Ver.  2008  

Trunnion  Ball  Valve  

INSTALLATION,  OPERATION  AND      
MAINTENANCE  MANUAL  
     
     
     
     
   

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TABLE  OF  CONTENTS  
 
1  APPLICATIONS...........................................................................................................2  
1.1  Applications.....................................................................................................2  
1.2  Performance  Specifications..............................................................................2  
2  APPLICABLE  STANDARDS...........................................................................................2  
3  DESIGN  FEATURES  AND  FUNCTION............................................................................3  
3.1  Body  Design.....................................................................................................3  
3.2  Block  and  Bleed ...............................................................................................3  
3.3  Unique  Sealing  Configuration ..........................................................................3  
3.4  Emergency  Seal ...............................................................................................3  
3.5  Fire  Safe  Design ...............................................................................................3  
3.6  Anti-­‐Static  Design ............................................................................................3  
3.7  Locking  Device .................................................................................................3  
3.8  Leakage  Free  Cover  Flange  Design ...................................................................4  
3.9  Full  Port  and  Reduced  Port ..............................................................................4  
4  VALVE  EXPLODED  VIEW.............................................................................................5  
5  INSTALLATION,  DEBUGGING  AND  USAGE ..................................................................6  
6  MAINTENENCE ..........................................................................................................8  
6.1  Reservation .....................................................................................................8  
6.2  Heavy  Repair ...................................................................................................8  
7  DISASSEMBLING........................................................................................................8  
8  ASSEMBLING.............................................................................................................9  
9  TROUBLE  SHOOTING ...............................................................................................11  
10  CAUTIONS .............................................................................................................11  
APPENDIX  I  –  GENERAL  ARRANGEMENT  DRAWINGS ..................................................13  
 

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1  APPLICATIONS  

1.1  Applications  
This  series  of  trunnion  ball  valves  are  applicable  for  natural  gas  industry,  petroleum  
products,   petrochemical   industry,   metallurgy,   city   construction,   environment  
protection,   pharmaceutical,   food   industry   etc.   The   sulfur   resisting   valves   of   this  
series   are   mostly   used   for   natural   gas   pipeline   transmission   of   media   containing  
hydrogen  sulphide  and  more  contaminants,  or  high  corrosive  medium.  

1.2  Performance  Specifications  

Size   NPS  

Pressure   Class  

Shell  (Water)   1.5  x  PN*  

Test   Seat  Test  (Air)   0.6  

Mpa  
Pressure  
HP  Seat  Test  
1.1  x  PN*  
(Water)  

Temperature  Range   Depends  on  the  selected  materials  

*  PN  =  the  working  pressure  at  the  specified  Class  under  -­‐29  to  38  deg.  C.  

2  APPLICABLE  STANDARDS  
API  Spec  6D  Pipeline  Valves  
API  Std  608  Metal  Ball  Valves  –  Flange,  Threaded  and  Welding  Ends  
API  Std  598  Valve  Inspection  and  Testing  
API  Spec  6FA  Specification  for  Fire  Test  for  Valves  
ASME  B16.34  Valves  –  Flanged,  Threaded  and  Welding  Ends  
ASME  B16.5  Pipe  Flanges  and  Flanged  Fittings  
ASME  B16.47  Large  Diameter  Steel  Flanges  
ASME  B16.25  Buttwelding  Ends  
ASME  B16.10  Face-­‐to-­‐Face  and  End-­‐to-­‐End  Dimensions  of  Valves  
MSS  SP-­‐25  Standard  Marking  System  for  Valves,  Fittings,  Flanges  and  Unions  

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3  DESIGN  FEATURES  AND  FUNCTION  

3.1  Body  Design  

The  body  of  trunnion  mounted  ball  valves  can  be  designed  according  to  customers’  
requirements   and   actual   working   conditions.   The   body   can   be   casting,   forging   and  
fully  welded  which  is  mainly  used  for  underground  service.  

3.2  Block  and  Bleed  

When  the  valve  is  in  fully  closed  position,  pressure  on  each  side  of  the  ball  is  blocked  
by  upstream  and  downstream  seats,  a  drain  valve  is  installed  at  the  bottom  of  valves  
for  draining  and  cleaning  dirt.  

3.3  Unique  Sealing  Configuration  

For   trunnion   ball   valve,   different   sealing   configuration   can   be   selected   based   on  
pressure   rating,   media   property   and   sealing   requirement,   they   are   Pre-­‐Ball  
Configuration,   Post-­‐Ball   Configuration   and   Pre-­‐   and   Post-­‐Ball   double   seal  
configuration.    

