This instruction manual includes installation and maintenance information for JP Make ball valves.This manual addresses lever operated ball valves only.
- Valve pressure ratings are based on many variables, including valve series and size, as well as body, seat, and bolt material. Verify that the application does not exceed the pressure or temperature rating of the valves.
- Always depressurize the line with the valve in the open position before disassembly.
- Wear protective equipment and take appropriate precautions to safeguard against injury caused by the discharge of trapped fluids.
- Use only JP recommended spare parts for maintenance.
- To ensure safety and to maintain warranty, never modify the valve in any way without prior approval from J P Engineering.
If the valves are not destined for immediate use, the following precautions should be taken:
- If possible, leave the valves in their packaging cases during the period of storage.
- Ball valves must remain in the open position while being stored.
- In order to prevent damage, protective plastic covers on valve ends should not be removed until immediately prior to installation.
- It is advisable to store valves in waterproof conditions. Ball valves should be protected to safeguard against humidity, moisture, dust, dirt, sand, mud, salt spray, sea water, or other forms of corrosive and erosive environments.
- Valves with actuators are to be stored in dry conditions.
- Valves to be stored for long periods of time should be checked by the quality control personnel or designee every six months; every three months when valves are automated.
Maintenance during this storage period can include:
- Internal surface should be inspected to check for dust or other foreign objects.
- Rust or dust must be removed by cleaning with proper solvent.
- After cleaning, ball valves must be lubricated with adequate lubricant.
- Ball valves should be operated for at least two complete cycles before installing or returning to storage.
To avoid personal injury to yourself, fellow workers, or damage to property from release of process fluid, before installation:
- Shut off all operating lines to the valve site.
- Isolate the valve site completely from the process.
- Release process pressure.
- Drain the process fluid from the valve site.
- The ball valves may be installed in any position using standard pipe fitting practices.
- Pipe must be free of tension both during and after installation.
- The ball valves are shipped in the full open position to prevent damage of seat and ball surfaces.
- The valve should be kept in the open position during installation.
- The ball valves are supplied with end caps for protecting the flange connections and the interior space of the valves. Remove the protective covers only just prior to installation of the valve.
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS
- There may be residual water from testing trapped between the ball and body. This can be removed by partially opening the valve, exposing the cavity to the through port of the ball.
- If the valve was supplied with an actuator, secondary support may be necessary. Contact JP Engineering for recommendations.
- Do not perform welding near an installed valve. Welding in the vicinity of an installed valve can damage the valve and cause leakage.
The rotating ball can cause injury. Keep body parts away from the space between ball and body (valve interior).
- Inspect the valve body port and associated equipment for any damage that may have occurred and for any foreign matter that may have collected in shipping or storage. Make certain the body interior is clean.
- Inspect the pipe line and mating flanges, making sure the pipe is free of foreign material that could damage the ball or seat and the flanges are clean and have no burrs or pits that could cause leakage.
- Cycle the valve at least twice to ensure proper operation.
- Prior to mounting the valve, flush the pipeline to remove soiling and weld residue.
- Make sure the protective end caps from the valve are removed.
- Ensure that the pipe flanges are spread sufficiently to clear valve flanges.
- With the valve in the open position, insert it, along with appropriate flange gaskets (not included), between the pipeline flanges.
- Insert appropriate size bolts and heavy hex nuts (not included) as recommended for the flange size and class.
- Verify proper alignment of all components and then tighten the flange bolts according to gasket manufacturer’s recommended practices or standard piping practices of stipulated torque.
- Do not operate the valve before flushing the pipeline. Keep the valve in the open position until flushing is complete. Residue in the line could cause damage to the seats.
- Note: this manual only covers the operation of manually operated valves. For operation of automated valves, consult the manufacturer’s manual for the actuator.
- Open and close the valve by turning the handle one-quarter turn (90º).
- Valve is in the open position when the handle is parallel with the pipeline.
- Valve is in the closed position when the handle is perpendicular to the pipeline.
Before starting maintenance, please read information contained in the CAUTION section of this manual.
- Open and close the ball valve at least once to release the pressure completely from the valve body.
- Ball valves, if correctly used, normally do not need any internal lubrication and maintenance. However, when necessary, ball, seat, or seals can be replaced by qualified personnel following the instructions of this manual.
- For further information, refer to the PARTS LIST section in the Drawing
- Valve Disassembly:
- To inspect and/or replace body seals, seats, packing & ball
- Inspection and replacement
- With the valve completely disassembled, clean and examine all components.
- The surface of the ball should be free from any defect, pitting, or scratches. If any are found, the ball should be replaced. Using a defective ball will be detrimental to valve performance.
iii. It is recommended that the seats and seals be replaced whenever the valve is disassembled.
- After cleaning, carefully examine all remaining components for wear, corrosion, erosion, and mechanical damage. Replace all defective parts.
- Clean inside of body and stem housing. Light grease, compatible with line on the ball, seals, and stem surfaces.
- After completing the re-assembly, check that the valve operates smoothly by opening and closing the valve several times.
- If the entire valve was removed from the pipeline and if facilities are available, test the ball valve to appropriate specifications.