API 6D Ball Valve Maintenance & Safe Use Instructions

BATUSAN is committed to personal safety and the long service life of its valves. This API 6D Ball Valve Maintenance manual provides all the necessary safety guidelines. It covers handling, storage, installation, operation, and API 6D Ball Valve Maintenance. Please read it carefully before installing or maintaining the valve.

Purpose

API 6D Ball Valve Maintenance Overview

The BALL VALVE is a type of valve that directs, transmits, or stops fluids with the movement of the sphere inside the body. It is essential that the valve is assembled according to relevant standards and conditions. This ensures that the valve operates in environments suitable for its design.

The user bears responsibility for any issues arising from actions contrary to the specified guidelines.

Considerations in ball valve selection

The API 6D Ball Valve Maintenance instructions list the following criteria for selecting the correct valve:

• The medium in which it will be used (the fluid passing through it) should be selected according to whether the fluid is liquid, gas, air or dark excess fluid containing solid particles and whether it is corrosive or not.
• Concentration and temperature of the fluid (max and min): the max temperature and min temperature of the fluid passing through the operating temperature valve must be known.
• Operating pressure (max operating pressure): max pressure of the fluid passing through the valve.
• Type of connection to the circuit: threaded, flanged, socketed, welded or unionized.
• Size or amount of fluid to be flowed per hour.
• Compliance with world standards: API, DIN, EN.
• Valve passage type: full passage (full bore) or reduction passage (reduced bore).

Packaging

Packaging requirements in the API 6D Ball Valve Maintenance instructions are as follows:

• Batusan valves are protected against foreign objects entering the line connection points and it is recommended not to remove the packaging and cover of the valve until you connect it to the cleaned line.
• Batusan valves are packaged, boxed and palletized in accordance with the Transportation, Storage, Packaging and Shipment procedure.

As Batusan, unless the customer does not specify a special request, the valves are shipped in a cardboard box on the pallet or in a wooden box on the pallet. It is recommended that the valves shipped are kept by the customer in a closed storage area away from water, moisture and dampness.

Storage

The API 6D Ball Valve Maintenance instructions define the following storage conditions:

• Valves should never be stacked on top of each other to avoid any adverse situation that could affect valve performance and cause injury to personnel.
• The boxes should be opened and the valves inside should be checked to ensure that users are not damaged by transportation.
• If the valve is removed from the box or pallet, the accessories on the valve must be protected from any crushing or impact.
• Long-term storage of valves min. 6 months: the line connection covers of the valve are opened and the unpainted parts are lubricated with anti-corrosion oils and the flanges are closed with covers.
• During shipment or storage, the weight information of the product is checked and it is deemed appropriate to be shipped with the appropriate carrier.

Transport

For transport, the API 6D Ball Valve Maintenance instructions require the following precautions:

• Cloth slings should be used when opening the box to prevent any damage to the valve.
• When lifting the valves, it is recommended to use lifting devices suitable for the valve weight.
• The transportation of ball valves larger than 25 kg is provided by the lifting lugs on the valve, which have their own lifting points designed to carry the load of the valve.
• For valves over 25 kg without carrying lugs, transportation can be made through the stud holes in the connection flanges to the installation.
• The gearbox must not be used to lift the actuator to the valve.
• Lifting equipment must always be double checked before each lifting operation for valve and occupational safety.
• Never remove the valve flange protection to prevent foreign matter from entering the valve during lifting / transportation.

Before delivery and connection to the line, label information must be checked. The label indicates the standard, size, pressure class, pressure/temperature rating, body material, trim identification, face-to-face dimension, date of manufacture, and serial number.

Points to be considered when using ball valves

The following operating points are taken from the API 6D Ball Valve Maintenance instructions:

• Batusan API valves are protected and cleaned against foreign objects entering the line connection points. It is recommended not to remove the packaging and cover of the valve until you connect it to the line.
• The valve should be left in full open position or full closed position. The valve left in the half-open position damages the ball sealing teflon due to its working principle and causes the valve to leak.
• You should apply force to the valve handles only for opening and closing positions in the direction of the arrow. Do not apply force when the movement of the lever rests on the stop pin.

Operating conditions are indicated on the valve, including the maximum working pressure in BAR.

Matters to be considered in ball valve installation

Correct installation is the starting point of trouble-free API 6D Ball Valve Maintenance; observe the requirements below.