3.4  Emergency  Seal    

When   seat   and   stem   seal   wears   out,   which   causes   leakage,   an   emergency   sealant  
can  be  injected  via  sealant  injection  valve  to  restore  seal  temporarily.  

3.5  Fire  Safe  Design  

Based  on  working  condition  and  customers’  need,  ball  valves  can  be  design  to  be  fire  
proof,   of   which   the   design   as   per   API   6FA   and   API   607.   Once   their   is   a   fire   which   will  
burn  out  the  soft  seal  ring,  fire  safe  design  will  effect  and  protect  from  mass  leakage,  
thus  does  the  best  to  stop  the  fire  from  expanding.  

3.6  Anti-­‐Static  Design  

When   operating   the   valve,   the   ball   and   seat   scrub   each   other,   which   generates  
electrostatic   charge   accumulating   on   the   ball.   To   stop   the   electrostatic   from   causing  
static  breeze,  an  anti-­‐static  device  is  applied  to  lead  out  the  electricity.    

3.7  Locking  Device  

In   fully   open   and   fully   closed   position   of   manual   operated   ball   valves,   a   locking  

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device  can  be  design  and  applied  on.  In  this  case,  it  can  prevent  misoperation  and  
unexpected  open/close  caused  by  pipeline  vibration,  especially  in  transmission  line  
of  flammable  medium  such  as  oil  and  chemical.  It  is  a  better  choice  when  the  valve  is  
for  outdoor  installation.  

3.8  Leakage  Free  Cover  Flange  Design  

Gasket   is   used   for   sealing   between   body   and   bonnet   connection,   to   prevent   leakage  
from  fire,  high-­‐temperature,  vibration  or  unequal  open  and  close  torque,  etc.,  body  
and  bonnet  is  designed  metal-­‐to-­‐metal  contact  to  ensure  no  leakage.  

3.9  Full  Port  and  Reduced  Port  

The  bore  of  full  opening  valve  is  of  the  same  diameter  as  the  pipe  inside  diameter,  
this  reduces  backset  and  it  is  easy  to  clean  the  pipe.  

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4  VALVE  EXPLODED  VIEW  

Figure  1  

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Figure  2  
5  INSTALLATION,  DEBUGGING  AND  USAGE  
5.1   Seat   and   body   pressure   rating   determine   the   safe   use   of   this   valve,   please   go  
through  the  nameplate  carefully  to  know  the  two  ratings.  There  are  varies  kinds  of  

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materials   for   seat,   some   has   lower   rating   than   body.   Pressure   rating   of   seat   and  
body   is   selected   based   on   valve   type,   size,   seat   material,   bolting   material   and  
temperature,  do  not  exceed  the  rating  in  using  the  valves.    
5.2   This   series   of   valves   is   design   and   manufactured   according   to   API   6D,   if   not  
otherwise   specified,   shell   test   pressure   is   1.5   time   of   body   pressure   rating   while  
seat   test   is   of   1.1   times,   and   air   test   pressure   is   0.6Mpa.   For   test   duration   and   test  
method,  please  refer  to  API  598.  
5.3  It  is  recommended  to  perform  the  pressure  test  before  installation,  if  otherwise  
requested,  stick  to  the  purchase  order.  
5.4  Before  installation,  the  valves  shall  be  in  open  position.  
5.5  Identity  if  there  is  flow  arrow  marked  on  the  valve  body,  if  not,  media  can  go  in  
either   side   and   valve   can   be   installed   horizontally   or   vertically,   otherwise,   please  
pay  attention  to  the  flow  direction.  
5.6  Take  notice  to  warnings  on  the  valve.  Take  off  the  covers  on  both  sides  as  well  as  
the  drier  in  the  cavity.  
5.7   Before   installing   the   valve   to   the   pipeline,   apply   some   grease   in   the   sealant  
injection  valve  of  the  stuffing  box  for  easy  operation.  
5.8   When   installing   welding   ended   valves   to   the   pipeline,   it   is   necessary   that   the  
sealing   faces   shall   be   protected   properly,   or   example,   paint   the   seat   ring   with  
enough  grease,  to  protect  the  seal  from  being  damaged  by  spatter.    
5.9  Arc  welding  is  recommended  for  base  of  pipeline  welding.  
5.10   For   welding   ended   valves,   sleeves   shall   be   applied   to   make   the   distance  
between   welding   and   valve   longer   to   reduce   the   possibility   of   welding   spatters  
intruding.  
5.11   For   flange   ended   valves,   companion   flanges   shall   be   welded   to   the   pip,   clean  
the   welding   spatter   in   the   pipe,   then   install   the   ball   valve.   It   is   prohibited   to   install  
the  companion  flange  to  the  valve  first  and  weld  the  flange  to  the  pipe  later,  which  
may  cause  the  seal  face  to  be  damaged  by  spatters.  
5.12  For  flange  ended  valves,  matching  gasket,  bolts  and  nuts  shall  be  applied.  Install  
the  flange  bolts  as  shown  in  Figure  3,  or  according  to  manufacturer  recommended  
method.  
5.13   It   is   recommended   that   the   bypass   valves   to   be   installed   when   cleaning   the  
main  pipeline.  

