SC FEPA SABRLAD

API SPEC 6DCE 1370-PED-H-FEP-001-09-ROM 6D-1123

INSTALLATION, OPERATION&MAINTENANCE

BALL VALVE TYPE TOP ENTRY

SC FEPA SAStr.REPUBLICII nr.316, Cod postal 731120, Brlad-RomniaTel.+40 0235 411812Fax +40 0235 421 618/0235 413729e-mail: fepa@fepa.ro / marketing@fepa.ro

FIRE SAFE !API 607API 6FA

1. INTRODUCTION

The manual is designed to give the user complete information regarding installation,operation, adjustment, perform periodic inspections and maintenance of valves RSD-BB type Topentrywhose producer is FEPA Birlad.

READ THE INSTRUCTIONS CAREFULLY BEFORE INSTALLING AND USING THE

PRODUCT!For any further information it is recommended to contact the manufacturer.User's responsibility to know all the information presented in this manual and the specific applicationfor which it was purchased valve.It is also the responsibility of the user to use for installation, operation and maintenance only qualifiedand trainedOn request the valve manufacturer can provide training to its headquarters or beneficiary.The user is obliged to ensure all measures for safe operation, the health of staff, environment andfunction of the equipment.Before delivery valves are tested by the manufacturer.If the instructions are not clear, please contact us addressSCFEPA SA str.Republicii nr.316cod 731120BRLAD, or fepa@fepa.ro.At www.fepa.ro can find other information about the products FEPA.

2. DESCRIPTIONThe Top entry ball valve is specifically designed for in- line maintenance. The removal of the

bonnet from the valve allows free access to the body cavity.Limited space is required around the valve for maintenance; therefore the top entry ball valve

can be installed in areas where space is critical.Upon completion of the in-line maintenance the integrity of the seat seals can be easily

checked by pressurizing the body cavity without involving the pipeline system or other expensive testapparatus.The top entry ball valves have complete flexibility in the use of materials for body trim and seal gasketselection. For this reason, they can be trimmed to meet your most severe application.

Seat sealantinjection

Stem

Bonnet

Stem sealingStem sealantinjection

Seat

Ball

Body

Drain plug

Body spiral woundgasket

Body O-ring

ISO 5211Mounting flange Gland

BODY/BONNET DESIGN

The body is designed and manufactured in accordance with ANSI B16.34. Flange dimension inaccordance with ANSI B 16.5 or EN1092-1 or welding ends in accordance with ANSI B 16.25 Face to face/internal bore dimensions in accordance with API 6D

The bolted bonnet design complies with ASME Code Section VIII, Div.1. A wide variety of sealing materials are available for special needs, such as low temperatures andsour gases. The spiral wound gasket (AISI316+graphite) can also be used to further guarantee the performanceof design under fire condition. (Fire safe tested acc. to API6FA&API607)

SEAT DESIGN

2 pieces design 1 piece design

The valve is double block and bleed, self reliving seats. Choice of soft seated, metal to metal seatedor both. Secondary seat sealing system

DOUBLE BLOCK AND BLEEDThe sealing system of valves, acting on both sides ofthe ball, leads to the block and bleed principle.Whenever line pressure increases, both upstream anddownstream seats move against the ball providingpositive sealing. The bleed valve may be opened toverify tightness or to relieve body pressure for otherpurposes.

SEAT SEALAT INJECTIONAn emergency sealant injection system through the seat up tothe ball contact circle may provide temporary sealing until theprimary seal is restored.

STEM CONSTRUCTIONThe stem of the ball valve is of the anti-blow-out design. The stem and ball connection is of ruggedconstruction.Therefore, the maximum allowable stem torque is approximately 3 times the required valve torque(shop functional test) at the maximum differential pressure.The stem design incorporates a triple barrier sealing system (CHEVRON packing-rings and graphitepacking) which is provided with our standard construction. The stem sealing can be replaced whenthe ball is in the closed or open position provided that the body cavity is fully vented.The top entry ball valve standard design features are : trunnion mounted ball for ease of operation athigh pressure antistatic device, stem sealant injection; drain plug.

ANTISTATIC DEVICEThe ball valve is provided with the anti-staticstructure and adopts the static electricitydischarge device to directly form a static channelbetween the ball and body or between the balland body through the stem.This device discharges the static electricityproduced by friction during the opening andclosing of ball and seat or by eddy/turbulence offluid in the pipeline, and ensures system safetyby preventing fire or explosion from static spark.

STEM SEALANT INJECTIONAn emergency sealant injection point between thesecond and third O-ring is provided to temporarily sealthe stem until the primary seal is restored.

Extended stems are easily fitted to top entry ball valves. Extended stems are suitable forinaccessible areas or where the valves are to be installed underground. The length of the extension is measured from the centre line of the valve to the top of the actuatormounting flange(this dimension is to be specified at time of quotation or order). The drains are normally piped to the top of the extension for ease of venting. We offer the full range of automation and control systems conforming to international standards,supplying custom solutions to meet customer specifications and requirements for pneumatic, electricand hydraulic actuators and controls.

