Nibco Three-Piece Carbon Steel Installation Manual

NIBCO Three-Piece Carbon Steel ball valves are designed for both residential and commercial use, and are well-suited for applications involving water, oil, gas, or steam. They feature a three-piece construction that allows for easy maintenance and repair, and are available in a variety of sizes and configurations to meet your specific needs. NIBCO ball valves are also pressure rated up to 600 PSI, making them ideal for high-pressure applications.

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N I B C O I N C .

W O R L D H E A D Q U A R T E R S

1 5 1 6 M I D D L E B U R Y S T.

E L K H A R T, I N 4 6 5 1 6 - 4 7 4 0

U S A

P H O N E : 5 7 4 . 2 9 5 . 3 0 0 0

F A X : 5 7 4 . 2 9 5 . 3 3 0 7

W E B : w w w . n i b c o . c o m

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

Review Date: 01/18/2012

Original Date: NA

Operation and Installation Instructions for

NIBCO

Three-Piece Carbon Steel and

Stainless Steel Ball Valves

Read carefully before attempting to install, operate, maintain or disassemble this valve. Protect yourself and others by observing all safety information.

WARNING

For your safety, it is important that the following precautions be taken prior to installation, any servicing or removal of the valve from the line or before any disassembly:

1. At all times during this entire procedure, keep hands out of the valve. A remotely actuated valve could close at any time and result in serious injury.

2. This valve must be installed in accordance with all applicable power piping standards

(ANSI B31.1) and all local codes.

3. Consideration should be given to the placement and position of the valve when installing. The valve should be positioned in such a manner that the handle will not be bumped or snagged and inadvertently operate the valve.

4. For applications having elevated temperatures (over 100°F) refer to the pressure/temperature performance curves published in the catalog to determine the maximum safe working pressure for the seat material. Do not exceed this rating.

5. Wear all protective equipment normally required to guard against discharge of trapped fluid before attempting to remove or disassemble this valve.

6. Do not attempt to remove or disassemble this valve while it is under pressure.

Depressurize the line and valve as follows: Place the valve in the open position and drain the line. Cycle the valve to relieve pressure trapped in the body cavity. After removal and before disassembly, cycle the valve several times.

INSTALLATION

The following procedures will aid you in the installation, please follow them carefully:

Use standard piping practices when installing valve. To prevent damage to the valve when tightening valve to pipe, apply wrench to the body end (11) nearest the pipe being tightened.

CAUTION: Only qualified personnel should undertake the procedures outlined in this document.

NIBCO INC., its agents, representatives and employees assumes no liability for the use of these procedures. These procedures are offered as suggestions only.

NIBCO Technical Services • Phone: 1.888.446.4226 • Fax: 1.888.336.4226

PTFE pipe tape is a suitable sealant for threaded valves. To prevent stainless steel pipe threads from galling, apply proper lubrication to the threads.

2. SOCKET AND BUTT WELD BODY ENDS:

WARNING: This valve must be partially disassembled before installing, as the seats and seals in the valve cannot withstand the high temperatures the valve will be subjected to during welding.

BODY SECTION

1. Turn handle (6) to the full open position.

2. Tack weld the valve body end (11) in place.

3. Loosen all four bolting; remove 2, 3, 4 bolts (12) and nuts (13).

4. Swing out the center valve section (1, 2, 3, 4, 5, 6, & 7); prevent the seats (9) from falling out.

5. Finish welding the two body ends (11).

6. Swing back the center valve section and slide assembly between the body ends (11) until the grooves in the body are resting on the body ends.

7. Install the 2, 3, 4 bolts and nuts, finger tighten all bolts, keeping center section centered between the body ends (11).

8. Tighten all body bolts (12, 13) torque valves are listed in drawing; use a cross corner pattern when tightening bolts (12, 13).