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5.14   Before   pressure   testing   and   debugging,   pipeline   shall   be   cleaned.   Do   not  
operate   the   valve   before   cleaning;   otherwise,   some   solid   contaminant   may  
damage   the   sealing   face   that   will   cause   leakage.   When   cleaning,   all   the   valves  
shall  be  in  fully  open  position.  
5.15   After   pressure   test   on   pipeline   finished,   the   drain   valve   on   the   valve   bottom  
shall  be  opened,  after  draining  medium  and  all  dirt,  close  it.  
5.16  Operate  the  valve  according  to  technical  procedure,  this  valve  is  for  on-­‐off  use  
(fully  open,  fully  close)  only,  and  cannot  be  used  for  regulating.  
5.17  The  valve  shall  be  maintained  periodically,  for  long-­‐term  unused  valve,  it  shall  
operate  once  or  twice  as  per  technical  needs.  This  is  to  make  sure  the  valve  will  
work  normally.  

6  MAINTENENCE  

6.1  Reservation  
A.  Ball  valve  shall  be  in  full  open  position,  to  be  stored  in  dry  and  ventilating  place.    
B.   Pay   attention   that   the   plastic   covers   in   both   ends   shall   not   fall   off,   this   is   to  
prevent  contaminant  from  intruding  and  scratching  the  flange  sealing  face.  

6.2  Heavy  Repair  

Heavy  repairs  include  replacing  seat,  ball  (as  requested)  and  each  gasket,  O-­‐ring,  etc.  
For  replacing  process,  please  refer  to  Disassembling  and  Assembling.  

7  DISASSEMBLING  
 7.1   Place   the   valve   on   worktable,   pay   attention   not   to   damage   the   flange   sealing  
face,  make  clockwise  rotate  to  close  the  valve.  
7.2  Lever  Operated  Valve  (See  Figure  1)  
    7.2.1  Dismantle  the  bolt  (49),  indicator  (45),  gasket  (46),  lever  (47)  and  key  (13)  
    7.2.2  Dismantle  bolts  near  stopper  (32)  and  stopper  (48).  
7.3  Gear  Operated  Valve  (See  Figure  2)  
    7.3.1  Dismantle  bolts  (20)  of  mounting  bracket  (18),  lift  the  gearbox  as  together  
with  mounting  bracket  (18)  from  the  valve,  put  to  some  place  clean.  
    7.3.2  Dismantle  stem  bolt  (12),  key  (13)  and  pin  (40)  

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    7.3.3  Dismantle  the  bolt  (32)  of  mounting  bracket  (18),  mounting  bracket  (18)  
and  packing  (14),  put  them  together  with  gearbox.  
7.4  Dismantle  the  nut  (4)  and  lift  lug  (5)  in  left  and  right  body.  
7.5  Dismantle  gently  the  left/right  body  (1)  together  with  spring  (28),  seat  ring  (43),  
seat   (29)   and   O-­‐ring   (23)   (26),   and   put   them   on   soft   cloth   or   on   hardboard;   end  
flange  face  down,  pay  attention  not  to  damage  sealing  face  of  flange.  
7.6  Dismantle  the  seat,  O-­‐ring,  seat  ring,  spring  from  the  left/right  body.  
7.7   Dismantle   bolts   and   lifting   lug   of   left/right   body   of   the   other   side,   lift   the   middle  
body  vertically,  put  it  on  soft  clean  cloth  or  hardboard  (for  big  size  valve,  lifting  with  
rope  through  ball  bore  is  allowable),  pay  attention  not  to  damage  ball  surface  and  
bolts.  
7.8  Repeat  step  4.6,  dismantle  the  other  left/right  body.  
7.9   Place   a   cork   under   the   ball   to   prevent   from   scratching;   for   big   size   valves,   it   is  
allowable   to   lift   the   ball   with   a   rope   going   through   the   ball   (22)   bore,   after   that,  
dismantle  the  stuffing  box  and  trunnion.  
7.10   Dismantle   the   bolts   (17)   off   the   stuffing   box,   remove   the   stuffing   box   (31)  
together  with  stem  (16),  thrust  ring  (21),  O-­‐ring  (6)  (15),  gasket  (39)  from  the  body.  
7.11  Remove  the  stem,  thrust  ring,  O-­‐ring  and  gasket  from  stuffing  box.  
7.12   Dismantle   the   bolts   (36)   of   trunnion,   remove   the   trunnion   (8)   together   with  
O-­‐ring  (15)  and  gasket  (39)  from  the  body.  
7.13   Remove   the   ball   from   the   body   carefully,   put   them   on   soft   clean   cloth   or  
hardboard;   for   big   size   valve,   it   is   allowable   to   lift   the   ball   with   a   rope   going  
through   the   ball   (22)   bore,   pay   attention   not   to   damage   the   ball   surface,   the  
chamfered  edge  and  corner  between  ball  and  bore.  

