Installation & Maintenance Instructions
FCT Ball Valves - type HPA - 150# to 1500#
Ball valves for all applications with an anti blow-out
stem, a fire safe design and an automatic relief body
cavity.
1. General
For the safety and reliability of ball valve delivered by FCT, we recommend you to follow the
directions for use described in this manual.
Proper maintenance is a guarantee for a correct operation of the equipment.
2. Subject
This manual deals only with the maintenance of FCT valves.
The electrical, pneumatic or hydraulic actuators are described in their own maintenance manuals
supplied by their manufacturers.
3. Storage
Each valve is protected in our workshop by means of:
• Plastic plugs on both ends (temporary)
• Peel-off varnish on the clamps (temporary)
• An external painting
• The lubrication of the passage port (temporary)
Table of Contents The temporary protections have to be removed before installing the valve on the pipe.
1. General 1
4. Operation/utilization
2. Subject 1 4.1. The valves must be installed in open position (as delivered)
3. Storage 1
Warning
4. Operation/utilization 1
Do not operate the valves before the line is cleaned. Do not keep the valves in middle
position.
5. Overhaul/procedures 2
5.1 External leaks (location and repair) 2 The seats would be damaged and tightness would be altered. The normal positions are: open
5.2 Internal “in line” leaks 3 position or closed position.
5.3 Restoring the line tightness 3
4.2. The closing or opening of the valve is obtained by a 90° rotation of the ball/stem assembly.
6. Seats replacement 5 The valve is closed clockwise. The position of the ball (“open” or “closed” position) is indicated
as follow:
7. Upper stem replacement 5
For bare stem valves:
8. Lower stem replacement 5
Appendix A: Pipe axis
Tightening torque for bolts 6
Tightening torque for bolts with
PTFE coating 6 Open position Open position
Appendix B:
Drawing and part list 7
Pipe axis
Closed position
Closed position
For gear operated valves:
With a position indicator fitted at the top of gear
Pipe axis
Open position Closed position
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Installation & Maintenance Instructions
FCT Ball Valves - type HPA - 150# to 1500#
5. Overhaul procedures
(See also drawing Appendix B)
5.1. External leaks (location and repair)
In most cases, a simple check is sufficient to locate and correct the defects.
5.1.1. Checking for external leaks
These leaks may occur:
• On the flange/body interface (seal) (106) (115).
• On the screwed fittings (injections, relief plug or valves, drain plug or valve)
(108), (118), (602), (605).
• On the upper stem seals (100) (102) (116) (56).
• On the lower stem seals (111) (128).
5.1.2. Repairing external leaks
5.1.2.1. Flanges/ body interfaces
In this case, it is necessary to remove the parts as follows:
• remove the valve in open position
• remove the gear operator and actuator if necessary.
Mark with indelible ink the position of the flange with respect to the body.
• disconnect the flange(s) (2) after having unscrewed the nuts (113).
• replace the seal(s) (106 or/and 115) after having cleaned the grooves.
• reinstall the flange(s) (2) after having cleaned the seals bearing surface in the body.
Before reinstalling, slightly lubricate the O-ring (106) with “Elf Proteran DN35X”
lubricant or equivalent.
• reinstall and tighten the nuts (113) according to the tightening torque values
mentioned in Appendix A tables.
5.1.2.2. Screwed fittings (injections, relief plug or valves, drain plug or valve) (108), (118), (602),
(605).
If there is any leak at the screwed fittings, simply tighten them slightly to obtain a good
seal.
5.1.2.3. Stem (upper and lower)
If there is any leak at the stems, correct as follows:
5.1.2.3.1.For valves with a gel injection device (on the upper stem only) inject sealant in order to
obtain a good seal (type Desco 800, Chemola or equivalent). As soon as possible,
recondition/replace the seals according to the procedure described hereafter.
5.1.2.3.2.For valves without gel injection device and valves the replacement of the seal(s) is (are)
necessary.
To replace these parts, it is MANDATORY that there is no pressure at the stem.
For this purpose:
• Either isolate the valve from the system and bleed it with the pressure relief plug or
drain plug (108 or 118) (main valve in open position or closed position).
• Or “close” the valve and bleed it with the pressure relief plug or drain plug (108 or
118) of the dead chamber.
Warning
Do not change a packing gland or rod seal if the pressure relief plug or valve (108 or 118) is
not in open position or if bleeding cannot be obtained.
Do not confuse the pressure relief plug or valve (108 or 602) and the drain plug or valve (118
or 605).
Then proceed as follows:
For the upper stem
• Remove the actuator, the gear operator or the lever.
