AOP Series D Trunnion Mounted Ball Valves (Size 2in through 6in)

21 Pages·2010·0.48 MB·English

INSTALLATION, OPERATION AND MAINTENANCE MANUAL
AOP SERIES D TRUNNION BALL VALVE, 2”FP – 6”RP

CONTENTS

1. Parts list……………………... 2

2. Description……..…………… 10

3. Safety information’s…….……… 10

4. Installation and storing… 10

5. Operation …….……… 12
6. Maintenance…………………. 12
7. D valve Reconditioning……… 14
7.1 D valve disassembly………. 14
7.2.a. Lever valve assembly …… 16
7.2.b. Gear valve assembly …… 19
8. Troubleshooting.......................... 21

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Figure 1 – D Series-Standard Seat (class 150-900) – BARE STEM
(see parts list below)

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Parts list – D Series Standard Seat 150-900 class– BARE STEM (reference
Figure 1):

Item Qty Description
1 1 BODY
2 1 ADAPTER- CLOSURE
3 1 BALL
4 1 STEM
5 1 LOWER TRUNNION
6 2 SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT)
7 1 BONNET (GLAND PLATE)
8 1 ADAPTER PLATE- GEAR
9 * ADAPTER STUDS
10 * ADAPTER NUTS
11 * CAP SCREW SOCKET HEAD- BONNET
12 * CAP SCREW SOCKET HEAD- LOWER TRUNNION
13 * CAP SCREW SOCKET HEAD- ADAPTER PLATE
14 1 O-RING, ADAPTER
15 1 O-RING, STEM
16 2 O-RING – SEAT MAIN SEAL
17 1 O-RING, BONNET
18 1 O-RING, LOWER TRUNNION
19 1 BACK-UP RING, BONNET (NOT SHOWN- 900/1500 CLASS
ONLY)
20 1 BACK-UP RING, STEM (NOT SHOWN- 900/1500 CLASS ONLY)
21 1 BACK-UP RING, TRUNNION (NOT SHOWN- 900/1500 CLASS
ONLY)
22 1 BACK-UP RING, ADAPTER (NOT SHOWN- 900/1500 CLASS
ONLY)
23 1 FIRE SAFE SEAL, TRUNNION
24 1 FIRE SAFE SEAL, ADAPTER
25 1 FIRE SAFE SEAL, BONNET
26 1 FIRE SAFE SEAL, STEM
27 1 GLAND BUSHING
28 1 BEARING RADIAL – DU - STEM
29 1 BEARING RADIAL – DU - TRUNNION
30 1 BEARING THRUST – DU - STEM
31 2 SPRINGS- SEAT
32 2 DRIVE PINS - STEM
33
34 2 TORQUE PIN
35 1 STEM KEY
36 1 FITTING- STEM
37 1 VENT/ DRAIN FITTING
38 1 BODY GREASE INJECTION FITTING

* QUANTITIES DEPENDING ON SIZE AND CLASS

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Figure 2 – D Series-Standard Seat (class 150-900) – LEVER OPERATED
(see parts list below)

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Parts list – D Series Standard Seat 150-900 class– LEVER OPERATED
(reference Figure 2):

