ANSI GKS (D) Nr.

154
MANUAL INSTRUCTION Full Bore Reduced Bore
FOR STORAGE, INSTALLATION, OPERATION Class 900-1500 NPS 3”-18” Class 900-1500 NPS 4”-18”
19/05/20
AND MAINTENANCE OF PEKOS BALL VALVES Class 2500 NPS 2 ½”-12” Rev.3
Class 2500 NPS 3”-12”

Table 1
Pos. Quant. Description
1 1 Body 1
2 2 Body 2
 3 1 Ball
 4 2 Seat
 5 1 Stem
 6 1 Stem seal
 7 1 Stem packing
 14 2 Body seal 1
 19 1 Spring
 20 1 Antistatic ball
22 4+4 Stop pin
 31 2 Bearing
 32 2 Bearing disk
33 2 Support bearing
 34 2 Body seal 2
 35 2 Stem O-ring
41 - Stud
42 - Nut
 44a 2 Ring seat 1
44b 2 Ring seat 2
45 - Spring seat
 46 2 Seat seal
50 1 Subjection ring
86 1 Drain plug
86a 1 Vent plug
 108 2 Seat O-ring
 109 1 Cover seal
110 1 Subjection ring seal
 148 1 Cover O-ring
149 1 ISO cover
151 1 Body cover 1
153 - ISO cover bolt
 165 2 Stem bearing
 170 7 Stop seal

 Start-up: 5% of ordered quantity

 SOFT PARTS KIT
  METALLIC PARTS

Suggested materials to be checked at

least every five (5) year service.
See point 5 (Maintenance)

Torque screw tightness values for bolts

(Nr. 41 & 42) can be found attached in
document DC-08-07-03 PF “Screw
torque”

1. SCOPE

This manual is intended as a guide to assist customers or end-users in the correct storage, installation and maintenance of
PEKOS ball valves.

2. APPLICABILITY

This manual is applicable to full trunnion ball valves as per norm ANSI in the following pressures and sizes: Full Bore: NPS 3”
– 18” Class 900-1500; NPS 2 ½” – 12” Class 2500 & Reduced Bore: NPS 4” – 18” Class 900-1500; NPS 3” – 12” Class 2500.

3. STORAGE

3.1 Maintenance during storage

a. Stainless steel and carbon steel valves should be stored separately, to protect the stainless steel against corrosion.
b. Valves must remain in open position with plastic end covers fitted.
c. If possible it would be advisable to leave the ball valves in their own packing cases.
d. Valves to be stored for a long time shall be checked by the quality control personnel every 6 months.
e. Degreased valves shall only be unpacked before installation.

3.2 Environment conditions

a. Valves shall be stored in dry conditions. Other corrosive environment conditions must be also avoided.
b. Valves must be protected against ambient dust.

4. INSTALLATION
a. Verify that valves have not been damaged during transit. Inspect inside of the valves and the pipeline of the installation to be
able to verify there are no strange particles.
b. It is advisable to use protective filters during the installation and check-in period while the possibility of dirt or even oxidation of
the pipes exists. They have to be used until pipes are absolutely free of particles in suspension.
c. If possible, valve shall be mounted in such way to allow periodic inspections.

DC 08-12-07 PF -1-
 ANSI GKS (D) Nr.154
MANUAL INSTRUCTION Full Bore Reduced Bore
FOR STORAGE, INSTALLATION, OPERATION Class 900-1500 NPS 3”-18” Class 900-1500 NPS 4”-18”
19/05/20
AND MAINTENANCE OF PEKOS BALL VALVES Class 2500 NPS 2 ½”-12” Rev.3
Class 2500 NPS 3”-12”

d. Valves are bidirectional, so fluid can run in both directions.

e. Valves can be mounted in any position but it is advisable to mount the valves with the stem in vertical position.
f. It is necessary to obtain correct alignment and parallelism to avoid any kind of stress.
g. Once the installation is completed, valve must be operated for at least one opening and closing action to ensure perfect
operation.
h. After cleaning, protective filters could be removed.
i. Protective filters should remain installed on dirty applications.

