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I855700.

F
M13859
Apollo Top Entry Ball Valves
Installation, Operation, & Maintenance Manual
(For Manual Valves and Automated Valves with Live-Loaded Stem Seal Option)

Introduction Some National/Local authorities may require periodic


hydrostatic testing.
This manual presents guidelines for the Installation, Only use Conbraco replacement parts.
Operation and Maintenance of manual and automated On-off service only (not to be used for throttling).
Apollo Top Entry Ball Valves equipped with the Valves are primarily intended for industrial use.
“standard” and “fugitive emissions” bonnet and “live- Level of training, experience or ability of users should
loaded” stem seal option. Review the entire manual be at least that of trained and skilled maintenance
before beginning any work. personnel or technicians.
Storage & Protection Installation

Valve should be stored in its original shipping container Proper valve selection is the first step in any successful
until just prior to installation with any protection means installation. Refer to an "Apollo Top Entry Ball Valve”
in place and protected from the environment or any catalog for application guidance or contact your
other potentially damaging effects. Valve should be distributor or the factory for more detailed assistance.
properly supported and secured before moving to WARNING: All installations shall be provided with
prevent possible damage to valve, property or harm to pressure relief devices in accordance with the
personnel. requirements of the Pressure Equipment Directive
97/23/EC. Proper installation prior to initial operation
Limitations is the user’s responsibility. Furthermore, where an
additional hazard can occur due to valve exposure to
Conditions supporting no greater than Category III fire or other unexpected external heat source, a
valves. Valves are not to be used in safety functions supplemental pressure relief device shall be installed to
such as safety loops or separating incompatible protect against excessive pressure. This device shall
fluids. prevent the pressure from rising more than 21%
For gases and liquids in Groups 1 & 2. above the maximum allowable working pressure.
In-line service only, not recommended for end of line
service. Pre-Installation Inspection
Service to be compatible with the materials of
construction. Prior to selection it is the user’s The leading cause of premature valve failure is poor house
responsibility to determine that the valve is keeping. Inspect the piping system prior to valve
appropriate for the intended application. Application installation whenever possible, to insure that it has been
not to allow corrosion >.002"/year (.05mm/year). properly flushed and cleared of construction and
The possibility of material deterioration in service fabrication debris. The seating surfaces in soft seated
and need for periodic inspections is the valves are particularly susceptible to weld slag and sand
responsibility of the user. blasting grit. Pipe scale, metal chips and other foreign
For carbon steel valves only, complete valve materials should be removed.
replacement will be necessary after 10 years of
continuous service above 800°F (426°C). While every effort has been made at the factory to
Mechanical supports are not to be welded directly to adequately protect the valve for shipment and storage,
the valve, however, they may be fitted to the damage is still possible and should be discovered and
associated piping. reported before the valve is installed. Verify that actuator,
It is the piping system designer’s responsibility to switches and mounting hardware, as appropriate, were
implement appropriate protection measures to included with the valve and are in good shape, that proper
minimize reaction forces and moments, which result tagging is in place and any warning labels are legible and
from supports, attachments, piping, etc. observed (refer to Figure 8).
Laws of the state must be observed as they apply.
In service inspections may be required by the national Most Apollo ball valves are non-directional, however,
authorities of the country where the valve is valves may be ordered with the vented body option, which
installed. safe guards against excessive pressure built-up in the body

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cavity, but renders the valve directional. Valves with this Operation
feature are identified by a special tag permanently affixed
to the valve body with the word “Flow” and an arrow Apollo valves are shipped with a securely fastened
showing the required orientation of the valve in red. nameplate and attached warning tags. Information
included on each is documented in Figure 8. Although
Just prior to installation, remove each valve from its each valve is thoroughly tested and inspected before it
packing and remove any end covers. Examine the flow leaves the factory, nameplate and/or warning tags could
bore for debris. All Apollo ball valves are shipped in the be lost or destroyed during shipment or while in storage.
open position to prevent damage to the ball surface. Any If either is missing or not legible, contact your
grit or foreign matter must be removed. Scratched or distributor or the factory for assistance before operating
dented balls must be replaced. Do not install a damaged valve. WARNING: Provide means to monitor filling
valve. valve to prevent over pressurization and instability.