• Remove the key (127) or the stopper spring (119) for lever operated valves.
• Remove the quarter-turn stop plate (7) for lever operated valves.
• Remove the Allen screws (101).
• Mark the position of the adaptor flange (9) or the cap (6) with respect to the body.
• Remove the adaptor flange (9) or the cap (6) by sliding it axially to extract the shear
pin (117).
• Remove the seals (100, 102 and 129) (primary sealing) and if necessary the seals (56
and 116) (secondary sealing, fire safety).
• Before reinstalling the new seals, carefully clean the parts and the sealing surfaces.
• If there is any corrosion on these surfaces, use an emery paper grade 500 or 1000 to
obtain a clean and smooth surface (maximum surface roughness Ra 1.6). Clean
carefully.
• Dry install the scraper ring (129) into its housing. Slightly lubricate the internal surfaces
of the ring with “Elf Proteran DN35X” lubricant or equivalent.
• Carefully install the lip seals (100) into the recess in the body. Slightly lubricate it
before installing. Do not use any metallic tool which could damage the seal.
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Installation & Maintenance Instructions
FCT Ball Valves - type HPA - 150# to 1500#
• Reinstall the adaptor flange (9) or cap (6) taking into account the shear pins and
observing the marks made during removal.
• The tightening torque values of Allen screws are mentioned in the table of Appendix A.
For the lower stem:
• Remove the Allen screw (122).
• Mark the position of the lower stem (5) on the body (1).
• Remove lower stem by sliding it axially.
• Remove the seals (111and 128).
• Before reinstalling the new seals, carefully clean the parts and the sealing surfaces.
• If there is any corrosion on these surfaces, use an emery cloth grade 500 or 1000 to
obtain a surface consistent with Ra 1.6 maximum surface roughness. Clean carefully
after sanding.
• Lubricate slightly the O-ring (111) with “Elf Proteran DN35X” or equivalent.
• Check that the anti-static device (179) is into its housing.
• Check lower stem bearing.
• Slightly fit the lower stem by sliding it axially into body (1).
• Tighten Allen screws (122) according to tightening torque values of Appendix A tables.
5.2. Internal “in line” leaks
To check the tightness of the line, a simple test can be carried out the valve must be
fitted with a pressure relief plug or valve (108 or 118) and must be in closed position.
Typical procedure:
After complete closing of the valve, depressurize the internal volume of the “body” by
means of the pressure relief plug or drain plug (108 or 118). This depressurization must
be performed gradually and completely.
This operation may be dangerous if any toxic or dangerous liquid is used. In this case,
the regulations applicable to the site must be strictly observed.
When the pressure relief device is in open position, a volume equal to the leakage of one
or two seats according to the pressure differential of the valve will be delivered.
Example:
If the upstream pressure amounts to 100 bar and the downstream pressure is 0, the
leakage will have to be considered on the upstream seat. If the upstream pressure
amounts to 100 bar and the downstream pressure is 50, the leakage will have to be
considered on the upstream and downstream seats.
If the leakage rate is not permissible and if it cannot be reduced by the gel-injection
device, or by adjusting the ball closing position (stoppers on gear and actuated valves)
the seats, and if necessary the ball, must be replaced.
Warning
This operation can only be performed with a pressure relief device. Do not use the drain plug
to relief the cavity.
5.3. Restoring the line tightness
5.3.1. Use “HPA line sealing kits” consisting of item 11 (11A), 10, 109, (if safety fire valve item
53 is used).
5.3.2. Before removal, it is necessary to apply following preliminary procedure.
5.3.2.1. Before removing the valve from the piping, mark the initial position of the assembly with
indelible ink (up stream, down stream, up/down). Bleed the line, put the valve in open
position.
5.3.2.2. Remove the gear operator or the actuator system and follow the instructions given by
the manufacturer of the equipment if necessary.
5.3.2.3. Mark with indelible ink the flange/body position of the valve and the lateral sides of the
flanges in order to preserve this correct position when reinstalling.
5.3.2.4. Set-up the lifting slings and transport the assembly in accordance with the elementary
precautions applying to this type of equipment.
5.3.2.5. Completely bleed the internal volume by opening the pressure relief general device (108
or 118) of the body provided for that purpose.
5.3.3. Disassembly of the valve and re-assembly
5.3.3.1. Disconnect the flanges (2) by unscrewing the bolts and nuts (112 and 113).
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Installation & Maintenance Instructions
FCT Ball Valves - type HPA - 150# to 1500#
5.3.3.2. Check carefully:
• The sealing contact area of the seats (11A) (scores, creepling, sinking). The sealing
contacts may not be scored or damaged and must be recessed with respect to the
metallic support (see drawing Appendix B).