3. INSTALLATION-OPERATION

Inspect the piping system prior to valve installation whenever possible, to insure that it hasbeen properly flushed and cleared of construction and fabrication debris. The seating surfaces in softseated valves are particularly susceptible to weld slag and sand blasting grit. Pipe scale, metal chipsand other foreign materials should be removed.

Verify that Actuator, and mounting hardware as appropriate were included with the valve andare in good shape, that proper tagging is in place and any warning labels are eligible and observed .Just prior to installation, remove each valve from its packing and remove any end covers.

Examine the flow bore for debris. All FEPA ball valves are shipped in the open position toprevent damage to the ball surface. Any grit or foreign matter must be removed. Scratched or damageballs must be replaced. Do not install a damaged valve.It is also important to check for valve operation clearances. Valves may be installed in any positionusing standard pipe fitting practices. If possible, mount the valve in such a position that the actuatorcan, if necessary, be detached without removing the valve from the pipeline. The actuator must nottouch the pipeline, as pipeline vibrations may damage it or cause disturbance.

Flanged End Valve InstallationAfter determining that the valve is in good condition, extra attention should be given to the raised facesurface. Dents and heavy scratches should be repaired.

Weld-End Valve InstallationBoth butt-weld and socket -weld valves require special consideration for installation. In addition tothe general cautions already discussed, the heat of welding may damage seats and seals. The valvesare mounted in the pipeline by using standard welding methods and must be supported during thewelding. When welding or annealing the joint, assure that the temperature of the body in PTFE orrubber sealing material,e.g.120C.The increase of temperature can be prevent by wet protectioncloth around the body during the welding.

Threaded-End Valve InstallationAfter removing the valve from its packing inspect the NPT threads for damage. Occasionally threadsmay require chasing prior to installation to remove burrs or other minor imperfections.Apply a good grade of pipe sealant compound to the male pipeline threads only. Do not use sealanton the female threads because excess compound would be forced into the valve body. This couldcause sticking of the ball or encourage the accumulation of dirt and debris that could prevent goodvalve shutoff.FEPA valves are shipped with a securely fastened nameplate. Information included on each isdocumented in next fig. Although each valve is thoroughly tested and inspected before it leaves thefactory, nameplate could be lost or destroyed during shipment or while in storage. If either is missingor not legible, contact your distributor or the factory for assistance before operating valve.

Identification plateEach valve is provided with label (identification card) that includes:

Depending on the requirements of the technical specification of the beneficiary may appear on thenameplate - CE, API 6D no. License / marking fire test API607 or API 6FA.

0 Design/producer1 API /CE marking2 Key number3 Length4 Nominal diameter5 Nominal pressure6 FEPA identification cod7 design standard

8 Rating9 Body material10 Stem material11Ball material12 Seat material13 Serial number14 Date(mm-yy)

Ball valves are intended to be on-off devices operating through 90 rotation of the stem.Operation is clockwise to close.

The most common service failures not related to the installation and start-up processes are:Exceeding the operating temperature or pressure limits of the valve due to a process upset condition.A chemical attack on valve components due to either misapplication or changes in the service.Violating temperature and pressure limits can result in immediate valve failure where chemical attackor corrosion generally occurs overtime.

Prior to installation or system pressurization, evenly tighten all bonnet bolting using thecriss-cross method .

CAUTION: Do not loosen bonnet bolts while the valve is pressurized.

Always utilize factory authorized replacement parts.Good operating procedure requires periodic inspection of valves and replacement of necessary partsto ensure proper valve function.NOTE: Valves showing through leakage or high operating torque may be damaged. DO NOT useexcessive force or bars to operate valve. Disassemble valve, inspect components, and replacedamaged parts.

CAUTION: before attempting removal/repair, always cycle valve with system pressure isolated

to relieve excess pressure which may be trapped in body cavity.

4. MAINTENANCE INSTRUCTIONS

4.1 Bonnet Gasket RepairPeriodically inspect condition of external valve components. Replace all parts showing

excessive wear or corrosion.If bonnet gasket leaks, immediately tighten bonnet bolting as described under Installation-

operation instructions (criss-cross method).If tightening bonnet bolting does not stop leak, remove pressure from valve and place valve in

open position. -Remove bonnet bolting and lift bonnet assembly off of valve body. -Carefully remove bonnet gasket from body recess or from bonnet. -Inspect sealing surfaces of both valve body and bonnet for damage. Replace damaged componentsas necessary. -Replace bonnet gasket and install bonnet assembly onto valve body.

NOTE: When replacing bonnet gasket, always place the gasket on the bonnet and carefullyinstall the bonnet (with gasket) onto the body to avoid damage to the seal.Install and tighten bonnet bolting in accordance with Installation -operation instructions (criss-crossmethod).

4.2 Stem Seal ReplacementThe stem packing was adjusted at the factory to provide a leak tight seal when the valve was

new, but compaction can occur within these seals that may make re-adjustment necessary. Stemleakage should be stopped as soon as it is detected.

