Instruction Manual

Trunnion Mounted Ball Valve

Series-8200
Aug 2015 Rev-01

0062 2 G/D T 3/4/5/6

CONTENTS PAGE NO.
1.0 Foreword 2
1.1 Scope of Instruction Manual 2
1.2 Copyright and Modification Rights Reservation 2
2.0 Storage & Preservation 2
3.0 Valve Marking 3
4.0 Health & Safety 5
5.0 Unpacking 5
6.0 Lifting Details 6
7.0 Installation 7
7.1 Pre-Installation Checks 7
8.0 Operation of The Valve 8
9.0 General Instruction for Disassembly & Reassembly of Valve 9
10.0 A Disassembly Trunnion Mounted Ball Valves. 10
10.0 B Reassembly - Trunnion Mounted Ball Valves 11
11.0 Sealant Injection & Valve cleaning & Greasing Procedure 12
12.0 Part Illustrated 13
13.0 Preventive Maintenance 14
14.0 Trouble Shooting 15
15.0 Recommended Part 16

1
 1.0 Foreword

1.1 Scope of Instruction Manual

This Instruction Manual covers information regarding Installation and Maintenance of Dembla's O Ball
Valve Flange Design, Series 8200

1.2 Copyrights and Modification Rights Reservation

Dembla Valves Ltd. retains the Copyright on the contents of this Instruction Manual.
The Total content of this Instruction Manual described here corresponds to the Information during
preparation of the Instruction Manual. It is user's responsibility to refer the latest version.
All data, specifications and Illustrations here are subjected to Technical Modifications and improvements
and hence Modification can be done by us at any time without any prior notice. No claim to Modification
or repair of these Valves, which have already been supplied by us, can be made.

2.0 Storage & Preservation

All Valves are dispatched in the closed/open position as ordered and it is recommended that they are left
in this position during storage. All protective packing should remain in position until the Valve is to be
installed. Valve should be stored in a clean and dry environment, without disturbing company setting. (e.g.
Gland, Seat etc.) Protect it from shock & lifting damage.

! Caution

If hoisting the Valve, use a nylon sling to protect the surface. Carefully position the sling to prevent
damage to Actuator tubing and any accessory. Also, take care to prevent people from being injured in
case the hoist or rigging slips unexpectedly. For Valve Weight refer Valve Packing Slip.

2
3.0 Valve Marking
1) Valve name plate attached on Valve by riveting carrying all Valve Identification Information.
2) Markings like Valve Size, Rating, Material etc. are as cast on valve Bodies.
3) Valve Serial no. punched on Valve Body Flange for Valve Traceability.

4) If the product is not CE marked, Then name plate also without CE mark.

Name plate for

Series:-8200 Valves
0062
INDIA

3
4.0 Health & Safety ! Warning

1) Before attending to Valve Installation / Maintenance, the Instruction Manual must be compulsorily read
and understood properly.
2) Valve must be operated by qualified personnel.
3) Ensure that the operator handling these Valves must follow Safety and Accident Prevention Rules and
Regulations.

4) Follow the Safety Instructions before Installation, Maintenance or removing the Valve.

5) Always wear protective gloves, clothing and eyewear when performing any Installation operations to
avoid personal injury.
6) All Safety Messages such as Cautions, Warnings and Notes are highlighted in this Instruction Manual
which must be strictly followed to avoid any possibility of arising danger / risk of damage to the
equipment / person's life.
7) No Liability on Manufacturer for any wrong handling, improper commissioning and wrong assembly.

8) Line must be fully drained and de-pressurized before Installation or maintenance of Valve.
9) Never handle Valves that have been used on harmful substances unless they have been completely
decontaminated and certified safe to handle.
10) Due to the large physical Size and Weight of some Size of this product, always use correct lifting methods
and equipment when installing , removing and maintaining the product:-
Use lifting lugs on the Body, wherever provided.

Valve without lifting lugs-use chains or slings wrapped around the Body.