It is also important to check for valve operation


clearances. Valves may be installed in any position using Ball valves are intended to be on-off devices operating
standard pipe fitting practices with the exception of the through 90o rotation of the stem. Operation is clockwise
special directional valves already noted. to close.

Flanged End Valve Installation The most common service failures not related to the
installation and start-up processes are:
After determining that the valve is in good condition,
extra attention should be given to the raised face surface. • Exceeding the operating temperature or pressure
Dents and heavy scratches should be repaired. 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.
Weld-End Valve Installation
Violating temperature and pressure limits can result in
Both butt-weld and socket –weld valves require special
immediate valve failure where chemical attack or
consideration for installation. In addition to the general
cautions already discussed, the heat of welding may corrosion generally occurs over time.
damage seats and seals. A warning label is included with
all weld end valves. To avoid this concern, the bonnet,
stem, ball and seats can be removed. The design of the
Apollo Top Entry Ball Valve makes the process of Maintenance
removing these components almost effortless. This
procedure will be covered under the “Maintenance” Preventive Maintenance Schedule
section of this manual.
A regularly scheduled and documented preventive
Once the body has been welded into the piping system, maintenance program needs to be established to achieve
using an appropriate welding procedure, it should be maximum useful valve life at the lowest cost.
allowed to cool and then be thoroughly cleaned before
reinstalling the internal components. Initially, it is recommended that valves be inspected
monthly for smooth operation and leak free
Threaded-End Valve Installation performance.

After removing the valve from its packing, inspect the For manual valves after an initial break-in period,
NPT threads for damage. Occasionally threads may approximately 100 cycles, stem packings may require
require chasing prior to installation to remove burrs or adjustment. In most applications, inspection and or
other minor imperfections. adjustments twice a year will be sufficient to assure
reasonable valve life.
Apply a good grade of pipe sealant compound to the male
pipeline threads only. Do not use sealant on the female For automated valves (generally see high cyclic duty)
threads because excess compound would be forced into after an initial break-in period, approximately 5,000
the valve body. This could cause sticking of the ball or cycles, stem packings may require adjustment. Monthly
encourage the accumulation of dirt and debris that could adjustments (approximately 20,000 cycles) should be
prevent good valve shutoff. sufficient thereafter.

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valve five times to allow the packing to seat, then
Valve Adjustments readjust the nut torque as needed. Take caution to
torque the hex nuts evenly on both sides to avoid side
At some point in the service life of the valve leakage may loading of the packing gland and packings.
occur. This should be noted in the maintenance history
log of the valve. The stem packing and bonnet gasket Caution: Never back off the packing gland jam nut
were adjusted at the factory to provide a leak tight seal when the valve is under pressure.
when the valve was new, but compaction can occur within
these seals that may make readjustment necessary. Stem Table 1: Maximum Packing Torque
leakage should be stopped as soon as it is detected. Valve Maximum Jam Nut Torque (ft-lb)*
Size ANSI 150 & 300 ANSI 600
For manual valves it will be necessary to remove the top (NPS) Std. Port Full Port Std. Port Full Port
jam nut and handle to make the packing adjustment. ½” 2 -- 7 --
¾” 2 -- 7 --
For actuated valves most mounting hardware allows 1” 2 3 7 12
access to the packing gland jam nut. If this is not the case, 1-1/2” 3 6 12 20
it may be necessary to remove the actuator to gain 2” 6 16 20 32
adequate access to make the packing adjustment. 3” 16 38 32 76
JAM NUT
4” 38 66 76 131
6” 66 20** 131 213
8” 118 23** -- 47**
10” 212 45** -- --
12” 23** 45** -- --
*Torque values may be increased up to 25% when graphite packing is used.
**Torque values for valves with gland plates and hex nuts.