8  ASSEMBLING  
8.1   Before   assembling,   clean   all   the   parts,   check   damages,   if   so,   repair   or   replace  
them.  
8.2  Insert  the  spring  (28)  to  the  hole  on  the  ball  (22)  (2”~  4”)  and  install  the  ball  to  the  
body  (2),  align  the  trunnion  hole  of  ball  to  that  of  body.  Place  a  wood  under  ball  to  
prevent  it  from  damaging;  for  big  size  valve,  the  ball  shall  be  lifted  in  to  the  body,  
the  lifting  rope  shall  not  be  released  until  the  trunnion  and  stuffing  box  is  installed.  
8.3  Install  the  gasket  (39)  and  O-­‐ring  to  the  trunnion  (8).  Apply  some  lubricant  to  the  

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O-­‐ring,  pay  attention  not  to  damageit.  Install  the  trunnion  to  the  body,  mount  the  
screws  (36).  
8.4  Install  the  gasket  (39),  O-­‐ring  (15)  (6),  thrust  ring  (21)  and  stem  (16)  to  the  stuffing  
box   (31),   apply   some   lubricant   to   the   O-­‐ring,   install   this   component   to   the   body,  
note  that  flat  head  of  the  stem  shall  be  into  the  slot  of  the  ball.  
8.5  Mount  the  screws  (17),  fastening  it,  rotate  the  ball  to  the  close  position.  
8.6  Install  the  spring  (28)  to  the  holes  of  left/right  body  (1),  apply  the  gasket  (42)  and  
O-­‐ring   to   the   left/right   body,   apply   some   lubricant   to   the   O-­‐ring.   Apply   washer  
(23),  gasket  (23)  and  seat  ring  (43)  to  the  seat,  apply  some  lubricant  to  the  O-­‐ring.  
Install   this   component   to   the   left/right   body,   apply   some   pressure   to   seat   ring   till  
it  touches  the  spring.  
8.7   Attach   the   middle   body   (2)   to   one   the   of   left/right   bodies,   pay   attention   to   the  
direction   of   the   sealant   injection   valve   of   the   left/right   bodies   (see   assembly  
drawing).  Install  the  nuts  (4)  and  lifting  lug.  Rotate  the  other  one  of  left/right  body  
over,  attach  it  to  the  middle  body,  then  install  the  nuts  and  lifting  lug.  For  big  size  
valve,  it  is  allowable  to  use  a  rope  through  the  ball  bore,  lift  the  middle  body  to  the  
left/right  body.  
8.8  Lever  operated  valves  (see  figure  1):  
8.8.1  Install  the  stopper  948)  and  screws  (32)  and  fasten  it.  
8.8.2   Install   the   key   (13)   to   the   stem   slot,   then   install   in   order   the   lever   (47),  
position  indicator  (45),  washer  (46)  and  screws  (49)  and  fasten  it,  rotate  the  lever,  
the  ball  shall  move  smoothly,  and  position  shall  be  indicated  correctly.  
8.9  Gear  operated  valves  (see  figure  2):  
8.9.1   Install   the   gland   follower   (14),   mounting   board   (18),   pin   (40)   and   screws   (32)  
and  fasten  it.  
8.9.2  Install  the  key  (13)  to  the  stem  slot,  then  install  the  screws  (12)  and  fasten  it.  
8.9.3   Install   the   gearbox   (10)   together   with   mounting   board   (11)   to   the   other  
board   on   top   of   the   stem,   pay   attention   to   that   the   key   and   slot   of   gearbox   shall  
match  each  other.  Then  install  the  nuts  (20).  
8.9.4  Rotate  the  handwheel,  the  ball  shall  move  smoothly;  adjust  the  limit  screw  
on   the   gearbox   to   make   the   open/close   position   meet   with   the   requirement,  
detailed  steps  as  follows:  
A.  Remove  the  cover  screw  and  cover  from  the  gearbox,  the  key  slot  will  appear,  