Do not attempt to lift the Valve using the Sealant Fittings, Gear unit, Hand wheel, Actuator, or the Valve
Stem.
11) If the processes or environments that the products are used in are likely to cause temperature (high or
low) that may cause injury to person if touched, then adequate insulation / protection must be fitted.
It is recommended that the insulation allows easy access for maintenance, to the sealant fittings , and to
the Valve operator.

12) Valve must be protected from earthquake loading, traffic & wind.

13) No Modification / Conversions are allowed without written authorization from Dembla Valves Ltd.

4
5.0 Unpacking

For Carton
· Keep Carton in position (Carton ‘up side’ should not be ‘down’).
· Cut plastic strip properly which is tied around Carton & remove it. (White in colour).

· Cut cello tape properly which is stuck on Carton opening.

· Open Carton properly.

· Remove foam properly along with polythene wrapping.
· Lift the valve properly & keep on clean & dry place

For Wooden Box

· Keep Wooden Box in Position (’upside’ of Wooden Box should not ‘down’).

· Cut iron strip properly which is tied around Wooden Box & remove it.

· Remove nail properly from top cover with proper equipment.

· Loosen and remove Valve fixing nut (from inside of Box).

· Lift the valve properly as shown in figure 1

5
6.0 Lifting Details
Valve should be lifted by using chain
or bearer cables that are looped around
the valve body as shown in figure 1.

(Take care valve should not damage wile handing).

Fig. 1

6
7.0 Installation

7.1 Pre-installation Checks:-

Before installing any Ball Valve

· Inspect it for any shipment damage and for foreign material that might have collected during packing
and shipment.

· Blow out all pipelines to remove pipe scale-chips, welding-slag, and other foreign materials.

· Install the Valve using accepted piping practices. Use a suitable gasket between the Body and pipeline
Flanges and tighten the Bolts evenly to avoid any strain on the Body or cracking of Flange.
· Install the Ball Valve preferably in a straight run of pipe away from bends or sections of abnormal
Velocity.

· Ball valves can be installed in any orientation but the normal method is with the actuator vertical.

· An air supply pressure regulator with filter should be installed in the air line ahead of any instrument
mounted on the valves.

! Warning

· Always wear protective gloves, clothing, and eye ware when performing any Installation operation to
avoid personal injury.
· Valve should be used by End-user with same pressure & temperature rating which was given in purchase
order. If there is any change please contact Dembla Sales Office.
· Our Valves can not be used for defiance, Nuclear, Telecommunication, Marine, Railway, Laboratory &
Mines.
· Our valve is valid for atmospheres having pressure ranging for 0.8 bar to 1.1 bar and temperatures
ranging for -20ºC to +60ºC such atmospheres.

· Please connect earthing with earthing pad on Body before operating the Valve.

7
8.0 Operation Of The Valve

· Ensure that the force applied on the hand wheel of the Gear bore or Lever shall not exceed
360 N.
· Clockwise rotation of Hand wheel close the valve & anticlockwise rotation open the Valve for
gear operated Valves.

· Do not disturb the Gear Box open / close adjustment bolt setting unless & utilities required.

*According to valve Size

8
9.0 General Instruction for Disassembly & Reassembly of Valve

Before starting disassembly.

· Use by-pass Valve or completely shut off the process to isolate the Valve from process pressure. Drain
fluid from both ends of the Valve.

· If the Valve opens with pneumatic signal pressure to actuator, remove air from the Actuator before
attempting to remove Valve from line.

· While dismantling the Valve, if any part is stuck up, do not use any pressure or force technique.
Use proven methods only.

9
10.0 A Disassembly Trunnion Mounted Ball Valves.
For detail drawing refer part illustrated( Refer .12.0)

1. Keep the Valve in vertical position (Gear Operator at top side as shown).
2. Loosen & remove bolts. Gear operator to mounting flange .

3. Lift the Gear Operator carefully from the Valve Body.

4. Keep the key of valve shaft properly .

5. Loosen & remove allen bolt mounting flange to bonnet .

6. Loosen & remove allen bolt bonnet to valve body .

7. Don't remove bonnet from body .

8. Rotate valve and keep on body flange. Make sure valve flange should rest on soft surface like wood rubber
etc. So that rest face serration should not damage.
9. Clamp side connection properly for lifting .