MAINTENANCE

Routine maintenance consists of tightening the adjustable pack gland (5) 1/4 turn periodically to compensate for the wear caused by the stem’s (2) turning against the resilient PTFE packing

(4). Periodically observe the valve to be sure of proper performance, more frequent observation is recommended under extreme operating condition.

Overall maintenance consists of replacing seats (9), packing (4) and body end seal (10). A standard repair kit consisting of these parts may be obtained from your distributor.

DISASSEMBLY

This ball valve is designed to be serviced in or out of the pipe line; the following instructions are for in-line disassembly.

1. Comply fully with the instructions in the warning section at the beginning of this document.

2. After bleeding pressure, be sure to cycle the valve, leave the valve in the open position. The center body section will not swing out if the valve is in the closed position.

3. Remove the handle nut (7), spring washer (7A) and handle (6, 6A).

4. Using an appropriate size wrench, loosen the four bolts and nuts (12, 13). Remove three of the four bolts from the valve. Leave the remaining bolt in place with the nut backed off at least 1/4". Swing the valve body (1) out of the pipe line. Be careful not to damage the sealing surface at each end of the valve.

5. Rotate stem (2) so that the valve is in the fully closed position. Remove the body end seal (10) from the body end (11) and the seats (9) from the valve body (1). Body seals may be tightly compressed in their groove; use extreme care when prying them

NIBCO Technical Services • Phone: 1.888.446.4226 • Fax: 1.888.336.4226

out. Damage such as scratches to the bottom of the groove will cause leaks. If the seats (9) are not easily removed, gently tap the ball (8) with a piece of wood or other soft material.

6. Remove the ball (8) from the valve body (1).

7. Press the stem (2) from the top into the valve body (1) and remove it through on end of the body.

8. Carefully pry out and discard the old stem packing (4) and the stem thrust washer

(3); a sharp instrument may be needed. Be careful not to damage any of the stem sealing or bearing surfaces.

ASSEMBLY

The following instructions are for in-line assembly. For bench assembly, which may be more convenient, follow a similar procedure by holding the valve in a vise by one body end. Use care not to cut or scratch the seats (9) or body end seals (10).

1. With the valve body (1) swung to the out-of-line position, insert the thrust washer (3) into the stem bore.

2. Insert the threaded end of stem (2) into the stem bore and up out the top of the valve. Be careful not to damage the stem thrust washer (3).

3. Holding the stem with thrust washer in place from inside the valve, install two packing (4), and the pack gland (5) on the stem (2).

4. Place a wrench through the body on the bottom of the stem blade (2) to hold the stem (2) stationary. Place another wrench on the stem (2) and turn the pack gland

(5) down until packing (4) bottom and the stem (2) comes snugly in place. Tighten the pack gland (5) until snug, plus an additional 1/4 – 1/2 turn.

5. Align the stem blade (2) inside the valve body (1) with the ball (8). Insert the ball (8) and rotate the stem (2) to the fully closed position.

6. Working at either end of the valve body (1), place a seat (9) into the valve body (1).

Push the seat (9) snugly against the closed ball (8).

7. Place a body end seal (10) into the machined sealing groove of the body end (11).

Be certain the groove and seal (10) are clean.

8. Repeat steps 6 and 7 for assembly of the opposite end of the valve.

9. Turn the stem (2) to the fully open position.

10. Swing the entire body assembly back into the properly aligned, and interlocked position between the body ends (11), being careful not to scratch the body seals

(10). The body end (11) may have to be spread slightly to accept the body (1).

11. Close the valve.

12. Bolt the valve together with body bolts (12), spring washers (12A), and Nuts (13).

Tighten the nut (13) in sequence 4, 2, 3 as shown on page 2.

13. Place the handle (6), spring washer (7A), and stem nut (7) over the stem (2). Tighten the stem nut (7) until snug.

NIBCO Technical Services • Phone: 1.888.446.4226 • Fax: 1.888.336.4226

For any technical enquiries please call NIBCO Technical Services.

NIBCO Technical Services • Phone: 1.888.446.4226 • Fax: 1.888.336.4226

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