• The surface of the ball. The part in contact with the seat may not be damaged and
may not show any scores or impact marks.
• O-ring at back section of seat (109).
It must not be porous or broken and the contact surface must not show any scores of
corrosion marks.
After these check, three cases may occur:
Case Nr. 1
The ball and the seats are not damaged, the O-ring item 109 is defective.
Case Nr. 2
The ball is not damaged, the seats are defective.
Note: the O-ring must be systematically replaced with the seats, we recommend also to
change the seats spring washers (10).
Case Nr. 3
The ball is damaged and the seats are consequently also damaged.
5.3.3.3. Repairing
Case Nr. 1
• Replace the seal (109 and/or 53) of the seat (11) and lubricate it slightly with “Elf
Proteran DN35X” lubricant or equivalent.
• If necessary, sandpaper the surface of the flange in contact with the seal (109) and
clear it carefully.
• Install the seat in the flange after having installed the spring washer (10). This
operation must be performed very carefully in order not to damage the O-rings (109).
• Body/flanges seal (see paragraph 5.3.1)
• Reinstall the flanges (2) after having cleaned the seals in the body. Before reinstalling,
slightly lubricate the O-ring (106).
• Reinstall and tighten the nuts (113) according to the torque load mentioned in
Appendix A tables (see also paragraph 6).
Case Nr. 2
• Apply the same procedure but with a new seat (11) and new spring washer (10).
Case Nr. 3
• Carry out procedure described in Cases Nr. 1 and Nr. 2 for the removal of flanges and
the replacement of seats.
• Remove the adaptor flanges (9) according to procedure paragraph 5.1.2.3.2.
• Remove the lower stem according to paragraph 5.1.2.3.2.
• Put the ball in open position.
• Attach the upper stem with a flexible sling through the passage or put stem axis in
horizontal position to avoid it to fall down into body access.
• Remove the ball from the body.
• Install a new ball.
• Put the ball in open position.
• Reinstall the flanges (2), the bolts (112) and nuts (113).
• Reinstall the lower stem.
All bolts must be tightened following diametrically opposite positions, as usual with all
bolted devices fitted with seals
Tightening torque values: see tables of Appendix A.
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Installation & Maintenance Instructions
FCT Ball Valves - type HPA - 150# to 1500#
6. Seat replacement
6.1. Remove a flange (2) by unscrewing assembly bolts (112) and nuts (113).
6.2. Remove the flange by acting axially. Carry out this operation very carefully.
6.3. Remove the flange seat assembly:
• Flange seal (106), safety fire (115)
• Seat (11)
• Seat O-ring (109)
• Seat spring washer (10)
6.4. Reinstall the O-ring (109) on seat (11). Place the spring washer (10) on the flange. Engage
the seat in the flange.
6.5. Place the flange O-ring (106) in its housing and if necessary, the graphite seal (115) for fire
safety valve.
6.6. Replace the flange on the body and observe the previously plotted orientation
6.7. Put the nuts on the assembly bolts. Screw manually until obtaining proper contact between
nut and flange. The bolts may not be lubricated if a torque load is applied.
6.8. Rotate the ball to the closed position
6.9. Gradually tighten nuts and bolts. Apply the tightening torque values specified in the tables of
Appendix A.
6.10. Overhauling of the second side of the valve is carried out by repeating the previously
described procedure
6.11. Reinstall the lever, gear operator or actuator.
7. Upper stem replacement
Remove the upper part according to paragraph 5.1.2.3.2.
Remove the flanges according to paragraph 5.1.2.1.
Remove the ball according to paragraph 5.3.3.
Pull the stem from inside
• Check if the bearings (104 and 105) and the thrust bearing (8) are damaged if necessary
replace them.
• Before replacing the new stem, reinstall the bearings (104 and 105) if it has been changed.
• Reassemble the valve according to paragraphs 5.1.2. / 5.3.3.
8. Lower stem replacement
• Unscrew the Allen screws (122).
• Check if the bearing (120) and the O-ring (111) and/or the graphite seal (128) are damaged, if
necessary replace them.
• Reinstall Allen screw (122) according to the tightening torque specified in Appendix A tables.
Warning
When installing or removing any parts, take care when adjusting the open or closed position
of the valves. These operations must be carried out before reinstalling the valve into the line.
Tyco reserves the right to change the contents without notice page 5
Installation & Maintenance Instructions - Appendix A
FCT Ball Valves - type HPA - 150# to 1500#
Tightening torque for bolts Note
Bolts material The torque values are valid only for non-
For standard applications For NACE MR0175 applications greased bolting.