10. Loosen and remove nut body to side connection.

11. Lift side connection along with seat retainer and keep clean & dry place .

12. Clamp O ball properly for lifting with soft belt ( Make sure ball should not damage while lifting)

13. Remove bonnet along with valve shaft o ring and gasket from valve body .

14. Lift o ball along with trunnion plate ( 2 nos) & thrust washer .
15. Remove trunnion plate from ball and keep ball & trunnion plate clean & dry place . ( Along with
thrust washer)

16. Remove seat retainer along with soft seat ring from the valve body .

17. Remove seat spring from body .

18 Remove seat retainer along with soft seat ring from side connection .
19. Remove seat spring from side connection .

20 If required remove and replace , retainer o ring, bonnet o ring , shaft o ring, o ring body to side connection

21. Replace all gaskets . Before reassembly like gaskets body to bonnet , Gasket body to side connection,
Gasket mounting flange to bonnet.

10.0 B Reassembly - Trunnion Mounted Ball Valve.

1. Keep valve body on body flange. Make sure valve flange should be rest on soft surface like Wood ,
Rubber sheet etc. So that rest face Serration should not damage.

10
2. Put greace on seat spring.

3. Insert spring in body ( in spring resting holeS )

4. Insert seat retainer along with retainer o ring and soft seat ring in valve body rest on spring.

5. Lift o ball with soft belt.

6. Insert thrust washer on ball ( resting side of ball top and bottom)

7. Insert trunnion plate on ball ( Resting side of ball top and bottom) make sure four dowel pin should be
along with one trunnion plate.

8. This sub assembly of o ball and trunnion plate insert in valve body .

9. Make sure trunnion plate rest on valve body inside and dowel pin properly insert in body dowel pin hole.

10. Insert gasket body to bonnet in valve body .

11. Insert valve shaft in bonnet .

12. Insert valve shaft along with bonnet in valve body .Make sure valve shaft properly inserted in O ball slot
(On top side)

13. Insert Spring in side connection (In spring resting holes )

14. Insert seat retainer along with retainer O ring and soft seat ring in side connection rest on spring .

15. Insert gasket body to side connection in body.

16. Insert side connection along with retainer in valve body . Make sure trunnion dowel pins properly inserted
in side connection dowel pin holes .

17. Insert nut body to side connection on stud and rotate it . But keep it loose.

18. Insert allen bolt bonnet to body and tighten it .

19. Rotate shaft for ball smooth rotation .

20. Tighten nut body to side connection .

21. Insert mounting flange in shaft and bolt it with allen bolt mounting flange to bonnet.

22. Rotate valve and keep it vertical for gear box assembly .

23. Insert key in valve shaft .

24. Lift gear operator and put in mounting flange . Make sure valve shaft properly inserted in gear operator by
maintaining key position .

25. Insert and tighten gear operator bolt in mounting flange to gear operator.

11
11.0 Sealant Injection :
In trunnion ball valve sealant injection device available for both seat as well as stem sealing . If
O ring damage at stem or seat damage accidently . Because of this medium or heavy
leakage found to stop this leakage inject sealant through sealant injection port as shown in
figure.

Sealant Injection Port Bonnet

Sealant Injection Port

Procedure to inject the sealant :

1) Close the valve FULLY .

2) Use sealant injection gun device for inject the sealant in ball valve through sealant port.

3) Start inject light grade sealant and if you don't succeed then use heavier sealant.

4) Pressure of sealing use higher than inlet pressure than only injection possible.
5) Quantity of sealant : Inject only enough sealant to stop the leakage.

Valve cleaning :
1) Disassemble the valve after sealant injection use for cleaning purpose refer 10.0 A Disassemble the
trunnion mounted ball valve.
2) Apply cleaning agent in the valve from the sealant injection port by using gun.
3) Clean the valve properly . ( Do not scratch on the ball)
4) After cleaning the valve use grease by using following procedure.