For valve mounting

• • Before valve installation, the line should be cleaned with compressed air or steam to remove any burrs, rust, foreign objects and dirt that may be present in the pipeline.
  • Line conformity check should be performed and line information and valve label information should be compared.
  • For the new valve to be installed, the labels / covers on both flanges must be removed.
  • If there is a flow direction on the valve, the valve is mounted on the line to be connected to the flow direction of the line. If the flow direction is not specified on the valve, it can be installed in both directions.
  • The valve to be used must be of suitable standard, pressure class and diameter for the line to be connected.
  • The axes of the pipes to be installed and the hole axes of the fitting to be used must be on the same axis. Example: if flange is used as connection element, bolt hole axes must be on the same axis. Excessive stresses occurring on the valve due to such axis misalignments will jeopardize the sealing.
  • If the connection element is flange, the gaps are removed by tightening the bolts mutually, then they are tightened mutually at the given torque values.

• If valve space is left during installation, it should be left by calculating the length of the valve to be used and the length of the sealing elements.
• If the connection type is threaded, the thread length on the pipe should not be less than the valve thread length.
• Leakage control should be performed by testing with a pressure 1.5 times the rated pressure indicated on the label.
• Care should be taken to ensure that the valve to be installed in the installation is in the open position, and the handle should be in the flow direction.
• The flange side of the valve to be installed in the installation, where the technical information is written, is mounted as input. Then the other side is mounted to the installation without giving the opportunity to create tensile stress.

For the flange sealing element

• The sealing element should be selected according to the fluid type and pressure.
• The surfaces of the sealing element to be used in flange connections must be smooth.
• De-assembled, deformed sealing element should not be used, a new one should be installed.

When installing the sealing element, care should be taken not to close the valve passage throat. (Sealing elements: Klingerit, Teflon, O-ring, rubber or rubber of suitable hardness.)

Periodic check and general API 6D Ball Valve Maintenance

Periodic API 6D Ball Valve Maintenance covers the inspection, checking and lubrication steps below.

Inspection

To ensure the design life of the valve, a regular API 6D Ball Valve Maintenance inspection program is required. Depending on the service conditions and the frequency of valve operation, the following checks should be carried out in the field, in parts and in whole, to verify that the valve is operating correctly:

• Paint integrity
• Powder precipitate
• Signs of rust, external corrosion and oxidation
• Vent, drain parts status
• Lubrication of screw threads and bearings
• Internal and external leakages

Periodic check

A routine API 6D Ball Valve Maintenance check is recommended at least every two years from the date of delivery. Underground valves cannot be subjected to routine API 6D Ball Valve Maintenance; however, preventive API 6D Ball Valve Maintenance and inspections are required annually.

Generally, shaft and sitring lubrication, gear box operation control and end connections, body flange gasket leakage control, relief and vent valves and drain plugs leakage control, if any. If there are signs of nonconformity during the control, it is recorded in the report. It is ensured that the relevant persons are notified and troubleshooting service is requested.

Additional API 6D Ball Valve Maintenance

Additional API 6D Ball Valve Maintenance operations are not performed according to the schedule; these interventions are necessary when the valve is malfunctioning. Qualified personnel should execute these interventions, accompanied by appropriate documentation.

Shaft lubrication and cleaning

Shaft lubrication is part of routine API 6D Ball Valve Maintenance: the shaft requires periodic lubrication based on ambient conditions, at a minimum once a year. Batusan recommends selecting oil type according to the environment. It’s crucial to ensure lubrication reduces friction. If grease injection isn’t suitable, the grease fitting must be replaced. For valves with spindle housing, clean the housing and reinstall the gauge, ensuring correct open-close positioning.

Replacement of gaskets

• Isolate or depressurize the line and operate with the valve in the open position.
• Mark the body and body flange with a fixed paint or marker on the right and left sides in the same alignment so that when reassembling, these marks will ensure that they are connected in the same position. This is very important as it guarantees sealing on the same surface. Unscrew and remove the housing studs and nuts.
• Remove the fitted cover and mark the position of the sphere in accordance with the marked side (do not mark on the surface where the Teflon or the SWG sit is in contact). Remove the old gasket and dispose of it at the universal waste collection point.
• Check the gasket contact surface for damage and deterioration. Clean the surfaces and remove any foreign material and/or debris. Clean the gasket seat with a rough cloth. Every leak in the seal can lead to damage. The contact surfaces must have a smoothness of 1.6 to 3.2 Ra to ensure a good seal.
• Install the new gasket without using any filler material during this replacement.
• Assemble the body flange of the valve with the body with the ball open. Tightening values of body-stud-nut or bolts will be according to Table 4 of the manual.