For manual valves it will be necessary to remove handle and the gland to make the packingadjustment.

For actuated valves it is necessary to remove the actuator and the gland to adequate accessto make the packing adjustment.Inspect and clean stem and the gland and replace any components which appear damaged.

Replacing stem seals:-PTFE rings or die-formed grafoil rings-PTFE chevrons and O-rings.

Then install the following parts over stem in the order listed:-Stem seal - apply a light film with compatible lubricant-gland

CAUTION: Do not over tighten. Over-tightening will result in excessive operating torque. If

stem leakage continues, or operating torque becomes excessive, depressurize the valve and replacethe stem seals after above instructions.

Cycle valve several times to assure proper operation and break in of seals.If the valve has been removed from pipeline for maintenance, reinstall in accordance with

Installation-operation instructions.

4.3 Seat ReplacementRelieve pressure from valve and place valve in open position. Remove bonnet bolting and lift

bonnet assembly off of valve body. Use suitable tool to lift the ball and seats out of the body. If the balland seats do not slide easily out of the valve, check to make sure that the ball is in the open position.The slot for stem engagement should be perpendicular to the pipeline during removal and insertion ofthe ball. Care should be taken not to damage the surface of the ball while the ball and seats are beingremoved from the body.

Inspect and clean the ball and the body sealing surfaces. Replace any components which arebadly scratched or gouged.

Apply a light film of compatible lubricant, to the ball and both sides of each of the seatassemblies. Hold the ball and seats such that the I.D.'s of the seats are aligned with the I.D. of the ballport. That is, place the seats on either side of the ball to simulate their position with the valve in theopen position. Simultaneously slide the two seat assemblies and the ball into the valve body. Force isnot necessary to properly position the components in the valve. Should the ball and seats not slideeasily into place, check to make sure that the ball is being inserted while in the open position.

Clean and inspect bonnet gasket recess in valve body and bonnet. Inspect gasket. Ifdamaged, replace bonnet gasket in accordance with item 4.1 Bonnet Gasket Repair Instructions

Install and tighten bonnet bolting in accordance with Installation -operation Instructions, item 3.Cycle valve several times to assure proper operation and break in of seats.If valve has been removed from pipeline for maintenance, reinstall in accordance with

Installation Instructions.

5. CORROSION PROTECTION- High-strength epoxy.

6. ACTUATION- Manual lever including up to NPS4 (DN100) / NPS4(DN 100) with gear over

7. TESTS- Products are tested by the manufacturer- Test pressure and loss rates are allowable according to SR EN12266 (without losses) /API598/API6D

9. CODIFICATION-Coding RSD-BB top entry type is presented in the general product specification 839/2008Rev.2

10. PACKING, TRANSPORT, STORAGE,10.1 Packing

Each valve must be drained of fluid test.The ends of the body must be covered to prevent foreign bodies and moisture-protective covers areremoved only when installing.

The valves are delivered with the obturator in the open position.!Products are delivered on a support of timber.10.2 Transport -handling

Because of physical dimensions and heavy equipment will be used properly and liftingmethods for transport, storage and installation.-valve are furnished in open position, in order to minimize the effect of mechanical loads andimpurities on seats, gaskets, and other pressure parts.Before handling the valve, verify it is open position. Lift valve with sling suitable for its weight. Neveruse lever, actuator or gear operator to lift the valve.

The valves are handles with care, shock, vibration, drops can damage the valve.Handling and transport to local installation is done with maximum attention to an insulationcompromised by impact and scratching

10.2 Storage.Valve must be stored packed in closed rooms free of dust or corrosive agents, fungi or mold.

11. HEALTH, SAFETY, ENVIRONMENT- products are designed, manufactured, tested and equipped in the system if necessary, so as toguarantee safety of the user and the environment.- the installation shall comply with all applicable law labor protection- will wear all required personal protective equipment- do not use the valve than the designed parameters-beneficiary will not make changes without consulting the manufacturer / or if the manufacturerrecommends- please check before installation if there reglementaride environmental, safety or other restricting useof the product.- Please firstly return to repair products that have circulated hazardous fluids decontaminated them.Also any faucet returned must be accompanied by minimal information regarding the conditions ofuse, changes in the product, operations decontamination and / or cleaning fluid and safety data sheet- used packaging and waste from the retirement harness the special without regulatory requirements.However please consider conditions of use of the product and to indicate the applicable legislationand packaging equipment.

14. MATERIALThe material will be chosen according to the conditions imposed by the data sheet(needs beneficiary) in compliance with the essential requirementsEuropean Directive (EC)-harmonized standard and / or requirementsAs the American Petroleum Institute (API6D)

15. SPARE PARTSThe spare parts list is supplied with the overall drawing

SC FEPA SAStr.REPUBLICII nr.316, Cod postal 731120, Brlad-RomniaTel.+40 0235 411812Fax +40 0235 421 618/0235 413729e-mail: fepa@fepa.ro / marketing@fepa.ro

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