Greasing Procedure :
1) This procedure can be use when valve is jam or required higher torque .
2) Inject the silicon grease in sealant port with the help of gun in ball valve .
3) Try to operate the valve slowly with proper supervision and complete 5 open & close cycles . .

Valve Cleaning & Greasing Procedure During Operating Condition :

1) Apply cleaning agent in the valve from sealant injection port by using gun.
2) Try to operate the valve slowly with proper supervision and complete 5 open & close cycles .
3) If it is operable after application of cleaning agent then complete 5 open & close cycles .
4) If it feel very hard to operate or stacked then apply light grease with the gun through the
sealant injection port .
5) Again try to operate the valve & complete 5 open & close cycles .

12
 3
SR.
20
NO. DESCRIPTION M.O.C.
21 9
1 VALVE BODY A 216 Gr. WCB
2 SIDE CONNECTION A 216 Gr. WCB
28
3 SEAT RETAINER A 182 GR. F316 16
12.0 Parts Illustrated

4 VALVE SHAFT A 182 GR. F316 4

8
5 'O' BALL A 182 GR. F316 13
6 TRUNNION PLATE A 216 Gr. WCB 25
c 23
7 BONNET A 216 Gr. WCB
15 12
8 MOUNTING FLANGE MS
17 DETAIL 'B'
9 RETAINER 'O' RING VITON 7
2
10 BONNET 'O' RING VITON
10
11 SHAFT 'O' RING VITON
12 'O' RING BODY TO SIDE VITON 26 24
CONNECTION
THRUST WASHER SS 316+PTFE 18
A
13 SHAFT TO BONNET 11
THRUST WASHER
14 SS 316+PTFE
BALL TO TRUNNION 5
ALLEN BOLT BONNET TO B 22
15 VALVE BODY A 193 Gr. B7

13
1
10
ALLEN BOLT MOUNTING
16 FLANGE TO BONNET A 193 Gr. B7
29
17 STUD & NUT BODY TO SIDE C. A 193 Gr. B7
DOWEL PIN TRUNNION
13
18 TO BODY & SIDE CONN. EN8

BEARING BUSH FOR

19 TRUNNION & BALL SS 316 + PTFE

20 SEAT SPRING INCONEL X- 750

DETAIL 'C'
21 SOFT SEAT RING R-PTFE
22 GASKET BODY TO BON. SS SPIRAL WOUND 14 SPRING
23 GASKET BODY TO S. C. SS SPIRAL WOUND
6
GASKET M. FLANGE TO
24 BONNET GRAFOIL
19
BLOTS GEAR OPERATOR TO X NOS OF ØY
25 A 193 GR. B7 / A 194 2H 27
MOUNTING FLANGE
26 SEALANT NIPPLE SS 316 BALL
27 DRAIN PLUG SS 316
DOWEL PIN MOUNTING DETAIL 'A'
28 FLG TO BODY . EN8
29
BEARING BUSH FOR (ANTI STATIC DESIGN)
SHAFT & BONNET SS 316 + PTFE
30 GEAR OPERATOR --
 13.0 Preventive Maintenance
· Annually check for any damage to Valve seats, ball & stem of the Valve.
· While doing Annually checks, it is recommended that the Seats, Gasket, Seals and Packing
should be replaced by genuine spares.
· Ensure Annually 200 grams lubrication of Gear Box with suitable grade of grease.

14.0 Trouble Shooting

The leakage could be caused by not having a sufficient quantity of sealant in the seat ring. A good rule of
thumb is (1 oz.= 28 grams) one ounce of sealant per inch of valve size per seat ring. In other words: a (16")
sixteen inch diameter valve would require approximately (16 ozs.= 1 pound) sixteen ounces of sealant into
each seat ring to fill from empty. If the valve is buried, add (2 ozs.) two ounces of sealant per foot of 1/2”
diameter riser pipe. Depending on the number of sealant risers and the design of the riser assembly, this can
vary the quantity of sealant required.

