B

SPLIT BODY BALL VALVE

OPERATION and MAINTENANCE
INSTRUCTIONS
VA-IM-E600.3R0/2013

VA-IM-E600-3R0

Table of Contents

1.0.0 BS6683 COMPARISON

1.1.0 INTRODUCTION
1.2.0 PURPOSE
1.3.0 GENERAL
1.4.0 PACKING, STORAGE AND TRANSPORT
1.5.0 MARKING
1.6.0 MOUNTING LINE CONNECTION
1.7.0 RISK ANALYSIS
1.8.0 START UP AND LINE TEST PROCEDURE
1.9.0 OPERATION
1.10.0 PERIODICAL CHECK AND OVERHAUL
1.11.0 VALVE PROBLEMS AND SOLUTION ADVICES

Page 2 / 52

VA-IM-E600-3R0

COMPARISON OF 1.0.0 BS 6683:1985 WITH VA-IM-E600-3R0

BS 6683:1985 ARTICLE
VA-IM-E600-3R0 ARTICLE
1.3.0 General
1.0 General
1.1 Purpose
1.2.0 Purpose
------2.0 Service and Environmental Factors
2.1 Fluid
2.2 Pressure-temperature ratio
2.3 Layout and positioning
2.4 Bend test
2.5 Fire test
2.6 Pressure fluctuaton and cycle
------2.7 Throttling
1.5.0
2.8 Flow coefficient
Kv Cv (Table 2)
2.9 Temperature effect
------2.10 Traped pressure
------2.11 Corrosion
2.12 Stem sealing
1.9.2, 1.11.4
2.13 Cryogenic services
------2.14 Operating force
Torque (Table 3)
2.15 Vibration
-------

Page

6
4

5
10
20

22 to 25 & 34 to 37
21

3. Storage and Handling

1.4.0 Packing, Handling

3.1 General

1.4.1, 1.4.2, 1.4.3

3.2 Handling

1.4.5, 1.4.7, 1.4.8

3.3 Storage

1.4.4,

4. Connecting to the Line

1.6.0

4.1 General
4.2 Inspection

1.6.1

11
11

1.6.0

11 to 14

4.3 Threaded valve assembly

4.4 Flanged valve assembly

8, 9

------1.6.3-1.6.4-1.6.5-1.6.8

13-14

1.8.0
1.8.0

17,18

4.5 Welded valve assembly

4.6 Test and adjustment
5. Operation and maintenance
5.1 General
5.2 Operating manual valves

17,18,19
-------

1.9.0

5.3 Operating valves with actuators

19
-------

5.4 Operating quarter turn valves

5.5 Noise
5.6 Maintenance

------1.10.0

25 to 46

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VA-IM-E600-3R0

1.1.0 INTRODUCTION
Do not take any action regarding the Valve without reading the information
corresponding to the symbol in this manuel
Do not perform the relevant operation without reading the information
corresponding to the symbol in this manuel
Index hereby has been arranged according to the headings defined by the
standards. If the content does not satisfy you, you should search it under another
heading.

1.2.0 PURPOSE
The purpose is fulfillment of functions by valves manufactured in compliance with
API 6D Standard and achieving a long operational life.
Procedures are established for information and operations providing appropriate
conditions and indictating actions preventing to achieve aforementioned purposes.
The user is solely responsible for problems and their consequences arising from
behaviors contradicting to the issues stated here.
Valves belong to pressurized vessel class and life security should be considered
and measures should be taken in full.
Important note This procedure can be applied for all Split Body type ball valves in

general. We kindly request you to take our following comments and advices into
consideration. If our procedure or advice is against your company policy, we
recommend your management or supervisor to contact us for discussing which
maintenance procedure you will follow and about the differences.

Explanation
Properties of Vasta ball valve
They have been designed in compliance with API 6D standard.
All types between NPS 2 and NPS 60 have API Monogram.
They have API 6FA Fire test certificates.
They have antistatic designs. (ASD)
They conform to ISO 14313 and TS 7843 standards.
They have steel construction. Watch is the safest material against frast and
earthquake accidents causing shock and deformations.
They have trunnion Ball design.
They have float ring seats.
Seats are spring supported and create an increasing sealing force line
Optional features;

Page 4 / 52

b



VA-IM-E600-3R0

(DPE) Bi-directional sealing ring (two-way sealing rings are not solf-reliving the
pressure and an extra adjustable safety valve should be attached to the body
cavitation.)
(SRS Uni directional sealing ring (one-way sealing ring meansa design of selfrelied.

Attention !

Seat design with Double Piston Effect (DPE) is applied to DBB & DIB-1
featured Valves.
Self-relief seat design (SRS) is used for DIB-2 featured Valves.
Pressure trapped in body cavity of DPE seated Valves might be relieved due
to thermal aspects. In such cases, pressure relief Valve option should be
offered, in addition to existing vent Valve.
Vent & Relief Valves create gas emission to the environment. When free
emission is not acceptable, down stream of such Valves has to be
connected to a separate line.

Anly leakape could be momtored alter the cavity is dralnetd.This feature also allows
safe operation on each side through bleeding the valve body.
o

Split Body Ball Valves Flanged Valves These valves are used on
the line throughout the operational life (provided that periodical maintenance
is performed). Closure tightness is carried out from drain and vent outlet,
benefiting from DBB feature. They require periodical maintenance when
needed or once in 14 months at the latest. During maintenance, leakage
check is carried out and lubrication is performed to provide cleaning or
sealing.

It is offered asequipped with Operator types as well as with manual operation. Mode of
operation conforms to MSS SP91 standard. Therefore manual operation type is
recommended in accordance with limits specified by the standard. However, different
operators may be equipped if required by the customer.

1.3.0 GENERAL
(DBB)Double block&bleed feature:Venting / bleeding the body cavitiy whwn
the two seating surfaces are in clused position underup &down stream
pressures.
1.3.1 The user will find compliance for the valves within the scope of this manual with
acceptance conditions of API591 standard.
1.3.2 The manual hereby conforms to procedure of BS6683 Maintenance and operation
standard procedure.
1.3.3 If the customer has placed the order with special terms, these terms will be valid.
The manual hereby is complementary to customer sequrements .

Page 5 / 52

VA-IM-E600-3R0

1.3.4 If the valve is driven by a gear box manualy conformity declaration by Vasta is
limited with the connecting flange of valve to gearbox.
1.3.5 The valve is designed for the minimum life period stated in the contract. If period
such a period is not specified, Vasta defines the operational life of valve as
minimum 30 years.
1.3.6 If the valve is used with continuous opening and closing actions, such period is
100000 hours. The valves have been designed according to the fatigue life
(opening-closing) cycle number specified in the contract. If such information is not
specified during the design stage, fatigue life (opening-closing) cycle number is
considered as 500.
1.3.7 Vasta guarantees that the valves will stay in service throughout the Economic life
of the facility if procedures in the manual hereby are fulfilled.
1.3.8 If fluid type is not specified by the order, responsibility of providing conformity of the
flowing fluid with valve materials belongs to the firm installing the valve on the line.
Vasta A.. rejects all of the adverse effects on the valve ceated by the solid
particles within the flowing fluid on the valve.
1.3.9 The valves have not been designed for underwater applications as well as for
environment with external pressure higher than atmospheric pressure.
1.3.10 In case of exceeding operating pressure and temperature values or line
contamination or damages by metallic particles within the flowing fluid valves
should not be forced,to forther operation an immediate maintenance should be
carried out and service should be requested.
1.3.11 In case of damage due to unwanted conditions, Vasta service should be applied
for and spare part support should be requested.
1.3.12 Vasta recommends that all valves are sent to Vasta in case of malfunction
whether they are under warranty or not. The result of inspection at the plant will be
communicated to you and up on your agreement it will be returned to you after
maintenance and repair.
1.3.13 If cost of repair exceeds its economic value, a new valve is recommended.
1.3.14 If faults are under warranty, they are eliminated free of charge.
1.3.15 Only authorized Vasta personnel may provide service for valves under warranty.
1.3.16 Vasta is not responsible for decrease in performance in case of intervention to
the valve apart from issues allowed in the procedure.
1.3.17 The following contacts may be referred to any time.
1.3.18 In this procedure, if the non-compliance issues, and will be deemed to have been
void the warranty conditions will be demanded on the cost of transactions.

Vastas Valf Armatur Sanayi Ticaret A.S.

.O.S.B Sabanci cad. No:22, 59500 Cerkezkoy / Tekirdag / Turkiye
 0282 758 36 50 (Pbx) Fax. 0282 758 36 59
http://www.vastas.com , [email protected]
After sale service is provided 7/24.
Page 6 / 52

VA-IM-E600-3R0

1.4.0 PACKING, STORAGE AND TRANSPORT

1.4.1 Inside of Vasta valves are protected from foreign materials by means of end
covers. They should not be opened until they are connected to properly cleaned
pipe line.

1.4.2 They are delivered on pallet/parcel packed unless otherwise is specified by order.
1.4.3 They are fixed on pallets safely and they are suitable for transport.
1.4.4 Wooden containers are not suitable for outdoor storage unless their exteriors are
covered with water-proof barriers. End covers of the valves should not be removed
for any reason during storage. Whic do not prevent humidity;but only prevent dust
& foreign materials from entering into the valve. All ferric surfaces without a
permanent coating should be protected with an anti-corrosive coating. External
surfaces of the valves are coated with a suitable protector indicated in the contract.

