic piping (when pneumatically actuated)
5. TROUBLE SHOOTING
5.1 General
(1) Prior to the disassembly of the valve, be sure the upstream & downstream pressure has been completely released.
(2) Be very careful to avoid the damage of the sealing surface of valve parts, especially for non-metal parts. The O-ring
shall be taken out by special tools.
(3) When assembling the valve, flange bolts shall be fastened symmetrically and equably.
(4) Cleaning solvent shall be suitable for rubber parts, plastic parts, metal parts and service fluid (e.g. gas). In the event
that the service fluid is gas, the metal parts can be cleaned by petroleum; meanwhile the non-metal parts may be
cleaned by pure water or alcohol.
(5) The individual parts disassembled can be cleaned by dipping in solvent. Undisassembled metal & non-metal parts can
be cleaned by means of soft silk (to avoid some tiny fibers left in the parts) dipped with solvent. All the dirts, stains
or dust must be removed from the parts.
(6) Non-metal parts shall be taken out of the solvent immediately as soon it is cleaned and it is not allowed to be dipped
in the solvent for long time.
(7) The cleaned parts shall be assembled until the cleaning solvent is volatilized (solvent may be wiping by un-dipped
silk). However, the cleaned parts may not be placed for long time, otherwise it is going to be rusted or polluted by
dust.
(8) New parts have to be cleaned as well prior to use.
Lubricant shall be suitable for the chemical properties of metal material, rubber parts, plastic parts and
service fluid. Normally, the grooves for sealing parts, rubber sealing rings, stem sealing & friction surfaces shall be
lubricated.
(9) When assembling the valve, there shall be no metal particles, fiber, oil (except those permitted), dust or other dirts
in the surface of the inner parts.
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Valves haven't been fully closed. When ball 1. Operate the valve to fully closed stop.
valve deviates the fully closed stop 2~3°, 2. Cut off and release valves to ensure that the leakage
it will appear leakage. stops. Please see the steps in section 7.3
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6.2 Replacement off-line: Replacement of seat inert (Item 9),O-Ring (Item 6 & 10)and body gasket (Item 11).
Valve seat insert, ball, stem and all other inner parts (except Item 29 and 31) could be repaired and replaced only after
the valve has been removed from the pipeline.
(1) To shut off the block valve in the upstream and downstream.
(2) To fully close the valve.
(3) To remove the valve from the pipeline and place the valve vertically and keep one body cap (Item 1) upturned.
(4) To loose bolts (Item 12) and remove body cap (Item 1).
(5) To remove seat ring (Item 8), Springs (Item 2).
(6) To remove the O-Ring (Item 10) and Body Gasket (Item 11)from body cap (Item 1).
(7) To take off the trunnion paltes (Item 14 and 21,) and ball (Item 17. For convenient re-assembly latter, it is not
necessary to take off the Thrust Bearing (Item 15 & 20) and Thrust Washer (Item 16 & 18) from the trunnion plate.
To remove the Anti-static Spring (Item 19) and keep it in right place.
(8) To turn over the valve and keep another body cap upturned, then follow the steps (4) – (6) to remove the inner parts.
(9) To Check if any inner parts damaged and then repair or displace the damaged parts. To clean all the inner parts.
(10) To lubricate the grooves of sealing parts and put the new O-ring (Item 10 ) and body gasket (Item 11) inside the
grooves in the body cap (Item 1).
(11) To put the new O-Ring (Item 6) and seat inert (Item 9) inside the Seat Ring (Item 8). To place the springs (Item 2)
in the correct position.
(12) To place the valve body (Item 18) horizontally on the ground and firstly put the lower trunnion plate (Item 14) inside
valve body (Item 18), and then assembly the ball (Item 17) inside the valve body (be sure the ball is in fully closed
position). Secondly to put the upper trunnion plate (Item 21) inside the valve body.
To put the Seat Ring (Item 8) against the ball (Item 17) and assembly the Body Cap (Item1) together with Valve
Body (Item 18) through Bolts (Item 12). Be sure the Trunnion Plate Pins (Item 3) are properly inserted into the pin
holes in Trunnion Plates (Item 14 & 21).
(13) Same procedures as Step (12) to assembly another body cap.