5. MAINTENANCE

Pekos recommends inspecting the valves at least every five (5) years. These inspection intervals could be affected by the
process service (fluid, temperature, service, and cycles), and environmental condition.
5.1 Valves revision
PEKOS ball valves do not need lubrication.
Ball (3), seats (4), stem (5), stem seal (6), stem packing (7), body seals (14 and 34), stem o-rings (35), seat seals (46), seat o-
rings (108), cover seal (109), cover o-ring (148), stem bearings (165) and stop seals (170) can be replaced easily using
common tools. As replacement pieces is advisable to follow the instructions below table1.
Prior to carrying out work on valves the pipeline must be completely empty, including the ball valve body cavity by half
opening valve to allow any pressure build up to escape.
Care must be taken to avoid contact with dangerous or toxic chemical products. The valves must be thoroughly cleaned, in
particular the body cavity, before handling and dismantling.
5.2 Stem leakage
a. Remove subjection ring (50) and subjection ring seal (110), remove ISO cover (149) and body cover 1 (151) by loosening
cover bolts (153).
b. Remove the stem o-ring (35), the cover o-ring (148), stop seals (170), the cover seal (109), the stem packing (7), the stem
seal (6) and the stem bearings (165), and replace them.
c. Reassemble the pieces accordingly as it is indicated in point 6.
d. This process can be carried out with the valve under pressure due to the double block and bleed characteristic. The only
condition is that the valve must be totally opened or totally closed.
5.3 Body leakage
These ball valves PEKOS ANSI are constructed in 3 pieces, body (1) and 2 ends (2). Body fasteners should be checked for
tightness. If leakage occurs and if necessary, body seals (14) and (34) should be replaced as it is shown:
a. Make alignment marks on the body (1) and ends (2) prior to dismantling, to ensure a correct alignment when reassembling.
b. Remove studs (41) and disassemble the adaptors (2).
c. Substitute body seals (14 and 34).
d. Assemble the pieces accordingly as it is indicated in point 6.
e. This process has to be done in one body end (2), and later on, in the other one.

5.4 Seat leakage

a. Maintain the valve in the closed position, loosen and remove the nuts (42), remove the bodies 2 (2) from the body (1).
Remove the seat (4) – ring seat 1 (44a) sets and change them. If necessary replace the seat o-rings (108), stop seals (170)
and the seat seals (46).
b. Reassemble the pieces accordingly as it is indicated in point 6.
c. This process has to be done in one body end (2), and later on, in the other one.

6. ASSEMBLY
a. Prior to re assembly all components and body cavity should be cleaned of any incrustation, dirt, rust etc., especially in the
locations of seats & seals.
b. Put the bearings (31) in the support bearings (33) and the bearing disks (32) in the ball (3).
c. Put the stem bearing (165), the stem o-rings (35), the cover o-ring (148), stop seals (170), the stem packing (7) and the cover
seal (109) onto the body cover 1(151).
d. Check the antistatic devices (pos. 19, 20).
e. Put the stem seal (6) in the stem (5). Assembly the stem (5) into the body cover 1 (151).
f. Place the spring seats (45) into their housings in the body 2 (2). Introduce the ring seats 2 (44b) and seat seals (46) in the
body ends (2). Put the seat o-ring (108) and stop seals (170) in the seat (4) – ring seat 1 (44a) sets, and introduce them in the
body ends (2).
g. Assemble the support bearing (33) in the ball (3) using the pins (22) in one of the body ends (2).
h. Put the body seals (14 and 34) into their housing of the body 1 (1), and assemble the body 1 (1) with the body ends (2). Join
them by means of studs (41) and nuts (42).
i. Maintain the valve in its closed position and position body adaptors (2) to body (1) ensuring that alignment marks are
matched. Assemble studs (41) and the nuts (42) evenly tighten in diagonal using a torque wrench.
j. After placing the pins (22), place the body cover 1 (151) together with the stem (5) into its housing in the body 1 (1).
k. After placing the pins (22), place the ISO cover (149) together with the stem bearing (165) in the body cover 1 (151), place the
ISO cover bolts (153) and tighten them.
l. Place the subjection ring seal (110) and subjection ring (50) into the stem (5).
m. Screw the drain and vent plugs (86 and 86a).
n. Slowly cycle the valve until completing 1 cycle to ensure coupling between the seats (4) and the ball (3).
o. Carefully cycle the valve twice in order to check the correct working. Stem (5) should rotate smoothly offering resistance as
indicated by the manufacturers torque figures. Tests should be carried out according to API 598, at the pressure rating that
corresponds to the valve, before reinstallation.

The end user is responsible, in case that the fluid is not communicated, checking the compatibility of the service media/ fluid with the valve materials.

DC 08-12-07 PF -2-