Item Qty Description
1 1 BODY
2 1 ADAPTER- CLOSURE
3 1 BALL
4 1 STEM
5 1 LOWER TRUNNION
6 2 SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT)
7 1 BONNET (GLAND PLATE)
8 1 LOCKING BEARING HOUSING FOR 2FP UP 4RP VALVES —OR
ADAPTER PLATE- GEAR FOR 4FP AND 6RP VALVES
9 * ADAPTER STUDS
10 * ADAPTER NUTS
11 * CAP SCREW SOCKET HEAD- BONNET
12 * CAP SCREW SOCKET HEAD- LOWER TRUNNION
13 * CAP SCREW SOCKET HEAD- BEARING HOUSING OR
ADAPTER PLATE (SEE ITEM 8)
14 1 O-RING, ADAPTER
15 1 O-RING, STEM
16 2 O-RING – SEAT MAIN SEAL
17 1 O-RING, BONNET
18 1 O-RING, LOWER TRUNNION
19 1 BACK-UP RING, BONNET (NOT SHOWN- 900/1500 CLASS
ONLY)
20 1 BACK-UP RING, STEM (NOT SHOWN- 900/1500 CLASS ONLY)
21 1 BACK-UP RING, TRUNNION (NOT SHOWN- 900/1500 CLASS
ONLY)
22 1 BACK-UP RING, ADAPTER (NOT SHOWN- 900/1500 CLASS
ONLY)
23 1 FIRE SAFE SEAL, TRUNNION
24 1 FIRE SAFE SEAL, ADAPTER
25 1 FIRE SAFE SEAL, BONNET
26 1 FIRE SAFE SEAL, STEM
27 1 GLAND BUSHING
28 1 BEARING RADIAL – DU - STEM
29 1 BEARING RADIAL – DU - TRUNNION
30 1 BEARING THRUST – DU - STEM
31 2 SPRINGS- SEAT
32 2 DRIVE PINS - STEM
33 1 STOP PLATE
34 2 TORQUE PIN
35
36 1 FITTING- STEM
37 1 VENT/ DRAIN FITTING
38 1 BODY GREASE INJECTION FITTING
39 1 SNAP RING
40 1 STOP PLATE CAP SCREW- ONLY ON 4FP AND 6RP VALVE
41 1 LEVER SUBASSEMBLY- NOT SHOWN
* QUANTITIES DEPENDING ON SIZE AND CLASS

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Figure 3:D Series Bare Stem Valve – Lubricated Seat - 1500 Class

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Parts list: D Series Lubricated Seat 1500 class– BARE STEM
(reference Figure 3):

Item Qty Description
1 1 BODY
2 1 ADAPTER- CLOSURE
3 1 BALL
4 1 STEM
5 1 TRUNNION
6 2 SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT)
7 1 BONNET (GLAND PLATE)
8 1 TRUNNION COVER
9 1 GEAR PLATE
10 * ADAPTER STUDS
11 * ADAPTER NUTS
12 * CAP SCREW SOCKET HEAD- BONNET
13 * CAP SCREW SOCKET HEAD- TRUNNION COVER
14 * CAP SCREW SOCKET HEAD- ADAPTER PLATE
15 1 O-RING, ADAPTER
16 1 O-RING, STEM
17 2 O-RING – SEAT MAIN SEAL
18 2 O-RING – SEAT SECONDARY SEAL
19 1 O-RING, BONNET
20 1 O-RING, TRUNNION
21 1 BACK-UP RING, BONNET
22 2 BACK-UP RING, SEAT MAIN SEAL
23 1 BACK-UP RING, STEM
24 1 BACK-UP RING, TRUNNION
25 1 BACK-UP RING, ADAPTER
26 1 FIRE SAFE SEAL, TRUNNION COVER
27 1 FIRE SAFE SEAL, ADAPTER
28 1 FIRE SAFE SEAL, BONNET
29 1 FIRE SAFE SEAL, STEM
30 1 GLAND BUSHING
31 1 BEARING RADIAL – DU - STEM
32 1 BEARING RADIAL – DU - TRUNNION
33 1 BEARING THRUST – DU - STEM
34 2 SPRINGS WAVE - SEAT
35 2 DRIVE PINS - STEM
36
37 2 TORQUE PIN
38 1 STEM KEY
39 1 FITTING- STEM
40 1 BODY VENT/ DRAIN FITTING
41 2 SEAT GREASE INJECTION FITTING
42 2 INTERNAL CHECK VALVE (BELOW GREASE FITTING)
43 1 BODY VENT PLUG

* QUANTITIES DEPENDING ON SIZE AND CLASS

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Figure 4 – D Series Lever Operated Valve – Lubricated Seats – 1500 Class

