Ball Valve Installation

Install Batu Valve ball valves in the sequence below, which follows our instructions for use from delivery through commissioning. Misalignment overstresses the valve and causes leakage.

• Valves leave the factory with their ends sealed against foreign matter. Leave the packaging and end covers in place until you connect the valve to a clean line.
• Standard shipment is on pallets, in cardboard boxes or wooden crates. Store the valves indoors, away from water and moisture.
• Do not stack valves on top of one another.
• For storage longer than six months, remove the end covers, coat the unpainted surfaces with corrosion-inhibiting oil and refit the covers.
• Check the label data on delivery and again before connecting the valve to the line.

• Use a textile sling for lifting.
• Lift valves over 25 kg by the lifting lug. If there is no lug, use the flange stud holes.
• Never lift a valve by its gearbox or actuator.
• Inspect the lifting equipment before every lift, and leave the flange protection in place.

1. Clean the pipeline with compressed air or steam. No burrs, rust or foreign matter may remain.
2. Compare the line data with the valve label: standard, pressure class and size.
3. If the valve shows a flow direction, install it in that direction. Otherwise you can install it either way.
4. Align the pipe axes and the flange bolt holes. Misalignment overstresses the valve and causes leakage.
5. Install the valve in the open position, with the lever in line with the flow. Connect the flange on the label side first, then the other side, without putting the valve under tension.
6. Tighten the bolts crosswise to take up the clearance, then tighten them crosswise again to the specified torque.
7. After installation, check for leaks at 1.5 times the nominal pressure.

• Choose a gasket that suits the fluid and the pressure and has an even surface.
• Never reuse a gasket once it has come off the flange or lost its shape.
• The gasket must not protrude into the bore.
• Gasket types: compressed fiber (Klingerit), PTFE, O-ring, or rubber of suitable hardness.

The table on the last page of the instructions for use lists bolt lengths and diameters for flange connections (DN 10 – DN 200, PN 16 and PN 40).

A monoblock ball valve has a one-piece body with no flanges of its own, and two line flanges hold it in place. Tighten the studs crosswise and in stages, and center the body between the flanges. An off-center body leaks and makes the ball hard to turn.

• Leave the valve either fully open or fully closed. A partly open valve damages the PTFE ball seats and starts to leak.
• Apply force to the lever only in the direction of the arrow, and do not force it once it rests against the stop pin.
• The operating limit is the maximum working pressure marked on the valve in bar.
• Strainers on main lines extend the service life of the valve.