No. Condition Possible Cause Corrective Action

1 Gland Leakage Worn out ‘O’ Ring. Replace Bonnet ‘O’ Ring

Sealing edge of seat damaged Replace soft seat ring

Valve pressurized to high pressure Reduce line pressure to rated
2 Seat Leakage pressure

Valve does not Foreign object got stuck up between Open the valve and clean the line
3 ‘O’ Ball and seat
open / close fully / valve to remove foreign object

Opening / Closing Foreign object got stuck up between Open the valve and clean the line
4
torque excessive ‘O’ ball and seat / valve to remove foreign object

Additional Sealing Procedures for Emergency Situations

You must keep in mind that this may require a substantial quantity of sealant, for instance a 16” diameter ball valve
would require approximately (100) one hundred pounds of Chameleon Sealant to completely fill the hole in the ball
and the body cavity. It is possible to over-pressure the body cavity, this procedure should only be performed by
experienced professionals. Contact Dembla Valves for additional information.

14
 15.0 Recommended Spares
It is recommended to stock the following spares parts for commissioning and routine service.

SR. NO. PART NAME RECOMMENDED QUANTITY

21 Soft Seat Ring One Set for every valve

9,10,11,12 'O' Rings(all) One set of 'O' Ring for every five valve

22,23,24 Gasket (all) One set of gasket for every five valve

Note: While ordering spares, please do not miss to indicate 'Valve Serial No.' appearing on nameplate
fixed on the Actuator Valve Serial No. also appears on the Valve Body dully punched. The valve serial
no. Begins with prefix V, eg V - 12345………

The contents of this publication are presented for informational purposes only, and while every effort has
been made to ensure their accuracy. They are not to be construed as warranties or guarantees, express or
implied, regarding the products or services described herein or their use or applicability. We reserve the
right to modify or improve the designs or specifications of such products at any time without notice.

Dembla does not assume responsibility for the selection, use or maintenance of any product.
Responsibility for proper selection, use and maintenance of any Dembla product remains solely with the
purchaser and end-user.

Sales Office: Dembla Works:

M/S. Dembla Valves Ltd. M/S. Dembla Valves Ltd.
C-30, Jai Matadi Compound, Kalher A/8, Arahm Logistic, Valshind Village,
Village,Thane-Bhiwandi-Agra Raod - Mumbai -Nashik Highway
421302, (NH3),Bhiwandi
Maharashtra,India. Thane - 421302. Maharashtra (India)
Tel - +91-9292234790 - 97
E-mail - [email protected]
More info - www.dembla.com
 Annexure -1
Additional Specifications For Sealant Injection accessories

1) Sealant Injection Gun :

Hydraulic Type
Pneumatic Type

Sealant gun should be capable to inject highly Viscous Fluid/Sealant into Ball Valves
installed in high pressure Natural Gas pipeline of size up to 42# Dia. The maximum pressure of
Natural Gas inside the pipeline is approx. 92 Kg/cm2.
Sealant gun should have minimum following specification/ arrangements.

1) Sealant gun should be of Hydraulic Or Air operated.

2) Sealant gun should be able to generate minimum 15,000 psi Pressure.
3) All the parts of the Sealant gun including connecting Hoses etc should be tested at not less
than 20,000 psi Pressure.
4) Sealant Injection rate should not be less than 10 OZ per minute
5) In built Safety system against back pressure should be available
6) Safety system should be available to avoid damage of valve, pipeline, operator and Sealant
gun itself.
7) Bleeder to be provided.
8) Sealant gun should be suitable to work in Indian Atmospheric condition up to 48 degree
centigrade and 5-6 hours continuously running.
9) Protection of Sealant gun against the failure of NRV installed on valves
10) Pressure gauge to be provided on the Sealant gun to know the pressure generated by Sealant
gun.

2)Sealant Lubricant :

As per the Manufacturer’s Specifications.

3) Valve Cleaner : Sealant Lubricants

As per the Manufacturer’s Specifications.

Recommended Accessories Suppliers

Valve Cleaner
1) MELCON ENERGY PRODUCTS (www.melconenergy.com)

2) SEAL WELD (www.sealweld.com)

3) VALTAX (www.valtax.com)