1.4.5 Storage period is two years unless overseas transport is made. During such
period, it is preferred to open end covers,and relubricate the un painted surfaces
and close the cover again within 6 months intervals according to the depot
conditions.

1.4.6

1.4.7

1.4.8

1.4.9

If the valves are to bestored outdoors, they should be kept above the ground
by placing om supports and they should be protected with a water- and humidityproof cover.
After transport, the valves should be checked against any damage caused
by transport.
Receiving inspection should be carried out by customer with Packing list,
Operating instructions and Certificatex for conformity ..

Refer to the weight details before handling the parcel and do not convey the
without providing a suitable carrier.

1.4.10

Use fabric lifting slings for conveying and take care that the coating is
not damaged.

 Ball valves are conveyed and stored in open position. They are
painted differently for under- and above-ground application . Underground paints
do not resist to UV rays; protect them from sunlight. Prefer indoors for long-term
storage.

1.4.11

 You should perform repair procedure in accordance with the type of

coating in case of paint and coating damage.

1.4.12

Page 7 / 52

b
1.4.13

1.4.14

1.4.15

1.4.16

VA-IM-E600-3R0

Accessory hardware (vent and drain valve-pipe-fitting, operating

system gearbox-actuator, lubrication,-fittings-,pipe-indicator,qauqes etc) should be
protected from crushing, jamming and shocks.

If it is impossible to protect accessories, they should be demounted

for transport and storage in stored separate packings.
You are recommended to ask Vasta service in order to.get assembly
of demounted accessories.

The valves and accessories should be protected from contamination

(being affected from external factors such as dust, sand and mug etc).

 Packing should be prepared in accordance with the conveying road,

storage area and period, and sufficient measures should be taken to fix the valves
in transport vehicle if there is no packing.

1.4.17

1.4.18

1.4.19

The valves should be protected from adverse weather conditions

such as humidity, rain etc during storage. It is preferred to store valves in dry &
closed areas with sufficient ventilation.

Keep the valves with cleaning and protecting lubricant (valve-flush)

dipending on storage duration. Sealing lubricants should not be used until start-up
and before the test.

Page 8 / 52

b
1.5.0

VA-IM-E600-3R0

MARKING

1.5.1 Each valve has a name plate. If its size does not allow fixing of the plate, it may be
attached.

1.5.2 Name plate details are as follows.

VASTA
Trim
Material

FIGURE No.
Design
Standard

Date of man. &

Serial number

SIZE
End type and
Standard

CLASS
MOP
max. operating
pressure

Body Material
MOT max.
Operating
temperature

Customer marking details

Read the plate details and do not use the valve under exceeding conditions.
These details should be checked separately during receipt, installing to the
pipeline and at the beginning of start-up.

Check the fluid type and its conformity with the valve material, and do not
perform any mounting without consulting to the manufacturer if you have
any suspect.

1.5.3 Marking details on the body are as follows.

TWO WAY SEALING

ONE WAY SEALING

FLOW DIRECTION

Vasta
Size
Class
Material
Standard logos
Flow closure sigins
Charge no.

Page 9 / 52

VA-IM-E600-3R0

1.6.0 MOUNTING LINE CONNECTION

1.6.1

Preparation;

Provide appropriate tools.

Check cuitability of the valve operating conditions with the information on the name
plate. If the valve is purchased with bare stem, follow instructions of the
manufacturer for mounting the gearbox.

Clean the mounting location once more and remove any dirt.

Perform line conformity tu ensure that correct valve is solected comparing the
valve spesifications with the line specifications with the line details.
Determine flow direction or closure direction if any. The valve can be installed in
both directions if there is no flow direction and closure direction sign on the valve.

Lifting equipment needs to be used depending on the weight of the valve. Refer
to Vasta product catalogues for valve weights.

1.6.2
Review of valve inspections and mounting criteria before
assambley ;
-

Does the mounting position have operational easiness?

Can maintenance and repair be made easily?

Is there enough space over the valve for demounting the cover for maintenance
purposes?

Is there any dirt, sand etc to be cleaned in the valve when protective end
covers are ta ken away?

Has any measure been taken to prevent any metal parts remaining inside the
pipe after installing?

Is it communicated that maintenance shall be carried out after first cleaning of

the filters?

Is there any mounting position against unwanted situations? (Please refer to the
following figures)
Page 10 / 52

VA-IM-E600-3R0

OK

Pos: H

Not
recommended
Tasviye
edilemez
(It cannot be drained, line
contamination gives may cause
damaqe
harm to the valve)
(Dreyn yaplamaz,
hat kirlilii Valfe

Pos: V1

zarar verir.)

OK

Pos: H

Pos: V2

Not recommended
Tasviye
(It
cannotedilemez
be drained, line
contamination gives harm to the valve)

(Dreyn yaplamaz, hat kirlilii Valfe

zarar verir.)

Figure 1- Recommended operating positions for ball valves

Page 11 / 52

b
1.6.3

VA-IM-E600-3R0

The valve wilth counter flanges

a) Equivalent flanged pulley with end to end dimension should be used instead of the
valve or.
b) If it has to be made with the valve itself , it is recommended to add gasket both ends
to provide correct positioning axial conformity and parallelism of valve center flange .
(The valve should be demounted after tack weld is made.)

1.6.4 

Parallelism tolerance of the flanges should not exceed 1 degree and also a
total of 2 mm axial eccentricity should not be exceeded.
Incorrect
Yanl

Incorrect
Yanl

Correct
Doru

0.5

Figure 2- Allowable parallelism errors

1.6.5 Flange stud bolt or bolt should be tightened at the torque values specified in Table
1 after all procedures finish.
Size (inch)

5/8

7/8
1
1 1/8

Torque
(Nm)
61
117
203
324
489
708

Size (inch)
1
1 3/8
1
1 5/8
1
1 7/8

Torque
(Nm)
984
1323
1731
2217
2785
3441

Size (inch)
2
2
2
2 5/8
2
3

Torque
(Nm)
4193
6013
8292
9622
11085
14443

Size (inch)
3
3
3 7/8
4
4
4

Torque
(Nm)
18419
28427
30157
34565
49367
58135

Table 1-Counter flange stud bolt/blot tightening torque values

1.6.6 Mounting positions making larper angle than 90 derege With flow direction will
not alow drolining of the valve cavity .Therefore after performing line cleaning and
chemical washing procedures, valves should be demounted and cleaned manually.

1.6.7 In general, drain connections should be used for cleaning purpose at the beginning
of start-up procedure and driving first maintenance process.

Page 12 / 52

VA-IM-E600-3R0

1.6.8 Before start-up, tightness of the flanges (Table 1) and body-bonnet flange bolts
should be checked and should be tightened according to torque values,if
necessary.

1.6.9 Steel valves have usually flanges with raised faces (RF) . Counter flanges should
also be RF. For ease of demounting, 3-6 mm of pipe flexibilitiy should be
maintained in order to take away the valve from.
1.6.10

If the valve has RJ ring-gasket connection, the counter flange should
have RJ face g too. For RJ connections a flexibility between the connecting pipes
olf atleast 20mm.should be maintained for easy dismantling.
The same openings are required for connections with SG - LG type canals.

1.7.0

RISK ANALYSIS

1.7.1

General
The valves should be operated under conditions written on the name plate.
Hazardous situation may emerge even ione of these conditions is exceeded.
The following conditions may be dangerous given the situation. Ask for ones that
might be affected by checking compliance. Valve gives Vasta Datasheet'lerde
explanation.
Wind, snow and ice;
Acoustic vibration and/or vibration caused by the fluid;
Water hammer;
Chemical effect;
Decomposition or deterioration of the fluid;
Uncontrolled chemical reaction;
Electrical current;
Shock waves;
Pressure change;
Adiabatic compression;
Induction current;
Acoustic energy emission;
Flame;
Lightning
Contamination;
Power interruption;
Electromagnetic waves from 3x10^11HZ to 3x10^12
Hz.
Page 13 / 52

VA-IM-E600-3R0

Radio frequency (RF) electromagnetic waves from

10^4 to 3x10^12;
Radiational ionization;
Optical ionization;
Thermal reaction;
Vortex formation;
Humidity formation;
Ultrasound;
Environmental variations;
Other external damaging factors.

1.7.2

Information That Should Be Specified by the User

If the following dangerous situations are not specified in contract documentation,
they shall not be taken under consideration during the design stage.
Possible dangerous situations;
Thermal fatigue
Seismic loads
Friction
Vacuum depression
External corrosion
Contaminated fluid
Abrasion
Cavitation and flashing
External fire
Piping loads exceeding the specified values

1.7.3

Measures and Points to Take into Consideration

The installer and/or the end user shall analyse the possible hazardous situations
initiated by one or more of the following causes and take appropriate protection
measures:

The surface temperature of the valve is a function of the temperature of the

process fluid, the maximum allowable surface temperature is shown on the
name plate.
External solar radiation with the line at atmospheric pressure causes the
internal temperature of the line to increase.
External temperature will redound the Valve internal pressure.
Page 14 / 52

1.8.0

VA-IM-E600-3R0

None of the pressure containing parts shall be changed when the Valves is
under pressure.
If it is necessary, Valve shall be dismantled in half open position otherwise
there can be pressure jamed in Valve while dismantling in closed position.
Deposits of flammable dust may form on the valve. Vastas recommends
limiting the thickness of dusts deposits by periodically cleaning the external
body of the valve, and in particular the areas near moving parts (stem).
The frequency of this operation shall be so as to prevent dust deposits
greater than 5 mm. Wastes resultant because of cleaning must be checked
environment expert and must be eliminated properly.
The valve may release to the atmosphere gases and/or flammable dust that,
in extreme cases, can cause an explosive atmosphere. The probability of
the formation of an explosive atmosphere is greater during venting and
draining operations.
Wastes accured because of Valve repair and maintenance, must be
properly eliminated according to environment standards and regional
reguletions.
After completion of service life of Valve parts can be delivered to recycling
by decompasing the hazardus wastes.