Do not over tighten. Over-tightening will result in


excessive operating torque. If stem leakage continues,
BELLEVILLE
or operating torque becomes excessive, depressurize the
SPRINGS
valve and replace the stem seals.

Many different packing styles are available ranging from


simple PTFE rings or die-formed graphoil rings to PTFE
Figure 1 chevrons and special contoured graphoil rings. The
valve model number contains information regarding the
The “live-loading” feature of the bonnet has design type of packing originally installed in the valve. When
allowances for the compaction or minor loss of stem ordering spare parts, be certain to include the valve
packing material, which make necessary adjustments less model number with the request.
frequent. The “live-loading” also makes allowance for
thermal expansion (or contraction) as the valve goes Bonnet leakage, like stem leakage, must be stopped as
through temperature cycles. The springs supply sufficient soon as it is detected. In addition to the obvious hazards
load to the packing to maintain the seal over a range of of a leak, allowed to go unchecked, the gasket sealing
travel. The arrangement of these springs is critical to their surface on the body or bonnet may be eroded requiring
proper function. Figure 1 shows two valve stem designs the replacement of one of these major components.
and their associated spring locations. Refer to Appendix
B and Appendix C for additional “live loading” Tighten bonnet bolts to the maximum torque shown in
configurations. Table 2. Follow the appropriate pattern shown in Figure
2. It is advisable to bring the fasteners up to the
For valves without gland plates, packing adjustments can specified torque level in two equal steps. When doing
be accomplished by defeating the star washer locking the the final torque check, torque adjacent bolts clockwise
upper jam nut, removing the upper jam nut and lever, if around the pattern. If the bonnet leak continues, de-
applicable, and turning the packing gland jam nut pressurize the valve and replace the bonnet gasket.
clockwise to the maximum torque shown in Table 1. When installing a new spiral wound gasket always place
For valves with gland plates, the two hex nuts can be the last rings tie-in spot-weld directly under the #1
equally torqued to the values in bold italic of Table 1. fastener.
After the hex nuts are tightened to specifications, cycle the

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Disassembly

• Once the spare parts are on hand, the first step in the
valve disassembly is to isolate the valve from line
pressure. WARNING: Do not attempt to work
on any valve under pressure, and depending on
the service, valve surface temperature may be
hot, use proper protective gear to protect against
burns. Also provide safe means for uncontrolled
release of fluid.

• Using handle for manual and adjustable or properly


sized open-end wrench for actuated valves, rotate
the stem until the valve is in the open position. Be
careful not to damage the stem.
Figure 2 • Bend the locking tab of the star washer down to
permit the removal of the top jam nut, lever if
Table 2: Maximum Bonnet Torque applicable and grounding spring.
Valve Size Bonnet Torque (ft-lb) • Caution: The ball cannot be removed from the body
Nominal ANSI 150 & 300 ANSI 600 if it is in the closed position!
(NPS) Std. Port Full Port Std. Port Full Port • Back off each of the bonnet fasteners ½ turn only.
½” 8 -- 20 -- This will release the bonnet gasket and assure that
¾” 8 -- 20 -- there is no pressure within the valve.
1” 8 12 20 20 • Loosen the packing gland jam nut. Remove the
1-1/2” 12 30 20 30 bonnet bolts. Lift off the bonnet assembly and
2” 30 60 30 60 spring.
3” 60 45 60 100 • Remove the stem nut and gland ring. Slide the stem
4” 45 100 100 160 out of the bonnet.
6” 100 245 160 245 • Remove the stem seals from the counterbore(s) using
8” 245 355 -- 800 care not to scratch the bore surfaces.
10” 245 500 -- -- • Insert a large screwdriver or similar tool into the oval
12” 355 680 -- -- slot in the top of the ball, as illustrated in Figure 3.
Resting the screwdriver on the valve body, pry the
Valves with high operating torque, not resulting from stem ball and seats lose and upward by pushing down on
seal over-tightening, or valves which have leakage by the the screwdriver’s handle. Use care not to damage
seat, may have damaged seats or ball surfaces. These the bonnet gasket sealing surface.
valves should be depressurized, disassembled, and
inspected for damage.