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6.3 Replacement off-line: Check & Replacement of Stem Sealing Unit – O-Rings (Item 25, 26 and 27)
(1) To follow the steps in Clause 6.1.1 to remove the Adapter Flange (33)
(2) To loose the Hex Screws (Item 32) and remove Gland (Item 28).
(3) To take out the O-ring (Item 25, 26 & 27) and check their condition & replace the damaged O-rings.
(4) To lubricate the stem sealing face
(5) To assembly the new O-rings.
(6) To assembly the Gland (Item 28) and Adapter Flange (Item 33)
(7) To assembly the driving unit.
(8) To check the operation of the valve
(9) To carry out the pressure test of the valve
(10) To install the valve on the pipeline and perform seat air sealing test as per the requirement of the pipeline.
(11) To carry out the pressure test of the valve.
CAUTION
(1) Ball shall be fully open and both of ends are with cover during the storage.
(2) Working conditions of the valve must be accordance with the nameplate and operation manual.
(3) The valve must be fully open or fully close when the system is running. It is prohibited that the valve is as
adjustment.
(4) When open the valve, must turn the lever slowly to avoid water hammer caused in the system due to rapid
opening, cause a previous flow volume or pressure fluctuation.
(5) In the event that valve body is eroded seriously or valve body became thin obviously due to wear and tear,
even leaking, the valve must be examined and repaired.
(6) During running the valve, it is not allowed to do welding repair and surface painting.
7. Maintenance
BTL pipeline ball valves only need little maintenance. In order to extend the life of valve, the following maintenance
needs to be carried out.
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that regularly, with the increase of these residues, it will damage valves or make them difficult to be operated, so it's
necessary to regularly make sewage for body cavity through release device in the root of valve body. If not, we
strongly recommend that take sewage treatment before freeze season
- Use the double block and bleed feature of valve to realize the sewage treatment.
7.3 Double block and bleed
Use of ball valve's double block and bleed features can make on-line sewage treatment for body cavity and inspection
of seat sealing integrity.
- In the discharge and relief process, the medium will spray out at fast speed under high pressure, and accompanied
by considerable noise. Stuffs must wear suitable personal protective clothes and stick to the relevant safety
requirements.
- Note the direction of the medium spray! Make sure that others and you are in safe condition.
- Forbid carrying out the discharge operation when the valve is in fully open or partly open position.
- Discharge operation process
1) The release device in valve root can choose release valve. As Figure 9 shows is our company's typical release
valve structure
2) Typical release valve has one or two bleeding holes, please notice their position. In discharge, any objects in
the valve or release valve will spray out at a fast speed. If necessary, it can change the direction of bleeding
hole through tightening the release valve.
3) Valve is in closed position.
4) Carefully counter clockwise loosen the hex nut of release valve to the ring, open the channel of release
valve.It must use wrench to fix release valve when loosen the internal hex screw, to prevent the connection
screw of release valve and body from loosen. Do not discharge the release valve when body is under pressure.
5) Close the release valve after bleeding.
6) If the valve can not stop flowing, which indicates the seat is leakage, please repair it according to Section 8.
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- If it is the first maintenance, and the valve has been used for more than 2 years, please fully clean it according to
Section 7.4.2
Injection Head
Non‐Return Valve
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Consumption of Consumption of
Valve's size
Each Seat(cm3) Each Valve(cm3)
2"(DN50) 25 50
3"(DN80) 35 70
4"(DN100) 55 110
6"(DN150) 70 140
8"(DN200) 85 170
10"(DN250) 95 190
Injecting Amount Of
Extended Pipe Pipe External
Unit Pipe Length
Size Diameter
cm3/m
1/4"(6mm) 0.540"(13.7mm) 46
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Product brand/manufacturer
Medium
Item
Val-Tex Sealweld
Natural gas Standard Seal Grease 80 bulk/80-Hs Stick Total Lube 911
Standard Valve Lubricant 2300 Silicone Light Lube Sealweld Silicone Lubricant
Dry CO2 Standard Seal Grease 302 bulk/Stick Sealweld Silicone Lubricant
Crude oil Standard Seal Grease 80 bulk/80-Hs Stick Total Lube 911
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