START UP AND LINE TEST PROCEDURE

1.8.1

Inspection and control

Depending on the type of the valve and mounting conditions, all of the following points are
followed and checked before pressurizing the valve after mounting process.

Check plugs, vents and drains and verify their tightness.

Verify tightness of the bolts on the stuffing box, body and flange.
Grease stem bearing and stem threads.

1.8.2

Check body/body flange connection bolts and tighten up to the value in

accordance with the test pressure.

After all connection controls are finished, in order to eliminate possibility of

foreign substance leftovers, allow flow of compressed air or cleaning fluid through
opening and closing the valve. Open,close cycles of the valve causes removal of
the deposit accumulated in valve cavity and line on the flow direction. At the end of
such procedure, deposits accumulating on the filter should also be removed.

1.8.3 Liquid used for pressure test of the line and successive start-up procedures should
be sultable for the soft and metallic parts of the valve.
Usage the following products and fluids may cause problems on the valve.

Amine corrosion inhibitors , Fluorocarbon may be harm ful to O-rings.

Methanol used to dry the pipes may give harm to o-rings.
Untreated water may increase rusting effect on the steel surlaces .
Chlorine within the waler may cause corrosion on stainless steel parts.
Page 15 / 52

VA-IM-E600-3R0

In order to perform line test, fill the line with the fluid while the valve is wide

1.8.5
1.8.6




When performing line test, bring the ball valve to and open position.

1.8.7

Ensure that the tightness is very well after pressurizing the system.
The test ensures that all connections under pressure are correct.

1.8.8

In order not to give harm to the sealing surface, differential pressure

between opening and closing should be 7 bar or less. For this purpose, by-pass
should be used. This is not important for valves that do not require by-pass.

1.8.9

1.8.4

open.

Ensure that there is no trapped air within the valve or if any release
the trapped air through the vent-relief valve.

If valves remain at the same position for a long time, you may encounter
operating difficulty. Lubricant loss might have happened and sealing elements
faces contact dimension might have changed. Therefore we recommend
programmed opening/closing.operations. Use a suitable lubricant hrough greasex
fitting which lubricates the stem and seatrings.

1.8.10

1.8.11

Test pressure should not exceed 1.5 times of the maximum operating
pressure under half-open position of the valve.
1.1 times of the operating pressure should not be exceeded during

closure test.

1.8.12

1.8.13

1.8.14

1.8.15

1.8.16

1.8.17

Before the test, the pipe line should be physically cleaned and
chlorine in the test water should be less than 2ppm. During disharge of the test
water, the valve must be wide open.

At wide open position of the valve you can use the body drain valve
discharge water in the body cavitation.
Valve-flush should be used to clean lubrications grooves, fittings and
pipes after the test. After cleaning sufficient lubrication should apply with lubricant
suitable for the flowing fluid.

Lubricant amounts given in the table are minimum values. Besides,

lubricant required for the extension pipes and additional lubricant installation
should be loaded.

In case of any problem regarding gearbox settings, refer to Operating

system problems section.
In case of any problem regarding sealing, refer to Sealing problems

section.

Page 16 / 52

VA-IM-E600-3R0

1.9.0

OPERATION

1.9.1

Trunnion Ball Valve

Never apply excess force on the lever or handwheel while the stem and
sealing surface (if there is foreign substance in the valve ) may get damaged.

The following figure shows regular operation of the Ball Valve.

OPEN
Opening direction
(Counterclockwise)

CLOSED
Closing direction
(Clockwise)

Figure 3-Open and closed positions of the ball valve

Page 17 / 52

VA-IM-E600-3R0

Kv / Cv Coefficients
Cross diameters and cross areas

NPS
(inch)

ID (mm)

Kv

2
3
4
6
8
10
12
14
16
18
20
24
28
32
36
40
42
44
46
48
56
60

49
74
100
150
201
252
303
334
385
436
487
589
684
779
874
976
1020
1070
1120
1166
1362
1458

326
816
1540
3720
6800
11950
18600
23500
30900
40900
49300
78000
102000
141000
178500
225500
252000
280000
301500
326000
442500
509500

Table 2- Kv table

Kv
Q
P
S

: Flow factor
: Flow rate
m3/h
: Pressure drop
Kg/cm2
: Specific gravity (1 for water)

Kv =

Q
P
S

Cv =

Kv
0.865

Page 18 / 52

VA-IM-E600-3R0

Opening (Take off )Torque values in Ball Valves

NPS

DN

2
3
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
48
54
56
60

50
80
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
1200
1350
1400
1500

ID
mm
49
74
100
150
201
252
303
334
385
436
487
538
589
633
684
735
779
830
874
925
976
1020
1166
1312
1360
1458

22 bar
Nm
120
160
230
480
750
1200
1900
2700
3700
4800
6900
8200
12000
13000
18000
20000
22500
27500
30000
35000
43500
50000
64000
75000
110000
150000

56 bar
Nm
140
180
350
750
1200
2200
3200
4400
6400
8200
11300
14000
18000
23000
26000
32000
34000
40000
45000
60000
70000
85000
105000
120000
175000
200000

112 bar
Nm
150
280
540
1200
2300
3600
6200
8000
11200
14000
19000
22500
32000
38000
48000
58000
64000
75000
85000
105000
115000
125000
165000
180000
250000
425000

Table 3- Torque values in ball valves

Page 19 / 52

1.9.2

VA-IM-E600-3R0

Operating Problems and Maintenance

1.9.2.1

Frosting

Frosting may occur in ball valves due to external weather conditions and quick
discharge if discharge and drying is not performed after the pipeline test. In such a
situation, operation of the valve gets more difficult or completely jammed. You have to
wait if atmospheric temperature is at the level that may eliminate frosting. In case of
weather conditions can not melt the frost, you have to provide service through heating or
using valve-Flush cleaner until frost is removed. Never try to overcome the jamming
caused by the frost through exceeding regular torque value.
If the valve is not of lubricated type, you have to dissambly the valve and perform
maintenance if frost does not thaw.
1.9.2.2

Seat-ball sticking

When the ball valve remains unused for a long time, sealing ring and the balls
stick to each other. The same situation occurs for o-rings between the body bearing and
the ring. In case of sticking, the valve cannot be operated just as in the frost case. It is
jammed at open or closed position. Staying within the upper torque values, try to make
opening and closing movements and if this fails, perform maintenance immediately. In
order to remove sticking, apply valve-flush through all lubricating fitting slowly. Avoid
excessive lubricant pressure, otherwise damage may occur. When amount of lubricant
given for the valve is reached to the max level indicated,apply opening and closing
movements again. Continue applying valve-flush until relief is achieved. After the desired
result is achieved, lubricate with the sealing lubricant suitable for the fluid at required flow
rate.
If the valve is not of lubricated type, you have to demount the valve and perform
maintenance if sticking is not removed.
1.9.2.3

Stem leakage

Any leakage observed in the ball valve stem should be quickly stopped by means
of lubricating. Again, lubricant should be applied with care, pressure should not be
increased and you should stop when leakage stops. Excessive lubricating may damage
the sealing.
If the valve is not of lubricated type, you have to demount the valve and perform
maintenance.

Stem Maintenance under Pressure

Such procedure is applied when stem leakage is observed on operating valve .

Observing the stem leakage means that all sealing elements of stem damaged or they
cannot fulfill the required function. Pre-packing Under pressure removes damaged such
leakage. However, general stem maintenance is recommended during line break.

Page 20 / 52

VA-IM-E600-3R0

17 d

4d

12a
12d

7
1, 1a

1e

Figure-4 Demounting Diagram for Stem Maintenance under Pressure for Valve with Handwell

Page 21 / 52

VA-IM-E600-3R0

17c

12b

4d

12a
12d

7
1e

Figure-5 Demounting Diagram for Stem Maintenance under Pressure for Valve with Gearbox
Page 22 / 52

VA-IM-E600-3R0

17d

4d

12a
12d
7
1, 1a

1e

Figure-6 Demounting Diagram for Stem Maintenance under Pressure for Valve with Safety
Shut-Off Scotch Yoke Actuator
Page 23 / 52

VA-IM-E600-3R0

Such procedure applies for only Full Welded valves having Anti-blowout type
stem.

2
3

Gearbox is removed from its place through unscrewing 12c screws .

4d key is removed from its place. Stem by hitting slightly to the side of it using a
hammer and a chisel.mpacts and strong impacts to unsuitable direction may
damage the key form and make it unusable.

Screws no. 12b are unscrewed and connection flange no. 12a is takon away
from its place through slight hits from the opposite side using a plastic hammer.

Packing no. 6 is demounted and renewed.

Mounting is finished reversing the procedures.