Valve Overhaul

As part of planned maintenance or as a result of a problem


that cannot be adjusted away, a valve may require a
complete overhaul. Because of the uncomplicated design of
the Apollo Top Entry Ball Valve, this can be accomplished
with the valve in line. The first step is to contact your
distributor to acquire an appropriate rebuild kit. These kits
typically contain a complete set of seats, seals, and gaskets.
If seat or ball damage is suspected, it is wise to order a new
ball when the seal kit is purchased. To properly order spare
parts, you will need the valve model number as shown on
the permanent nameplate. A list of recommended spare
parts to hold as maintenance items are shown in Appendix
“A”. This list is generic, as the severity of the service and
availability of some exotic alloys can also affect Figure 3
recommended spare parts stocking levels.
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Inspection

• Thoroughly clean all the components in preparation for


inspection.
• Examine the flat seating surfaces within the body cavity
(see Figure 4). If these surfaces are pitted or scratched
the body must be replaced. A scratch is anything you
can feel with your fingernail. Machining marks may be
present and will not interfere with sealing. Scratches
that can be seen but not felt may be polished out using
#120 grit emery cloth or finer.

Figure 5

Figure 4
Figure 6
• Inspect the bonnet gasket surface on the body and
bonnet. If they are pitted or scratched then those
components must be replaced. Re-assembly
• Examine the packing gland surfaces. Polish these
surfaces with #120 (or finer) grit emery cloth and • When installing new seat inserts in the metal rings, be
inspect for pits and scratches. Deep scratches running certain that the sealing surface on the back of the
down the side of the packing gland will necessitate the seat protrudes uniformly beyond the metal seat
replacement of the valve bonnet (see Figure 5). ring(s). It is essential that the seat insert clear both
• If the ball has pits or scratches as described above it the inner (if provided) and outer seat rings.
should be replaced. • Lightly lubricate the stem and stem seals with a
• If the seats are worn or scratched, push the inserts out of lubricant compatible with the intended service(1).
the metal seat rings (illustrated in Figure 6) and replace Slide the inside set of packings on the stem, then
the inserts with new ones. Keep the metal rings. insert the stem into the bonnet. Slide the outside
• Inspect remainder of body & bonnet interior for pitting packing set one at a time over the stem, and use the
or corrosion, replace either if excessive. gland ring to push each packing to its final installed
• Inspect all parts for wear due to erosion or abrasion and position in the bonnet counterbore.
replace if excessive. • For manual valves apply a small amount of anti-seize
compound to the jam nut threads. Install the gland
ring and jam nut on the stem finger tight and set the
sub-assembly aside.
• For automated valves with Live Loaded Fugitive
Emissions Stem Seal Option apply a small amount