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Parts list – D Series Lubricated Seat 1500 class– LEVER OPERATED
(reference Figure 4):
Item Qty Description
1 1 BODY
2 1 ADAPTER- CLOSURE
3 1 BALL
4 1 STEM
5 1 TRUNNION
6 2 SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT)
7 1 BONNET (GLAND PLATE)
8 1 TRUNNION COVER
9 1 LOCKING BEARING HOUSING FOR 2FP UP 4RP VALVES —OR
ADAPTER PLATE- GEAR FOR 4FP AND 6RP VALVES
10 * ADAPTER STUDS
11 * ADAPTER NUTS
12 * CAP SCREW SOCKET HEAD- BONNET
13 * CAP SCREW SOCKET HEAD- TRUNNION COVER
14 * CAP SCREW SOCKET HEAD- ADAPTER PLATE
15 1 O-RING, ADAPTER
16 1 O-RING, STEM
17 2 O-RING – SEAT MAIN SEAL
18 2 O-RING – SEAT SECONDARY SEAL
19 1 O-RING, BONNET
20 1 O-RING, TRUNNION
21 1 BACK-UP RING, BONNET
22 2 BACK-UP RING, SEAT MAIN SEAL
23 1 BACK-UP RING, STEM
24 1 BACK-UP RING, TRUNNION
25 1 BACK-UP RING, ADAPTER
26 1 FIRE SAFE SEAL, TRUNNION COVER
27 1 FIRE SAFE SEAL, ADAPTER
28 1 FIRE SAFE SEAL, BONNET
29 1 FIRE SAFE SEAL, STEM
30 1 GLAND BUSHING
31 1 BEARING RADIAL – DU - STEM
32 1 BEARING RADIAL – DU - TRUNNION
33 1 BEARING THRUST – DU - STEM
34 2 SPRINGS WAVE - SEAT
35 2 DRIVE PINS - STEM
36 1 LOCKING STOP PLATE
37 2 TORQUE PIN
38
39 1 FITTING- STEM
40 1 BODY VENT/ DRAIN FITTING
41 2 SEAT GREASE INJECTION FITTING
42 2 INTERNAL CHECK VALVE (BELOW GREASE FITTING)
43 1 BODY VENT PLUG
44 1 SNAP RING
45 1 STOP PLATE CAP SCREW- ONLY ON 4FP AND 6RP VALVE
46 1 LEVER SUBASSEMBLY- NOT SHOWN

* QUANTITIES DEPENDING ON SIZE AND CLASS

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2. Description

D series ball valves 2” FP to 6” RP are full bore, through conduit, bi-directional, anti-blowout stem,
double block and bleed with trunnion mounted ball for easy operation.
These valves are equipped with seats with plastic insert; self relieve type seats to eliminate cavity
pressure lock. The trunnion ball valve uses metal- backed self lubricating PTFE sleeve bearings and
thrust washers to reduce torque. The stem and lower trunnion is separated from the ball to eliminate
side loads.
The lever and wrench head can be easily removed/ reassembled by means of set screws.
The handwheel can be removed from the gear shaft by taking out the split pin.

3. Safety Information’s

Valves shall be operated and maintained strictly in accordance with these procedures. Operation or
maintenance outside of these procedures constitutes abuse of the product and voids all warranty and
claims.
When special operation is required, a formal written request to the company must be made for
approval to operate in this manner if warranty and product liability is to be maintained.
Before any work is performed on a valve, personnel working on the valve must obtain the proper work
permits required by his employer. Personnel shall always use safety precautions set forth by the law
and regulations required by his employer. Personnel shall also be aware that any venting or draining of
fluids from the valve shall be done in accordance with safety and environmental procedures in force at
the particular location.
The maintenance personnel doing the repairs should be well trained, and familiar with all of the
information contained in this manual.
The valves shall be appropriately used for the intended purpose. Any safety or protection devices on
the valve shall not be permanently removed or altered unless written approval is received from AOP
representative.
Transport, unpacking, lifting, connections to the different types of systems (electric, pneumatic,
hydraulic systems, etc.) shall be made by expert and qualified personnel
Should any difficulties or abnormalities arise which cannot be solved by the technician, contact AOP
representative.
Any servicing not covered by these instructions must be made by an authorized service center, after
preliminary approval has been given by AOP representative.

4. Installation and storing

Valves delivered by AOP

After the valves have been assembled and tested, the valves are drained and painted.
Sealing surfaces of connection flanges are greased and covered by protectors.
All valves are delivered in fully open position, unless is actuated with a normal close position actuator.
If the valve is lever operated, the lever may be separately packaged for easier handling and
transportation.
If the valve has a gear operator, the gear is installed on the valve and factory adjusted for open and
closed position. The gear handwheel may be separately packaged for easier handling and
transportation.

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