After these procedures, Val-tex sealing lubricant is applied at suitable

lubricating pressure through lubricating fitting no. 1e on the gland.
1e

Scale

1:1

Figure -7 Stem lubricating nozzle

1.9.2.4

Closure leakage

If there is leakage in the ball valve to the body cavitation at open or closed position
and leakage does not stop, you have to apply suitable lubricant to the system from the
lubricating fittings. When leakage stops, continue lubricating making opening-closing
movements. If leakage does not stop, it means that there is damage. In such situation,
ask for service enclosing damage record or use damage eliminating lubricant by means of
specialized personnel if any. This procedure should not be confused with opening-closing
position error. Otherwise, the procedure will not be useful.
1.9.2.5

Gasket leakage

In order to ensure that the flange connection, where external leakage is seen, is
not loose, tighten all bolts on the side with leakage. If leakage does not stop, release the
pressure and replace the entire gasket set. (Note: Check whether there is axiality and /or
parallelism errors in connection flanges on the line correct it if there is any. Besides, free
opening should not exceed 2-4 mm except the gasket thickness.

Page 24 / 52

b
1.10.0

VA-IM-E600-3R0

PERIODICAL CHECK AND OVERHAUL

1.10.1  Inspection

In order to realize the design life of a valve, regular maintenance program should be
applied.
In order to verify proper operation of the valve, the following checks should be made
on site partly and / or complety depending on service conditions and operation
frequency of the valve.
Integrity of the coating

Dust deposit

Rust, external corrosion and oxidation signs

Status of the vent, drain parts

Lubrication of screw threads and bearings

Internal and external leakage.

1.10.2  Periodical Check,

Routine maintenance check should be made biennially at the latest beginning

from the date of delivery. Trained personnel of Vasta A.. would make the
aforementioned intervention at required dates with suitable documentation. Regular
maintenance activities are not carried out for underground valves but preventive
maintenance and inspection program is required once a year.

Before any maintenance procedure, the valve pressure is velieved and

temperature is checked from vent and drain lines. Electrical connections are
separated and the valve is cleaned.

Failing to perform any of the aforementioned procedures causes very serious

personnel health and safety issues.
In general, stem and seatring lubrication, gearbox operation check andendconnections, body flange gasket leakage checks as well as relief and vent valves
and drain plugs leakage checks (if any) are made. If you encounter nonconformity
signs during checks, record them in reports. Communicate them to the authorities
and require the troubleshooting services help.

1.10.3

Additional Maintenance

Additional maintenance procedures are not carried out according to the calendar; these
operations mean intervention in case of failure of the valve. Trained personnel should
make the aforementioned intervention whenever necessary with suitable documention.
Before any maintenance procedure, the valve pressure is eliminated and temperature is
checked from vent and drain lines. Electrical connections are seperated and the valve is
cleaned.
Failing to perform any of the aforementioned procedures causes very serious personnel
health and safety issues.

Page 25 / 52

b
1.10.4

VA-IM-E600-3R0

Lubrication and cleaning of the stem,

The stem has to be lubricated periodically depending on the environmental conditions a

heast once a year. Vasta recommends you to select type of the lubricant according to
the medium. Lubricating and friction-reducing properties of the lubricant are of great
importance. Besides, if grease fitting is not suitable, replace the grease nozzle. In valves
with stem protector, clean the protector and reinstall the indicator, having checked
whether open-closed positioning is correct.
If you detect leakage from the stem, apply the emergency procedure mentioned in the
manual hereby.
If scratch and porosity has dimensions around Rms 250 (6.3 Ra ) depending on the
size of the stem (rough turning surface), it should be recorded on the report that the stem
should be repaired or replaced as soon as possible.

1.10.5

Gasket Replacement

Gasket (13) (if any) replacement should be as follows. Phases mentioned in figure
6 are for Ball valve and can be used for other valves;
1. Isolate the line or eliminate pressure and work at open position of the valve.
2. Mark the body (1)/Body flange (1a) from the left of right at the same alignment with
a permanent coating or marker, so that such marks provide connection at the same
position during reassambley. Such marking is very important since it ensures
tightness at the same surface. Unscrew and remove body stud bolts (15) and nuts
(14).
3. Remove the installed cover and carry out position marking of the ball in
accordance with the marked side (do not make marking on the surface contacting
Teflon or SWG seat). Remove the old gasket (13) and discard it to the universal
waste collection place.
4. Check the gasket contact surface against damage and deterioration. Clean the
surfaces and remove any foreign substance and/or deposit. Clean the gasket seat
with hard and rough fabric. Any leakage through the gasket may cause damage.
In order to obtain good tightness, smoothness of the contact surfaces should be
between 1.6 and 3.2 Ra.
5. Insert the new gasket without using any filling material during such replacement.
6. Attach body flange (1a) of the valve to the body (1) while the ball is in open
position. Tightening torque values of the body stud bolt-nut (14) or bolts (15) shall
be according to Table 4.
Bolt size (inch)
3/8
7/8

5/8

7/8
1
1 1/8
1

Torque
Ft.lb

Torque
Nm

Bolt size (inch)

Torque
Ft.lb

1 3/8
15
20
900
1
25
34
1200
1 5/8
40
54
1600
1
75
102
2000
1 7/8
135
183
2500
2
200
271
3000
2 1/8
350
475
3600
2
500
678
4400
2
675
915
6000
Table 4-Tightening torque values of the Body /Body flange bolts

Torque
Nm
1220
1627
2170
2712
3390
4068
4882
5966
8135

Page 26 / 52

VA-IM-E600-3R0

1a
14, 15
1e
2i
2c

3g
3h
3
1
2g
2

2e

3f

Figure-8. Body Gasket Replacement

1.10.6

Maintenance preparation

Find DS or DRWG drawing numbers ref. no. and instructions of the valve
Subject to the maintenance. Maintenance should not be carried out without
drawings and instructions.

Check security of the area of maintenance.

If there is inflammable, explosive, air pollutive or, poisoning materials and

unprotected electric or pressure sources within the medium, warn the
authorities to remove them.

Provide the required maintenance devices and hand tools as well as those seen
on drwg.
Page 27 / 52

VA-IM-E600-3R0

Ensure that you have sufficient equipment for demounting and mounting torque
(details are attached).

Provide enough amount of required lubricant types (refer to Valtex product

catalogue)

Provide enough amount of required cleaners (refer to Valtex product catalogue)

If there are gearbox and actuator, keep catalogues and maintenance

instructions ready in hand.

1.10.7

Maintenance and lubricating procedure

Emergency sealing system with large and special type connection head
made from NPT steel material has been mounted on side cover flange on both
sides of the body (Refer to figure-5).
Seats of the all Split Body series Vasta valves have been designed with full
sealing feature, requiring no additional sealing substance. However, foreign solid
particles in the installation may enter between the seat and ball and may damage
the sealing surfaces. Damaged sealing surfaces have a negative effect on the
tightness of the valve. Furthermore, foreign solid particles in the installation may
cause erosion damage in the valve due to the effect of the ultra rapid flow. Valve
circuit leakage arising as a result of the damaged high flow faces of the seat and
/or ball may be temporarily eliminated using a special valtex sealing material.
Which is injected into the seat and ball area using valve emergency sealing
system.
1

Cleaning shall be made after safety measures are approved. Take measures
for cleaning waste and avoid spreading them to the environment.

Special purpose and quality Vasta seat flush cleaning agent is injected into
the emergency sealing system. This process provides aged lubricant and
other foreign substances that may cause lakage and high level of
operational torque, to be eliminated from the critical sealing area.

When the valve is at full closed position, additional special purpose Val-tex
sealing lubricant selected according to the type of the fluid flowing is slowly
injected into the emergency sealing system on the high pressure side of the
valve.

Read the lubricating procedure mentioned on Drwg or DS of the maintained

valve or Valtex lubricating procedure and perform the recommended
process.

If possible, provide that the additional sealing lubricant is spread evenly on

the all ball surface by means of moving the ball slightly.

Damaged or faulty emergency sealing fittings can be replaced when the

valve is under the line pressure. However, first of all ensure that the checkvalve works.
Page 28 / 52

b
7

VA-IM-E600-3R0

Lubracation Vastas should be discarded according to the Waste

Management procedure.

Split Body Sealing Lubricant Usage

Amount
Ball Valve
Size
2

( oz )
3

( gr )
85

113

141

170

226

10

10

282

12

12

339

16

14

395

20

20

565

24

32

904

28

36

1017

30

40

1130

36

48

1356

40

64

1808

48

80

2260

56

96

2712

Table 5. Sealing Lubricant Usage Quantity [ounces ~gram]

Lubricating Process of the Split Body Ball Valve:

Such process should be carried out by a technical person specialized on
valves or by Vasta A.. technical service.
Lubricating procedure cannot be realized when there is no pressure in the
line.

Page 29 / 52

VA-IM-E600-3R0

Quantity of lubricant to be used for Split Body ball valve is indicated in Table
5. Quantity of lubricant specified in the table should be used.
Pressure should be read between 2000 6000 Psi at lubricating gun during
lubrication.
If pressure value is exceeded without using lubricant at quantity mentioned
in the table, you have to consult Vasta A.. technical service.

