Natural Gas Ball Valve Maintenance & Safe Use Instructions

Preface

BATUSAN is committed to personal safety and the long service life of API-6D Ball Valves with this instruction manual, Installation, Operation and Maintenance Manual. This Natural Gas Ball Valve Maintenance manual will provide all necessary safety guidelines for the valves, including information on handling, storage, installation, operation and Natural Gas Ball Valve Maintenance. Please read it carefully before installing or maintaining the valve.

Purpose

It is to ensure that the BALL VALVE, which is a type of valve that provides the functions of directing, transmitting or stopping the fluids with the movement of the sphere inside the body of the valves produced according to the relevant standard, is assembled in accordance with the valve conditions in order to fulfill the working principles and to ensure that the valve is operated in environments suitable for the conditions of the valve. For this purpose, information and instructions are given about the appropriate conditions and situations / issues to be considered.

The user is responsible for the problems and consequences arising from behaviors contrary to the specified issues, including those caused by neglected Natural Gas Ball Valve Maintenance.

Considerations in ball valve selection

The Natural Gas 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 TSE, API, DIN, EN.
• Valve passage type: full passage (full bore) or reduction passage (reduced bore).

Packaging

Packaging requirements in the Natural Gas 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. To keep Natural Gas Ball Valve Maintenance costs low, 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 Natural Gas 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 Natural Gas 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 without transportation lugs, transportation can be made through the stud holes in the connection flanges to the installation.
• Gear box, actuator and flange connection holes should not be used for lifting 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.

Points to be considered when using ball valves

The following operating points are taken from the Natural Gas Ball Valve Maintenance instructions:

• Batusan natural gas ball 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 as maximum working pressure in BAR.

Matters to be considered in ball valve installation

Correct installation is the starting point of trouble-free Natural Gas 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. After installation, and after any Natural Gas Ball Valve Maintenance, the installation should be tested with 1.5 times the operating pressure and leakage control should be performed.

For the flange sealing element

Sealing elements are the most frequent item in Natural Gas Ball Valve Maintenance:

• 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.

During Natural Gas Ball Valve Maintenance, 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.)

Things to be considered when using ball valve

Day-to-day use directly affects Natural Gas Ball Valve Maintenance intervals:

• Natural Gas Ball Valve Maintenance starts on delivery: remove the valve from its packaging when you connect it to the installation.
• The valve should be left in the fully open or fully closed position. According to the operating principle of the valve left in the half-open position, it damages the sphere sealing teflons and causes the valve to leak.
• You only need to apply force to the valve handles for opening and closing positions in the direction of the arrow. Do not apply force when the movement of the arm reaches the stop pin.
• Working conditions are at the value specified on the valve as the maximum working pressure in BAR.
• The operating temperature range is limited to -5 to +60 °C.
• Valves that comply with TS 9809 and TS EN 331 Standards are used as distribution and service valves in Natural Gas, LPG and Combustible Gas installations, and Natural Gas Ball Valve Maintenance follows the same standards.

Natural Gas Ball Valve Maintenance

• There is no specific periodic Natural Gas Ball Valve Maintenance time. A disc-shaped spring is placed under the drive shaft nut. This ensures permanent sealing in the labyrinth stuffing box at varying internal pressure and temperature. If the sealing ability decreases slightly after long-term use, tightness can be ensured for a long time by tightening the drive shaft nut a little.
• Natural Gas Ball Valve Maintenance is straightforward because Ball Valves are designed in three parts: the middle body part, which contains all the moving parts, can be easily removed and the parts can be replaced.
• Burak Type Ball Valves are designed in two parts, which simplifies Natural Gas Ball Valve Maintenance: the parts can be replaced by easily removing the cover on the middle body part, which contains all the moving parts.

Tools and materials to be used

Natural Gas Ball Valve Maintenance requires only a simple tool set: a double-ended wrench, suitable for connecting bolts and nuts.

Connection bolts used in flanges

The Natural Gas Ball Valve Maintenance instructions give the following connection bolt dimensions for tailed flanges. L is the bolt length and Ø d the bolt diameter, both in millimetres.

Valve size	PN 16 (DIN 2633 tailed flange) — L	PN 16 — Ø d	PN 40 (DIN 2635 tailed flange) — L	PN 40 — Ø d
DN 10	50	12	50	12
DN 15	50	12	50	12
DN 20	50	12	50	12
DN 25	50	12	50	12
DN 32	50	16	55	16
DN 40	55	16	55	16
DN 50	55	16	60	16
DN 65	55	16	65	16
DN 80	60	16	65	16
DN 100	60	16	75	20
DN 125	65	16	80	24
DN 150	70	20	85	24
DN 200	75	20	90	27

Conclusion

If the BALL VALVE, which we call the valve of our age, is desired to work properly, placing a strainer (filter) in the main circuits will reduce operating costs. The BALL VALVE connected to the installation should be operated in fully open or fully closed positions to prevent possible leaks and operating costs.

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