API 6D Ball Valve Maintenance preparation

Before any API 6D Ball Valve Maintenance work begins, complete the following preparations:

• Find the instructions with drawing numbers ref. no. of the maintenance scope valve. API 6D Ball Valve Maintenance must not be performed without instructions and drawings.
• Check the safety of the API 6D Ball Valve Maintenance area.
• If there are any flammable, explosive, electric current, pressure, air pollutant or poisonous substances, warn the relevant persons to remove them.
• Check that you have sufficient equipment for disassembly and assembly torque.
• Ensure that you have an adequate supply of the necessary lubricants and cleaners.
• If there are gearboxes and actuators, have their catalogs and maintenance instructions available.

API 6D Ball Valve Maintenance and lubrication procedure

This procedure is built around the emergency sealing system, which is made of 1/2″ NPT steel material with large and special type connection head is mounted on the side cover flange on both sides of the body. The seat of all Split Body series Batusan valves is designed to be fully sealed so that no additional sealant is required.

However, foreign solids in the installation can enter between the seat and the ball and cause damage to the sealing surfaces. Damaged sealing surfaces adversely affect the sealing of the valve. In addition, foreign solids in the installation can cause erosion damage to the valve with the effect of high speed fluid.

Valve circuit leakage caused by damage to the seat and ball sealing surfaces can be temporarily eliminated by using an additional special sealing material. This special sealant is injected into the seat and globe area using the valve emergency sealing system.

• Cleaning will be carried out after safety measures have been approved. Take precautions for cleaning waste, prevent it from being dispersed into the environment.
• A special purpose and high quality Batusan seatflash cleaner is injected into the emergency sealing system. This process removes old oil and other foreign materials from the critical sealing area, which will cause leakage and high torque.
• When the valve is in the fully closed position, additional special purpose Batusan sealing oil, selected according to the type of fluid, is slowly injected into the emergency sealing system on the high pressure side of the valve.
• If possible, the additional sealing oil is evenly distributed over the entire sphere surface by moving the sphere slightly.
• Damaged or defective emergency sealing fittings can be replaced when the valve is under line pressure. However, it must first be ensured that the check valve is working.
• Post-lubrication waste must be disposed of according to the “Waste Management” procedure.

Lubrication process of Split Body ball valve

Split Body valves have their own API 6D Ball Valve Maintenance lubrication rules:

• This operation must be performed by technical staff specialized in valves or Batusan A.Ş. technical service.
• Lubrication cannot be performed when there is no pressure in the line.
• During lubrication, the pressure value in the lubrication gun should be between 2000 and 6000 psi.
• If the pressure value is exceeded without using the amount of oil as much as the value in the table, Batusan A.Ş. technical service should be contacted.

Control procedure

The control procedure in the API 6D Ball Valve Maintenance instructions covers these steps:

• Confirm safety precautions for control and live test.
• If there is a situation to measure the system pressure for the test, get information from the source.
• For DBB type valve, open the drain or vent valve and start relieving the pressure from the body cavitation.
• If the pressure inside the casing is relieved, perform leak measurement with API 6D leak tolerances. For this, it will be sufficient to measure bubbles using a tube.
• If the measurement exceeds the standard values, record a leak and suggest a repair procedure (gearbox adjustment, seat and shaft seal adjustment or seat repair lubrication, etc.).

Dismantling procedure

The API 6D Ball Valve Maintenance & Use Instructions describe the dismantling sequence as follows:

• • Cleaning will be carried out after safety measures have been approved. Take precautions for cleaning waste, prevent it from being dispersed into the environment.
  • Clean, especially the areas to be accessed for API 6D Ball Valve Maintenance, ensuring that they are thoroughly cleaned.
  • If there are weights and sizes that cannot be lifted and dismantled by hand, install lifting equipment.
  • Follow the recommended sequence by referring to the detailed drawings of the dismantling operation. During dismantling, always mark, paint or pencil and number the parts without separating them from each other, in such a way that the direction can be easily understood, and in such a way that they coincide with the same direction when installed.
  • During disassembly, inspect the parts and photograph any damage such as corrosion or deformation immediately.
  • Record the actions to be taken to remove the damage and attach photographs as evidence.
  • Remove rust and/or dirt without damaging the dismantled parts.
  • Separate the parts to be replaced and check the compatibility with the replacement.
  • Valves that cannot be sealed have ball and o-ring damage. The valve must be disconnected from this line.