ASTM A 193 Gr B7 ASTM A 193 Gr B7m
ASTM A 320 Gr L7 ASTM A 320 Gr L7m
ASTM A 320 Gr B8m cl2
ASTM A 193 Gr B8m cl2
Tightening torques (Nm) Tightening torques (Nm)
Ø screw min max min max
8 16 24 10 20
10 32 48 30 40
12 55 80 40 60
14 90 130 70 100
16 135 200 100 150
18 180 270 140 200
20 255 380 200 300
22 340 510 250 380
24 440 660 350 520
27 640 960 480 720
30 800 1200 600 900
33 1180 1760 800 1320
36 1520 2270 1140 1700
39 1940 2910 1450 2180
42 2410 3610 1920 2880
45 2990 4480 2350 3520
48 3600 5400 2700 4050
52 4620 6940 3460 5190
56 5780 8670 4330 6500
60 7220 10830 5410 8120
64 9020 13530 6760 10150
68 11060 14380 8290 12440
Tightening torque for bolts with PTFE coating Note
Bolts material The torque values are valid only for non-
For standard applications For NACE MR 0175 applications greased bolting.
ASTM A 193 Gr B7 + PTFE coating ASTM A 193 Gr B7m + PTFE coating
ASTM A 320 Gr L7 + PTFE coating ASTM A 320 Gr L7m + PTFE coating
ASTM A 320 Gr B8m cl2+ PTFE coating
ASTM A193 Gr B8m cl2 + PTFE coating
Tightening torques (Nm) Tightening torques (Nm)
Ø screw min max min max
8 12 18 7,5 11,25
10 24 36 23 30
12 41 60 30 45
14 68 98 36 75
16 102 150 75 112,5
18 135 203 105 150
20 192 285 150 225
22 255 383 188 285
24 330 500 263 390
27 480 720 360 540
30 600 900 450 675
33 885 1320 600 990
36 1140 1705 885 1275
39 1455 2185 1090 1635
42 1808 2710 1440 2160
45 2243 3360 1770 2640
48 2700 4050 2030 3040
52 3465 5210 2600 3895
56 4335 6500 3250 4880
60 5415 8130 4060 6090
64 6765 10150 5070 7620
68 8295 10785 6220 9330
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Installation & Maintenance Instructions - Appendix B
FCT Ball Valves - type HPA - 150# to 1500#
Lever operated
Stem injection for ball 297 298 299 ball valves
300
sizes 6” - 8” For ball sizes
600 602 Gear /
1 1/2” and 2”
Actuated 150# 600# and
ball valve 3” 150# 300# 6
9 101 105 4 127 119
For 6”
117 7
900# 1500#
and for 8”
600# 1500# 129
2 112 113 115 106
176 56
100
108 116 8 104 102
Cavity
602
injection
605
D
600
Detail D
(Seat ring and flange not
drilled for sizes ø = 4”)
11 11a 53 109 10
3 122 128 111 179 5 120 1
118
Recommended spare parts Components of seal injection device: items 600 + 602
Notes
Fire safe according to API 6FA, API 607 and BS 6755 part 2.
(1) Injection feature: 2”, 3”, 4” (FB) = Cavity injection
6”, 8” (FB) = Stem injection (Qty = 1) and Seat injection (Qty = 2) (1 per seat)
(*) Quantity according to valve size and pressure class
Parts list
Item Qty Designation Material Notes Item Qty Designation Material Notes
1 1 Body 111 1 Trunnion O-ring
2 2 Flange 112 (*) Bolt
3 1 Ball 113 (*) Nut
4 1 Stem 115 2 Flange fire safe seal
5 1 Trunnion 116 1 Adaptor fire safe seal
6 1 Cap 117 2 Pin
7 1 Stop plate 118 1 Drain plug
8 1 Thrust bearing 119 1 Circlip
9 1 Adaptor flange 120 1 Trunnion bearing
10 2 Seat spring washer 122 (*) Allen screw
11 2 Seat 127 2 Shaft key
11a 2 Seat insert 128 1 Trunnion fire safe seal
53 2 Seat fire safe seal 129 1 Scrapper
56 1 Stem fire safe seal 176 1 Anti-static device
100 1 Lip seal 179 1 Anti-static device
101 (*) Allen screw 297 1 Spacer
102 1 Stem O-ring 298 1 Screw
104 1 Stem bearing 299 1 Washer
105 1 Stem bearing 300 1 Lever
106 2 Flange O-ring 600 • Mini check (1)
108 1 Relief plug 602 • Injection plug (1)
109 2 Seat O-ring 605 • Injection fitting part (1)
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