1.10.8

Checking procedure

1 Approve safety measures for checking and Live test.

2 If it is possible to measure the system pressure for the test, obtain information
from the source.
3 For DBB type valve, open drain or vent valve and begin to release the pressure
from the body cavitation.
4 If pressure within the body is released, make leakage measurement with in API
6D leakage tolerances. For this purpose, it would be sufficient for you to make
bubble measurement using the tube.
5 If a measurement exceeding standard values is made, take leakge record and
recommend repair service (gearbox adjustment, seat and stem sealing
adjustment or seat repair lubrication etc).

1.10.9

Dismantling procedure

1 Cleaning shall be made after safety measures are approved. Take measures
for cleaning waste and avoid distributing them to the environment.
2 Make cleaning and especially get areas to be maintained thoroughly cleaned
3 In case of heavy and oversized objects that cannot be lifted and demounted
manually, install lifting mechanism.
4 Follow the recommended order, referring to the detailed drawings for the
demounting procedure to be performed. During demounting, mark the parts
without separating them from each other, make signs with a pen or paint and
number them in such a way that directions will be understood easily and the
same direction will coincide when installing.
5 During demounting, check the parts and if you face any damage such as
corrosion or deformation, photograph them.
6 Record procedures to be made to eliminate the damage and add photos as
evidence.

Page 30 / 52

VA-IM-E600-3R0

7 Clean rust and/or dirt without giving damage to the demounted parts.
8 Set apart parts to be replaced and check their conformity with their spare parts.
9 Check measurements and tolerances specified in drwg and DS images and
instructions, record your measurements on opposite of the instructions or
arrange a report.
10 There is ball and o-ring damage in valves failing to satisfy tightness. The valve
has to be taken out of the line.

1.10.10

Recollecting mounting

You have to perform the demounting procedure from the reverse. You must
take into account of the warning on the relevant Drwg and Ds and their
attachments for body mounting. When you are unsure for anything, you must
consult to Vasta technical service or request service.

1.10.11

Final adjustments and checks

Verify accuracy of opening-closing direction signs.

Measure and record opening-closing torque.

Carry out full opening-closing check (you can do this with tightness control).

Approve safety measures for checking and Live test.

If it is possible to measure the system pressure for the test, obtain

information from the source.

For DBB type valve, open drain or vent valve and begin to release the
pressure from the body cavitation.

If pressure within the body is released, make leakage measurement with

API 6D leakage tolerances. For this purpose, it would be sufficient for you to
make bubble measurement using the tube.

If a measurement exceeding standard values is made, make there is

leakage record and recommend repair procedure (gearbox adjustment,
seat and stem sealing adjustment or seat repair lubrication etc).

1.10.12

Maintenance marking

Copy the records you made on maintenance document on the file regarding the
valve. Add it to the service attachment if service has been made. Record and sign
maintenance approval made on Drwg and Ds.
If any spare part is used, add spare part entries to the valve file and service form
attachment.
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VA-IM-E600-3R0

Adjustment and measurement records and comments of the person performing

the maintenance and recommendation for the next maintenance will be stated in service
form.

Make labeling regarding the field service and record the latest maintenance
date. Such period should not exceed 12 months.

1.10.13

Taking out of the Line and Discarding

At the end of operating life, the valve is uninstalled from the line through a
procedure in accordance with the type of the valve and mounting conditions. In order not
to contaminate the environment during valve uninstalling, you have to use equipment
preventing the leakage on the inlet and outlet of the valve from contaminating the
surrounding. Bring the valve to a suitable place conforming to European, national and
regional standards and keep them until disposal date. The valve may contain toxic,
corrosive and dangerous substances. They must be cleaned with high pressure steam
before being demounted.
The personnel must wear protective equipment suitable for contamination during
performing such procedures.
Waste occurring during the procedure should be destroyed under European,
national, regional and municipal directives and/or laws regarding waste and/or laws
regarding hazardous substances. Coating on the valve is removed through sanding
process.
Waste metallic parts can be recycled in a steel plant. Plastic parts (O-ring, ring
packing etc) should be destroyed under European, national, regional and municipal
directives and/or laws regarding waste and/or laws regarding hazardous substances.

Additional documents
Mounting drawing with Gear Box
(This is a special order document, refer to the order file)

Part list and definitions

(This is an order document, refer to the order file)

Page 32 / 52

b
1.11.0

VA-IM-E600-3R0

VALVE PROBLEMS AND SOLUTION ADVICES

3 different valve problems and procedure to be followed for these problems are
described below.
-Difficult to operate or non-working valves
-Stem leakage
-Seat leakage
If you have valve problems, you can always inspect downwards beginning from the top.
For example, the area to be inspected is valve adjustment you think as reason for seat
leakage, beginning from the operator. Things to be done for these procedures:
Determining the type of procedure;

1.11.1

Manually operated valves

As a rule, external reasons may be observed obstructing operation of the valve. They can
be corrected or replaced. If the valve continues to be operated with difficulty after these
corrective procedures, it is understood that the problem stems from the inside.

1.11.2

Gearbox commanded valves

Perform error check for all internal parts of the gearbox:

Bearing checks

Gear checks

Set screw checks

Check to see whether the gears are lubricated and all metal-metal contact surfaces
are coated with grease.

Grease used in such surfaces is petroleum-based and may be exposed to water

contamination. Such water freezes under cold weather conditions and blocks the
valve. In such situation, demount the gearbox, remove all ice and water and wipe
water contaminated grease. Apply new grease. If working medium is very cold, you
can prefer glycol based grease due to its resistance against cold weather. Ensure that
gearbox is well-connected to the valve and stud bolts will not get loose.

1.11.4

Difficult to operate or non-working valves

 Internal causes
After reviewing all external causes that you think to be blocking valve operation, you
have to review internal causes in four areas mentioned below.
Page 33 / 52

VA-IM-E600-3R0

Frosting

If your valve is connected on a gas line, most gas lines contain water in small
quantities (condensate). Water accumulates at the lowest part of the valve. This water
turns into ice under cold weather conditions.
Corrective actions;
Block the valve to the body cavitation from body bleed fittings and make the water
get out of the valve. (You may discharge the water by opening the drain valve) Or: If
frosting occurs, use a suitable and accepted method to melt the ice. For example, spread
a heated part around the valve or inject a non-icing liquid (e.g. alcohol) into the valve.

Seat-ball sticking

Seats in valves with free-seat on lines that are idle for a long time tend to form a
set against the ball. This situation requires an additional force to release the ball and
continue operation. This will increase operating torque required for high line pressure.
Corrective action;
Exert appropriate additional force and operate the valve. If your valve is of
lubricated type, inject flush into the valve to separate valve sealing element and seats
from the ball and if possible, open and close the valve for many times.

Seat ring

Sticking of the waste, sand, dirt or aged hard lubricants coming from the line may
increase at seat ring area and blocks movement of the seats. Seat-ring sticking usually
causes leakage between the seat and the ball.
Corrective action
If your valve is of lubricated type, inject Valve flush in the valve to solve and
degrade the waste as much as possible. If possible, open and close the valve for many
times to degrade such waste.
If your valve is not of lubricated type, demount the valve, remove the rings and
make required cleaning. O-ring and Teflon rings may need to be replaced.
Note: Vasta recommends you to request service.

Stem leakage

Vasta valves have been designed with three stages of stem sealing. If there is no
leakage in the valve stem, do not tamper the stem. Performing unnecessary maintenance
on the stem causes problems. In general, if there is leakage in stem area of the valves,

Page 34 / 52

VA-IM-E600-3R0

the cause is reaching of pressure from the seat leakage to the upper stem sealing
element.
If your valve is of lubricated type;
If there is leakage in stem area, inject the sealing lubricant from the fitting
Until the leakage stops and do not inject more.
Danger: Excessive pressure in stem area may block the valve.
Always take care of the line pressure in performing any procedure.
If leakage cannot be eliminated, demount the valve, remove the stem, make the
required cleaning and replace the O-rings. Follow the following procedures.

Page 35 / 52

VA-IM-E600-3R0

17a
17

4d
12d
4
12a

7a

1e

3c

6
4c

14, 15
1a

Figure-9. Stem Maintenance Demounting Diagram for Valves with Handwell (For unpressurized lines)

Page 36 / 52

VA-IM-E600-3R0

17c
12b
4d
12a
12d
7
7a
3c
6
4c
4
1
14, 15
1a

Figure-10. Stem Maintenance Demounting Diagram for Valves with Gearbox (For unpressurized lines)
Page 37 / 52

VA-IM-E600-3R0

17d
4d
12a
12d
1e
7
7a
3c
6
4c
4

1a

Figure-11. Stem Maintenance Demounting Diagram for Valves with Safety Shut-Off Scotch Yoke Actuator
(For unpressurized lines)

Page 38 / 52

VA-IM-E600-3R0

Such procedure should be carried out by a technical person specialized on

valves or Vasta A.. technical service.

First of all, the valve should be put in closed position and drained.

Gearbox is removed from its place through unscrewing 12c numbered screws in
valves with gearbox. 4d wedge is removed from its place. During such
procedure, the wedge is removed from its place through hitting slightly to the
side of it looking to the stem by means of a hammer and a chisel. Firm impacts
and impacts with unsuitable direction damage the wedge form and make it
unusable.

Screws no. 12b are unscrewed and connection flange no. 12a is demounted
from its place through slight hits from the opposite using a plastic hammer.

Packing no. 6 is demounted and replaced.

4e centering pin and 12c bolts are unscrewed in their places and gland no. 7 is
demounted.