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of anti-seize compound to the jam nut threads. Install
the gland ring, grounding spring, washers, Belleville Final Adjustments
springs and jam nut on the stem finger tight. The
arrangement of the Belleville springs is critical, if Occasionally after testing or initial start-up, a minor stem
uncertain contact the factory for details. or packing leak may occur. Adjust the packing jam nut or
• Wipe any foreign particles from the flat seating bonnet bolting as appropriate and as described in section
surfaces within the body. Wipe the seats and ball entitled “Valve Adjustments”.
clean. Apply a small amount of lubricant compatible
with the intended service to both sides of the seat and Special Application Valves
ball, which will allow them to temporarily “stick”
together(1). With the ball between the seats in the Valves designed for high temperature applications (above
open position, insert the ball and two seats 500°F) and valves using ceramic balls and seats come
simultaneously into the valve body. equipped with an adjustable ball stop. Should the valve to
• The oval slot in the ball should be near 90° to the be serviced have this feature, characterized by the extra
pipeline. The slot must be facing the bonnet opening. components installed in the bottom of the valve body, as
• The seats and ball are lined up with the pipe centerline illustrated below, several specialized steps are required to
by four lugs in the valve body. The amount of successfully complete the overhaul.
spacing between the seats and the lugs should be
equally distributed on both sides so that the ball is
aligned with the centerline of the valve. A large
screwdriver can be used to gently adjust the alignment
if necessary.
• Put a new bonnet gasket in place on the bonnet. When
installing the new spiral wound gasket always place
the last ring’s tie-in spot weld directly in line with the
#1 fastener.
• Line the stem tang up with what corresponds to the
open position. Test fit the bonnet assembly. Position
the bonnet over the bonnet opening in such a manner
that the stem slides into the ball slot. When
everything lines up properly, remove the bonnet and
slide the larger spring over the stem tang and
reposition the bonnet on the body.
• Press the bonnet down against the valve body using
care not to damage the bonnet gasket. Apply a small
amount of anti-seize compound to all fasteners. Insert
the bonnet bolts or studs and nuts and torque to the
value shown in Table 2 using the appropriate pattern
illustrated in Figure 2.
• Torque the packing gland jam nut to the value shown
in Table 1. Cycling the valve from open to close
Figure 7
several times and rechecking the torque helps seat the
packings and the ball. This also verifies the valve is
operating freely. Disassembly Process Changes
• For manual valves, place the grounding spring over the
packing gland jam nut; install the handle, star lock Because of the presence of the ball stop it should not be
washer and top jam nut. For actuated valves install necessary to pry the ball and seats out of these valves, no
the star lock washer and top jam nut. force should be required to disengage them.
• Bend one tab of the lock washer up against the top jam
nut on a flat that most nearly aligns with one of the Once the ball and seats are removed the ball stop should
tabs. be disassembled in the following order: Remove cap, nut
The valve is now ready for testing and use. and packing gland from outside the valve, then lift
adjustment screw out from inside the valve, packing can
(1) Warning: For Chlorine, Oxygen and other like then be removed from outside. All parts are then to be
services assemble without lubricant. cleaned and new packing ordered with the seal kit.

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Special Inspection Requirements seating feature. Slowly turn the adjusting screw
clockwise until it just contacts the ball. You will be
Scratched or otherwise damaged balls and seats cannot be able to feel it when it meets this resistance. Hold this
repaired and must be replaced. adjustment and tighten the nut to 10 ft-lb.
• On all seat styles except the ceramic seats, the
No scratches or pits are permissible on the seat faces in adjustment screw should be backed out about ¼ to ½
the body. Simple polishing is not adequate. These turn, do not back out the ball stop on valves with
surfaces are match lapped to the seats. They must be truly ceramic seats.
flat and flawless. These surfaces cannot be repaired. If
there is damage, the body must be replaced. The valve is now ready for testing and use. Just like with
more standard valves some final seal adjustments may be
When examining the ball stop components, make certain necessary. Refer to the “Adjustment” section of this
all evidence of the old packing has been removed. Order manual.
replacements for any corroded parts. Name Plate/Hand Tag Information
One of three possible identification tags may be attached
Re-assembly Process Changes to the valve. ASME/ANSI qualified valves feature a
stainless nameplate secured to the side of the body by
Note: Before installing ball and seats, first insert the
drive rivets. On qualified designs, 1-1/4” and larger, the
adjustment screw from inside the valve (see Figure 7). stainless tag features the CE logo.
Ceramic seats and ball sets require no additional attention ASME/ANSI NAMEPLATE
prior to installation. New metal to metal seats and ball MODEL
sets and new Carbon-Graphite seats and ball sets and new MANUFACTURING DATE
Carbon-Graphite seats and ball sets come from the factory DESIGN CODE
match lapped. BALL/STEM
SEAT/PACKING
With the high temp Carbon-Graphite seats or metal to DN – SIZE
metal seats, when reinstalling old seats, the seats must be
PS – MAXIMUM ALLOWABLE PRESSURE @ 38°C
matched lapped to the ball and lapped to the seat faces in
CWP @ 100°F
the body. If a “final fitting” lap seems necessary, use a
CONBRACO IND., INC. Made In U.S.A.
small amount of lapping fluid (very fine abrasives mixed
with a light oil or even water) in conjunction with the
CE NAMEPLATE
seats to lap these surfaces smooth.
CE MARK
NOBO NO.
If the seating surfaces are good, wipe them clean and MODEL
apply a small amount of a lubricant compatible with the MANUFACTURING DATE
service. They can be installed dry if necessary, but DESIGN CODE
handling does become more difficult. Install the ball and BALL/STEM
seats as directed in the standard re-assembly procedure. SEAT/PACKING
DN – SIZE
Ball Stop Installation
PS – MAXIMUM ALLOWABLE PRESSURE @ 38°C
CWP @ 100°F
• Completely assemble the valve as described in the
CONBRACO IND., INC. Made In U.S.A.
body of this manual before proceeding.
• Apply a small amount of anti-seize compound to all
WARNING TAG
threads. A good grade of Teflon pipe sealant may be
Carefully read the applicable Installation, Operation, &
substituted for the anti-seize but do not use Teflon
Maintenance Manual in its entirety before removing
tape.
valve from shipping container. To obtain manual,
• Carefully slide the new packing over the adjustment
download from http://www.conbraco.com/iom.
screw and push into place at bottom of weld bushing
DO NOT REMOVE TAG.
and slide packing gland against packing.
• Thread the nut onto the adjustment screw, finger
tighten. Back out the adjusting screw while holding Figure 8
the nut stationary, until it bottoms against the back