Reassembly and assembly

For reassembly, the API 6D Ball Valve Maintenance dismantling procedure must be reversed. For fuselage assembly, strictly observe the warnings on the relevant technical drawing and its annexes. When in doubt, always consult Batusan technical service or request service.

Final adjustment and checks

Close every API 6D Ball Valve Maintenance operation with the following adjustments and checks:

• Verify the correctness of the opening and closinFg direction signs.
• Measure and record the opening and closing torque.
• Full opening and closing check (you can do it together with sealing check).
• Confirm safety precautions for check and live test.
• Get information from the source if there is a possibility to measure the system pressure for the test.
• Open the drain or vent valve for DBB type valve and start to release the pressure from the body cavitation.
• If the pressure inside the casing is relieved, measure the leakage with API 6D leakage tolerances. For this, it will be sufficient to measure bubbles using a tube.

If the measurement exceeds the standard values, record a leak and suggest a repair procedure (gearbox adjustment, seat and shaft seal adjustment or seat repair lubrication, etc.).

API 6D Ball Valve Maintenance marking

Copy the API 6D Ball Valve Maintenance records we made in the maintenance document to the valve file. If service is done, add it to the service attachment. If there are spare parts used, add the spare part entries to the valve’s file and the service form attachment. Adjustment and measurement records and the opinions of the maintainer, suggestions for future API 6D Ball Valve Maintenance will be indicated on the service form.

Label the field service and record the latest API 6D Ball Valve Maintenance date. This period should not be more than 12 months.

Decommissioning and disposal

API 6D Ball Valve Maintenance ends with decommissioning: at the end of its working life, the valve is removed from the line with an appropriate procedure according to the valve type and installation conditions. In order not to pollute the environment during valve dismantling, equipment should be used to prevent the leakage of the valve inlet and outlet from contaminating the environment. Bring the valve to a place in accordance with European, national and regional standards and store it until the date of disposal.

The valve may contain toxic, corrosive and harmful substances. It must be cleaned with high pressure steam before disassembly. The waste generated during this process must be disposed of in accordance with European, national, regional, municipal directives and/or waste laws and/or hazardous material laws. The paint layer on the valve is removed by sandblasting. Residual metallic parts can be recycled in a steel mill. Plastic parts (O-ring, ring packing, etc.) must be disposed of in accordance with European, national, regional, municipal directives and/or waste and/or hazardous material laws.

Additional documents — mounting drawing (gear boxed) and parts list and definitions — are special order documents; refer to the order file.

Venting and draining of Batusan API 6D ball valves

Venting and draining are the most hazardous part of API 6D Ball Valve Maintenance.

• For operator safety, Batusan A.Ş. recommends the use of a bleed fitting vent. The vent plug must be removed before all pressure between the body cavities is completely relieved.
• For operator safety, Batusan A.Ş. recommends the use of a bleed fitting with a minimized drain. The drain plug should not be removed until all pressure between the casing and the cavity is completely relieved.
• In either case the fluid in the pipeline may be toxic, corrosive or flammable. The valve must be decontaminated with a suitable standard before the operator works on the valve.
• The operator must use protective equipment suitable for the chemical and physical effects to which he/she will be exposed.
• If a safety valve is available to prevent the uncontrolled release of fluid with high temperature and pressure that may be harmful to human health, it is recommended that this safe equipment be connected to the appropriate manifold to control the released fluid. If a bleed fitting is not available, do not use vent and drain plugs to remove pressure from body cavities.
• Surfaces (grinding, welding, cutting etc.) worked on the valve exterior surfaces must have anti-sparking properties. The use of these tools must be authorized. This authorization is not valid in the presence of explosive atmosphere and flammable precipitate outside and inside the valve. This precipitate must be removed before starting the process.

Conclusion

To reduce API 6D Ball Valve Maintenance costs and ensure the BALL VALVE operates correctly, it is advisable to place a strainer (filter) in the main circuits. The BALL VALVE connected to the installation should remain fully open or fully closed to avert potential leaks and associated costs.

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