7a gasket (SWG) and 7b o-ring on the gland are replaced.

1e lubricating fitting on the gland is demounted and gland and lubricating fitting
canals are cleaned.

The stem is removed from its place and three no. 4c o-rings and no. 4b washer
(PTFE) elements on the stem are replaced.

10

The procedure is reversed and stem elements of the valve is mounted. During
mounting, ensure that the 3c anti-static device element is positioned properly.

11

After these procedures, Val-tex sealing lubricant is applied at suitable

lubricating pressure over lubricating fitting no. 1e on the gland shown in Figure5.

Seat leakage

A general ball valve problem is leakage from valve seats. Seats of the Vasta ball
valves are positioned opposed to passing.
Seat leakage may occur when the valve is at open or closed position. Therefore
valve seats may be checked at both situations.

Page 39 / 52

VA-IM-E600-3R0

Test procedure for seat leakage

1-) For quick check, ensure that the valve is wide open. This will reduce the pressure
within the valve body and shorten the time required for valve draining. Repeat the same
process while the valve is at closed position without performing any operation towards the
reverse direction.
2-) Verify that the ball rotates in full and keep in mind that the ball rotates 90. If any ball
remains open for 3 it causes leakage regardless of its being open or closed.
Your error ratio should be minimum.
3-) For manually operated ball valves, you can verify from the indicator on the valve that
the ball has completed its turn.
4-) Check the stem stopper;
a- In small sized ball valves you can see the stem stopper.
b- In great sized ball valves, check the foreign substances squeezed or accumulated
between the stem stopper and the stem itself from the area next to the stem area.
Such dirt formation may cause full rotation of the valve and leakage.
If the valve is embedded, dust preventing full rotation of the valve may fill inside from the
extension and this may cause leakage. If stem stoppers cannot be seen and you cannot
see the stem head, sometimes listening to the increasing or decreasing sound inside of
the valve may be effective to understand that the valve completes 90 turn.
5-) For valves with gearbox, mostly it can be checked whether the ball returns to its place
in full rotation. When gearbox is mounted on ball valve, stoppers are removed from the
valve. Sometimes stopper is in the valve. Incorrect adjustment of any of these stoppers
causes leakage.
Causes of seat leakage
If seats in the valve are stuck/cannot move, this is probably because previous hard
dirt in the line combined with waste blocks movement of the seat and this causes leakage.
Waste caused due to the same reasons leads leakage between the ball and the seat.
In case of damaged or scratched ball and/or seat, replacement or repair is made after
inspection of Vasta service personnel.

Seat leakage repair and overhaul

Note: First of all, the valve should be taken out of the line by means of pipe cutting and it
should be demounted, having processing one side of it on the weld connection point
according to the instructions.

Page 40 / 52

VA-IM-E600-3R0

17a
12b

12a
17

7a
1a

14, 15

4c
1e

1e

2i
2c

4
3g
3h
3
1
2g
2

2e

3f

Figure-12. Demounting diagram of the valve with Lubring and Handwell

Page 41 / 52

VA-IM-E600-3R0

17c
12b
4d

12a
12d
7

7a
1e

3c

6
1a

4c

14, 15
1e

2i
2c

3g
3h
3
1
2g
2

2e

3f

Figure-13. Demounting diagram of the valve with Lubring and Gearbox

Page 42 / 52

VA-IM-E600-3R0

Figure-14. Demounting diagram of the valve with Lubring and Safety Shut-Off Actuator
Page 43 / 52

VA-IM-E600-3R0

1 Such procedure should be made at Vasta A.. by Vasta technical personnel.

2 If there is leakage in the stem, stem leakage procedures apply.
3 If each demounted part will be reused, they are subjected to dust and oil removal
procedure.
4 If demounted 2e springs are deformed or have lost their elasticity, they have to be
replaced with suitable ones.

2g
2
2e
2c

2i

Figure - 15. Diagrammatic view of seatring application

Page 44 / 52

2i

VA-IM-E600-3R0

2e

2c

2
2b

2c

2g

2i

2b

2c
2d

Figure-16 Primary Metal to Metal Soft Seal

Figure-17 Primary Soft Seal Secondary

Metal to Metal

No. 2c o-rings on the Lubring and seat ring should be replaced.

Replacement should be made only when there is deformation on 2b seatface

(PTFE) on the seatring and deformation on 2b seatface (PTFE) on the valve with
size greater than 30 inch and additionally deformation on 2g secondary ring
(PTFE). Such procedure should be made manually. Any tool that may give harm to
lubring and seatring location should not be used.

After o-ring and seal of valve sealing rings are replaced, 3g Drybearing and 3h
washer must be replaced in ball area.

Page 45 / 52

VA-IM-E600-3R0

3f
3g

3h

2b

Figure-18 Valve ball assembly

1e seatring lubricating plug is removed from its place and lubricating canals on 1a
bonnet are cleaned.

Mounting is performed reversing the procedures.

Finally Val-tex sealing lubricant is injected into seat assembly canals at suitable
lubricating pressure through 1e seat lubricating fitting on 1a bonnet.
Page 46 / 52

VA-IM-E600-3R0

1e
1e

Figure-19 Seat lubricating fitting

Fitting problems

Vasta valves are shipped optionally up on request of the customer with blind plugs
and fittings installed or with fittings (in box or bags) with plugs installed on them. Fittings
are installed before valves are connected on the line. Reason for shipping valves in such
status is to prevent fittings from breaking during transport. If installing fittings is forgotten
and blind plugs are left in place, the following procedure is followed.
Note: Vasta recommends replacing blind plugs only when there is no pressure in the
line. If you want to remove such plugs when the valve is under pressure, you should pay
maximum attention.
In such situation and when installing body bleed fittings, you will be directly
exposed to line pressure. Do not install fittings when the valve is under pressure.
Carry out the following procedures after you examine the instructions and policy of
your firm: In some situations emptying the whole line is required to install the fitting.
This is the safest and always recommended method.
If you will replace the blind plug under pressure:
A.

Ensure that no substance that may come out of the valve will jeopardize
you, your personnel or the environment.

B.

Never stand against the blind plug.

C.
If body pressure continues due to seat leakage, hold a valve at open
position with the same thread as the fitting on its one end in your other hand.
D.
Release the pressure in the valve body. Open the blind plug with spanner
and allow the pressure within the valve to be released. Do not open the blind plug
quickly; this procedure requires care and patience. When the pressure inside
begins to decrease, open the plug slowly, so that the pressure remaining inside
gets out through the threads.
D.

After blind plug is opened install the valve stated in article c.

Page 47 / 52

VA-IM-E600-3R0

Venting and draining Vasta ball valves:

Valve spaces are pressurized when performing valve vent procedures. It is recommended
that experienced personnel perform such dangerous process.
Vasta A.. recommends using a bleed fitting vent for operator safety. Vent plug should
not be removed unless all pressure between spaces of the body is completely released.
Valve spaces are pressurized when performing valve drain procedures. It is
recommended that experienced personnel perform such dangerous process.
Vasta A.. recommends using a bleed fitting and minimum drain for operator safety.
Drain plug should not be removed unless all pressure between spaces of the body is
completely released.
In both situations, the fluid in the line may be toxic, corrosive or inflammable. Operator
should decontaminate the valve under a suitable standard before working on the valve.
The operator must use protective equipment in accordance with chemical and physical
effects he will be exposed to.
If there exists a safety valve that will prevent uncontrolled release of the fluid with
temperature and pressure at a high level giving harm to human health, it is recommended
to connect such safety equipment to a suitable manifold to take released fluid under
control.
If there is no bleed fitting, do not use vent and drain plug to release pressure out of the
body spaces.
Tools used on external surfaces of the valve (grinding, welding, cutting etc) should have
anti-sparkling feature. Usage of such tools should be subjected to permission.
Such permission is not valid for explosive medium forming in and out of the valve as well
as for combustible deposit medium. Such deposit situation should be eliminated before
beginning to the procedure.

Page 48 / 52

VA-IM-E600-3R0

12a
7
1
1e

4
3c
3g
3f
3h
3, 3a

17c
18
1e

14, 15

19

1a

1i

13
13a

1g

2e
2c

2k
2h
2f

2e
2c

2k
2h
2b

2b

X Detail
Primary Metal to Metal Secondary Soft Seal

X Detail
Primary Soft Seal Secondary Metal to Metal

6
4c
4
1e
7a

Y Detail

Figure-20 Split Body Ball Valve Part List

Page 49 / 52

Part Name;

VA-IM-E600-3R0

Spare for
Maintenance

Part Name;

Repair

Spare for
Maintenance

Repair

1 Body

3c Anti statik device (ASD)

1a Bonnet

3f Retainer (Tayc)

1b Mapa ve destek

3g Yatak DB (Trunnion)

3h Pul (PTFE)