7
Appendix A

Recommended Spare Parts for Initial Start-Up and 1 Year Service


Number of Valves to be Supported
Item 1 to 10 11 to 25 26 to 50 51 to 100 101 Plus
Seal Kits* 1 2 4 8 10
Stem 0 1 2 4 5
Ball 0 1 2 4 5
Spare Valve(s)** 0 0 1 2 3

Recommended Spare Parts for 2 Years Service


Number of Valves to be Supported
Item 1 to 10 11 to 25 26 to 50 51 to 100 101 Plus
Seal Kits* 2 4 8 16 20
Stem 1 2 4 8 10
Ball 1 2 4 8 10
Spare Valve(s)** 0 1 2 3 4

Recommended Spare Parts for 3 Years Service


Number of Valves to be Supported
Item 1 to 10 11 to 25 26 to 50 51 to 100 101 Plus
Seal Kits* 3 6 12 24 30
Stem 1 3 6 12 15
Ball 1 3 6 12 15
Spare Valve(s)** 1 2 3 4 5

* Seal Kits consist of Stem Packing Set, Bonnet Gasket and Seats
** Recommended if order quantities do not already include spare valves.

Appendix B

HEX NUT
BELLEVILLE
WASHER BELLEVILLE SPRING WASHER
CONFIGURATIONS

GLAND ASSEMBLE AS SHOWN


PLATE 2 STACKS PER VALVE

STUD
FIG #1 FIG #2 FIG #3
(6/STACK) (12/STACK) (15/STACK)

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Appendix C

1" 150#/300# TEV 1-1/2" 150#/300# TEV 2" 150#/300# TEV 3" 150#/300# TEV
(2) E230500 (2) E236200 (4) E230700 (10) E230500

4" 150#/300# TEV 6" 150#/300# TEV


(6) E230700 (16) E230700

150#/300# TEV VALVES

1" 600# TEV 1-1/2" 600# TEV 2" 600# TEV 3" 600# TEV
(4) E236200 (8) E230700 (9) E236300 (20) E230500

4" 600# TEV 6" 600# TEV


(12) E230700 (24) E230700

600# TEV VALVES A REDRAWN, NO CHANGE

NO TE: This drawing and the subject matter disclosed therein is the property of Conbraco Industries, Inc. and is not to be

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