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unfasten  two  lock  nuts  and  limit  screw  of  the  gearbox.  
B.   Verify   that   the   key   slot   of   the   axis   hole   is   vertical   to   the   valve   bore   (closed  
position),  if  not,  rotate  the  handwheel  to  adjust  to  the  right  position,  then  fasten  
one  of  the  limit  screws  (near  the  handwheel),  fasten  the  lock  nut  after.    
C.  Rotate  the  handwheel  counter  clockwisely,  make  sure  the  ball  bore  is  aligned  to  
the  body  bore,  then  fasten  one  of  the  limit  screws,  fasten  the  lock  nut  after.  
D.  Install  the  cover  and  screw  back,  fasten  the  screws.  

9  TROUBLE  SHOOTING  

Malfunction   Possible  Cause   Remedial  Action  

1.   Unfasten   the   nut   and  
1.  Packing  too  tight  
readjust  
Valve  will  not  rotate   2.   Damages   or   dirt   between  
or  operate   stem  and  other  parts   2,   Dismantle,   repair   and  
3.   Open/close   exceed   the   limit   clean  the  dirt  
times  
1.   Pretightening   force   not   1.   Increase   pretightening  
enough   force  
Leakage  in  sealing   2.   Damages   or   dirt   in   sealing  
faces   faces   2.  Repair,  replate  the  faces  
3.   Sealing   faces   distorted   or   and  clean  the  dirt  
failed  
1.   Packing   pretightening   force   1.   Replace   the   nuts   and  
Leaking  in  stem   not  enough   bolts  
packing   2.  Packing  failed  after  long  time  
2.  Replace  the  packing  
use  
Leakage  between   Refasten   the   bolts   &   nuts  
Bolting  of  cover  flanges  loose  
cover  flanges   of  cover  flanges  
10  CAUTIONS  
10.1  Release  the  pressure  of  pipeline  and  valves  with  following  procedure:  
A.  Open  the  valve,  release  the  pipeline  pressure  
B.   In   order   to   release   all   the   pressure   remaining   in   the   valve   cavity,   before  
removing   the   valve   from   pipeline,   it   is   necessary   to   close   and   open   the   valve  
again  and  leave  the  valve  in  open  position.  

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FBV/IOM/BA02     Ver.  2008   Trunnion  Ball  Valve  

C.   Before   disassembling,   put   the   valve   vertically   on   the   worktable,   open   and  
close   the   valve   repeatedly   for   a   few   times,   release   or   drain   all   the   remaining  
media.  
10.2   The   type   of   valve   is   designed   in   consideration   of   normal   working   condition,  
please  specify  in  the  purchase  order  if  it  is  specially  required.  
10.3  The  actual  range  of  working  temperature  shall  not  exceed  the  ratings  specified  
in   performance   specifications,   users   shall   be   held   responsible   for   consequences  
cause  by  exceeding  (including  instant  exceeding)  the  regulated  ratings.  
10.4   The   surface   temperature   during   valve   working   in   pipeline   might   hurt   people,  
users  shall  setup  relevant  warning  signs  in  proper  positions.  
10.5  Welding  repair  or  surface  painting  is  not  allowed  when  the  valve  is  in  operation.  
10.6  It  is  not  allowed  to  disassemble  the  valve  under  pressure.  
10.7  Valve  shall  be  repaired  according  the  Table  of  Material  specified  in  point  4.  
10.8  User  shall  examine  and  replace  (when  necessary)  the  valve  periodically.  

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FBV/IOM/BA02     Ver.  2008   Trunnion  Ball  Valve  

APPENDIX  I  –  GENERAL  ARRANGEMENT  DRAWINGS  

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 FBV  Inc.      
    New  York     Houston  
    41-­‐22  Fuller  Place     2121  Brittmoore  Rd.  Suite  500  
Add   Flushing,  NY  11355,  USA   Add   Houston,  TX  77043,  USA  
Tel   (347)  535-­‐0788   Tel   Tel:  (832)  203-­‐5459  
Fax   (347)  438-­‐3221   Fax   Fax:  (832)  203-­‐5461  
[email protected]   [email protected]  

    www.fbvalve.com