1g Drain

4 Mil

1i Vent

4b PTFE

1m ek valve

4c O-Ring

2 Seat ring

6 Packing

2a Seat ring face

7 Gland

1e Lub. fittings

2b PTFE ring

7a Gasket

2c O-Ring

7b O-ring

2e spring

12a Mountaing Flage

2i Fire Safety Ring

18 Ticket

3 Ball

19 Paint

3a Ball Face

Page 50 / 52

VA-IM-E600-3R0

Declaration of conformity
According to Directive 97/23/EC for a pressure equipment
The manufacturer herewith declares, that the pressure equipment
Description: Ball Valves; Split body and Full welded, Floating and Trunnion type, Top entry & side entry,
Soft seated & metal to metal seated, from Class 150 upto Class 2500.
Type-, Serial-, Identification-No: E610-E61 / E620-E62 / E630-E63 / E640 / E650 / E660
max. allowable pressure PS: 20 bar / 51 bar / 102 bar / 153 bar / 255 bar / 425 bar
Allowable min. / max. temperature TS: - 46 / +100 C
Volume V: 0,4 to 3.500 Liter
Year of manufacturing: 2010 & following years
Test pressure PT: 30 bar / 77 bar / 153 bar / 230 bar / 383 bar / 638 bar
Test fluid: Water
Corresponds to the Pressure Equipment Directive 97/23/EC.
Applied conformity assessment
procedures:

Module H+H1

Applied standards and technical

specifications:

API 6D

Other applied EC-Directives: NA

Engaged notified bodies:
Surveillance of the QS-System: TV Rheinland
Examination / inspections / test
during manufacturing:

TV SD, Bau und Betrieb GmbH

Certificates which are included

EC- modul H/H1 Full quality assurance / Full quality assurance with design examination and special
surveillance of the final assessment.
Cert. No: DGR-0036-QS-1072-12
Location, Date: Tekirdag / Cerkezkoy, 01.04.2013

Signature

Page 51 / 52

VA-IM-E600-3R0

Page 52 / 52

Signed

01.12.2006

K.KORKMAZ

.KOAK

N.ERGN

REV.

Description

Date

Prepared by

Control by

App. by

Technical Instructions
Assembly, Operating and Maintenance

VASTA
1/2" ~ 2"
(NPS15 ~ NPS50)
COMPACT VALVES
OPERATING AND MANTENANCE
NSTRUCTON

Location

Document

DES
Scale

A4

VA-IMS-0-R1

B
Valf Armatr Sanayi Ticaret Anonim irketi
.O.S.B. 59500 Tekirdag TURKEY tel. 0282 758 36 50 fax. 0282 758 36 59

VA-IMS-0-R1

Contents

INTRODUCTION
1.0.0

GENERAL

1.1.0

PACKAGING STORAGE AND TRANSPORTATION

1.2.0

BRANDING

1.3.0

ASSEMBLY LINE LINK

1.4.0

START UP and LINE TESTING

1.5.0

OPERATION

1.6.0

PERIODIC CONTROL AND GENERAL MAINTENANCE

1.7.0

EMERGENCY MAINTENANCE

1.8.0

SPARE PART ORDERING

1.9.0

PERSONNEL QUALIFICATION

1.10.0

CALIBRATION

1.11.0

REVISION HISTORY

Page 2 / 20

VA-IMS-0-R1

BS 6683:1985 AND VA-MS-0-R1 CROSS REFERANCE

BS 6683:1985 ITEM
VA-IMS-0-R1
1.0 General

1.0 General

1.1 Spore

1.0 General

Page
4
4

2.0 Service & Environmentol Factors

-------

2.1 Fluid

1.2.0 Marking

2.2 Pressure-Temprature Rating

Pressure-Temprature Table (Table 1)

2.3 Laydut & Erection

1.3.0 Mounting

2.7 Throttling

1.5.0 Operation

2.11 Corrosion

1.1.4 Storage

2.12 Stem Fightness

1.4.0 Line Test

6
7
9
11
5
10
2.14 Operating Power

Torque Table (Table 3)

9

2.15 Vibration

-------

3. Storage & Handling

1.1.0 Packing, Storage & Transport

3.1 General

1.1.1, 1.1.2, 1.1.3

3.2 Handling

1.1.5, 1.1.7, 1.1.8

3.3 Storage

1.1.4,

4. Erection

1.3.0 Assembly Erection in Line

5
6
6
6
7
4.1 General

-------

4.2 nspection
4.3 Threaded Valve / Pipe Connection

1.3.1
Figure 1, Figure 2

7
8

4.4 Flanged Valve Mounting

Figure 3

1.3.6

1.4.0 Line Test

1.5.0 Operation

10

4.5 Mounting By Welding

4.6 Test and Adjustment
5. Operation & Maintenance

11
5.1 General

-------

5.2 Operation of Manual Valves

1.5.1-1.5.2-1.5.3-1.5.4-1.5.5

11, 12, 13

5.4 Quarter- Turn Valves

1.5.5

13

1.6.0

14

5.6 Maintenance

Page 3 / 20

VA-IMS-0-R1

INTRODUCTION
Do not perform any actions on the valve without reading the information
marked with symbol in this manual.
Do not perform the related operation without reading the information marked
with

symbol in this manual.

This index has been arranged in accordance with the titles defined by the
standards. If the content does not meet your requirements, make sure you
search for this content under another title.

Content and Valve definition

Design features
Usage features
Photograph and Data sheet
Disassembly drawing and part list and
spare parts

Adjustments and controls

(For further information, please refer to related valve

catalog and Drwg)

Drwg and DS)

Maintenance preparation
Maintenance scope drawing numbers
with ref. no.
Maintenance equipment and hand tools
Disassembly and assembly information

On-off adjustments warnings

Full on-off control
Tightness control
Tests (For further information, please refer to

Maintenance branding
Recording in maintenance document
Adding spare part input
(See warranty and service document)

Adjustment and measurement records

(see service document)

Opinions of the service man (see service

Disassembly procedure
Cleaning
Examinations and controls

Reassembly assemblage
Body assembly - warnings
Disk assembly - warnings
Gasket assembly - warnings
Cap assembly - warnings
Complete assembly warnings

document)

Field labeling and latest maintenance

record (this is the service document)

Additional documents
Assembly drawing
(This is a custom order document)

Part list and definitions

(This is an order document)

Page 4 / 20

b
1.0.0

VA-IMS-0-R1

GENERAL

1.0.1 This manual can be applied to all Standard valves produced by Vasta.
1.0.2 The user shall find the suitability to API591 standard acceptance conditions in the
valves that are within the scope of this manual.
1.0.3 This manual is in conformity with BS6683 Maintenance and usage Standard"
procedure.
1.0.4 If the customer has ordered with special conditions, those conditions shall prevail.
This manual is the complement of those conditions.
1.0.5 Provided that the procedures in this manual are followed, Vasta guarantees that
the valves will be in service during the "economic live of the facility".
1.0.6 The valves should not be constrained in case the pressure and temperature values
are exceeded or in case there is line pollution and damages in metal parts and
maintenance should be carried out immediately and service should be requested.
1.0.7 In case the valves are damaged by undesirable conditions, Vasta service should
be applied and spare part support should be requested.
1.0.8 Whether under warranty or not, Vasta recommends you to send the valves to
Vasta in case of malfunction. In this case, you will be notified about the control
results of the valve and the valve will be delivered to you after maintenance and
repair with your consonance.
1.0.9 If the repair costs exceed the value, a new valve is recommended.
1.0.10 If any defects are determined within the scope of warranty, these defects are
repaired free of charge.
1.0.11 The valves under warranty can only be repaired by authorized Vasta services.
1.0.12 In case there are any interruptions with the valve apart from the conditions allowed
by the procedure, Vasta will not be responsible for any performance problems.
1.0.13 You can apply to the following resources anytime.

Vasta A.. .O.S.B 59500 Tekirdag Turkey

 0282 758 36 50 (Pbx)

Fax. 0282 758 36 59

http://www.vastas.com , [email protected]
Directorate of after-sale services is at your service.
Page 5 / 20

VA-IMS-0-R1

1.1.0 PACKAGING, STORAGE and TRANSPORTATION

1.1.1 Vasta valves are protected with caps.
1.1.2 Unless otherwise specified in the order, the valves are delivered in parcels /
packages over palettes.
1.1.3 They are securely placed on the palette and suitable for land / air transportation.
1.1.4 Storage retention period is 2 years provided that the valves have not been transported
abroad. Within this period, the valves and their caps should be opened, the unpainted
parts should be lubricated and the valves and caps should be closed within 12 months in
accordance with the storage conditions.

1.1.5

Watch out for any damages on the package after transportation. Package

damage means there may be damages inside of the package, as well. Transporter
and the insurance company should be immediately notified.
1.1.6

Instruction book and Certificate are in the package. Order conformity control

must be performed from the Package list during delivery.

1.1.7

Please check the weight info before removing the package and do not

remove the package without providing the proper carrier.

1.2.0

BRANDING

1.2.1 Each valve has its own identification label. If the size of the valve is not suitable for
labeling, the label might be clipped on the valve.
1.2.2 The label information is as follows.
VASTA
INTERNAL
COMPONENTS
Material
Production date
and Serial number

FIGURE No.
Design Standard

SIZE
Tip type ans
Standard

CLASS
Body Material
MOP primary max. MOT max. Operation
Operation
temperature
pressure

Customer branding information (May be provided separately upon request)

Please read the label information and do not use for the conditions exceeding these
values. This information should be separately controlled during delivery
acceptance, while connecting to the pipeline and during hot start up.
Check the fluid type and Valve material compatibility, and do not assemble without
consulting the producer in case of any doubt.
Check the compatibility of your valve connection (especially cogwheel) type and the
connection type of your pipe, incompatible screw threads will break the threads of
your valve or pipe. (such as NPT or R type threads) Unless otherwise specified, the thread
valves are in NPT (ASME B1.20.1) standard.

Page 6 / 20

VA-IMS-0-R1

The branding information on the body is as follows.

1.2.3

Vasta
Size
Class
Material
Standard logos
Cut off sign
Charge no.

FLOW DIRECTION

Pressure & temperature ratings

-29

TEMPERATURE
C

38

50

100

150

200

250

300

325

350

375

400

425

bar

19,6

19,2

17,7

15,8

13,8

12,1

10,2

9,3

8,4

7,4

6,5

5,5

bar

51,1

50,1

46,6

45,1

43,8

41,9

39,8

38,7

37,6

36,4

34,7

28,8

bar

102,1 100,2 93,2

90,2

87,6

83,9

79,6

77,4

75,1

72,7

69,4

57,5

bar

153,2 150,4 139,8 135,2 131,4 125,8 119,5 116,1 112,7 109,1 104,2 86,3

bar

255,3 250,6

150

Material Gr. 1.1

ASTM A105

CLASS
300
CLASS
600
CLASS
900
CLASS
1500
CLASS

233

225,4

219

209,7 199,1 193,6 187,8 181,8 173,6 143,8

Not: recommended touse over 427 C

Table 1- pressure temperature ratings

1.3.0 ASSEMBLY LINE LINK
1.3.1 Preparation;
-

Provide the proper equipment.

Perform line conformity control and compare the label information and line information
to ensure that the correct valve is used.
 Determine the flow and cutoff directions. Find the proper direction to the flow and cutoff
directions specified on the valve that you use.
Clean and purify assembly location and pipe-flange-washer- screw threads-connection
components for the last time.
In case the valve is welded to the line, make sure that PTFE seat and washers will
endure the heating, if necessary, do not weld without taking proper cooling precautions.
 In straight or slip-on flange pipe connections, you may only perform welding by method
welding until adjusting the connection position.
 Perform welding electrode selection and procedure compatibility control.
 follow the welding procedure instructions strictly for tip welded or socket welded type
valves.
 Please check the external temperature that reaches the seat materials during operation.

Page 7 / 20

VA-IMS-0-R1

The following table shows the frequently used materials.

MOT.

MOP.

MATERIAL

TYPE

MAX. TEMPERATURE

MAX. PRESSURE

PTFE

PTFE

260 C

100

Buna-N

NB

130 C

100

Viton

FP

220 C

100

Table 2- MOT and MOP values of frequently used materials

1.3.2 Review the valve control and assembly criteria before the assembly;
- 

Does the assembly position have ease of operation?

- 

Can the maintenance and control be easily performed?

- 

Is there a cap demountable area for ease of maintenance?

- 

Is the location suitable for gasket control and addition?

- 

When the protective caps are disassembled, are there any dirt-sand in the valve that
have to be cleaned? (If yes, you can clean the valve with pressure air)

- 

Any precautions taken to prevent any metal parts remaining in the pipe after
assembly?

- 

Have you been informed about the maintenance that will be performed after the first
cleaning of the filters?

- 

Are there any undesired assembly positions? (See the following figures)

Correct

Correct

Incorrect

Incorrect

Figure 1- Allowable operation positions of Gate and Globe valves

Page 8 / 20

VA-IMS-0-R1

Incorrect
Yanlis

Correct
Dogru
Correct
Dogru
Incorrect
Yanlis

Correct
Dogru
Incorrect
Yanlis
Yanlis

Incorrect

Yanlis

Incorrect
Yanlis
Figure 2- Allowable operation positions of Check valves

1.3.3 

If flange assembly will be performed:

a) An equivalent flanged spool must be used instead of the valve, or...

b) If you have to make connection with the valve, it is recommended to use 1.5 3 mm of
puller support, excluding the washer, in order to ensure axiality and parallelism in
flange connections.
1.3.4 
Parallelism tolerance of flanges must not exceed 1 degree and total of 2 mm
axial radial run out.
Correct

Incorrect

Incorrect

0.5

Figure 3- Allowable parallelism and axial errors

1.3.5
Sporting of entry and exit pipes must be complete. Valve can be used as
pipe carrier neither before nor after the welding.
1.3.6 
In connections with necked flanges, make sure there are no strains or radial
run out by loosening the flange connection components after the root weld.

Page 9 / 20

VA-IMS-0-R1

1.3.7 Flange screws must be loosened for the post-welding heat treatment (PH).
1.3.8 After completing all operations, flange bolts or screws must be tightened at the
torque values specified in Table 2.
Bolt size

Torque
Nm

Bolt size

Torque
Nm

1/2 "

61

7/8"

324

5/8"

117

1"

489

3/4"

203
Table 3 Opposite flange bolt/washer tightening torque values

1.3.9 
After line cleaning and chemical washing, the valves must be disassembled
and cleaned manually.
1.3.10 Drain connections must generally be used at the beginning of start-up operation
and at the process of first maintenance for the purpose of cleaning.
1.3.11 Before start-up, the tightness of flange (Table 3) and cap screws (Table 5) and the
tightness of gasket (Table 4) must be checked and the loose ones must be
tightened in accordance with the proper torque value.
1.3.12 The valves must be kept half-open during welding. In order to protect the washer
and the gasket socket, it should be ensured that cap/body system is not overheated.
1.3.13 Due to the reasons stated above, post-weld heat treatment for homogenization of
the weld should only be applied to the welded spot.
1.3.14 In metal-seated valves, the valve body should not be heated more than 400 C in
order to prevent any damages on disk seat. In case it exceeds 80 C in Globe
valves, the seats will be damaged. The welding must be made by chilling.
Please check if the gasket and washer materials are suitable for the
1.3.15 
achieved temperature during operation.

1.4.0

START-UP and LINE TEST OPERATION

1.4.01

After completing all connections, allow the flow with pressure air or cleaning

fluid by opening and closing the valve in order to prevent any foreign material
residues. Opening and closing ensure the disposal of the residues accumulated in
the valve and the line in the direction of the flow. At the end of this process, the
residues that may be collected in the filter must be cleaned.

Page 10 / 20

VA-IMS-0-R1

1.4.02 
Fill the line with fluid in order to perform line test.
1.4.03 
Make sure there is no air trapped in the valve.
1.4.04 
Check body/cap connection screws, check gasket connection or if any,
tighten adjustment screws to the appropriate values for test pressure. Overtightening will shorten the life of gasket.
Globe Valves
Stud
Diam. 150# 300# 600# 800# 1500#
(lnches) Nm Nm Nm Nm Nm

Gate Valves
Stud
Diam. 150# 300# 600# 800# 1500#
(lnches) Nm Nm Nm Nm Nm
7/16''
10 10 10 15
15
3/8''
12 12 12 25
25
5/8''
15 15 15 30
30

7/16''
3/8''
5/8''

10
12
15

10
12
15

10
12
15

15
25
30

15
25
30

Table 4 Gasket bolt/screw tightening torque values

BOLTNG MATERAL Civata malzemesi

Stud Size
Civata
ls

B7M/L7M
ft.lb

15
3/8''-16 UNC
25
7/8''-14 UNC
40
1/2''-13 UNC
8/18''-12 UNC 55
75
5/8''-11 UNC
3/4''-10 UNC 135
200
1/8''-9 UNC
350
1-8'' UNC
500
1 1/8''-8 UN
675
1 1/4''-8 UN
900
1 3/8''-8 UN
1 1/2''-8 UN 1200

B7/B16

660

630

B8M CL.1

B8M CL.2

(Nm)

ft.lb

(Nm)

ft.lb

(Nm)

ft.lb

(Nm)

ft.lb

(Nm)

ft.lb

(20)

20

(27)

20

(27)

20

(27)

15

20

20

(Nm)
(27)

(34)

30

(41)

25

(34)

35

(47)

25

(34)

25

(34)

(54)

50

(68)

40

(54)

55

(75)

35

(47)

45

(61)

(75)

70

(95)

60

(81)

80

(108)

55

(75)

65

(88)

(102)

100

(136)

80

(108)

100

(136)

70

(95)

85

(115)

(183)

170

(231)

150

(203)

200

(271)

125

(170)

150

(203)

(271)

270

(366)

250

(339)

300

(407)

200

(271)

200

(271)

(475)

400

(542)

350

(475)

450

(610)

300

(407)

300

(407)

(678)

600

(814)

500

(678)

650

(881)

450

(610)

450

(610)

(915)

850

(1153)

700

(949)

950

(1268)

650

(881)

650

(881)

(1220)

1200

(1627)

1000

(1356)

1300

(1763)

900

(1220)

900

(1220)

(1627)

1500

(2034)

1300

(1763)

1700

(2305)

1200

(1627)

1200

(1627)

Table 5 Body cap bolt/screw tightening torque values

1.4.05 

Fully open Gate and Globe valves, half open the ball valves.

1.4.06 

Test pressure cannot exceed 50% of the nominal pressure of the valve.

1.4.07 

After pressurizing the system, ensure full tightness. Test guarantees the

accuracy of all connections under pressure.

1.4.08

"Backseat" (5) in Gate and Globe Valve stems operates when the valve is

fully open. The valve allows for additional gasket, when under pressure on the line.
In order to prevent damage to Backseat tightness surface, you should avoid overloading to flywheel when the valve is fully open.
1.4.09 

If the valves remained at the same position for a long time, you may

encounter difficulty of use. Stem gears have lost oil and gasket size has changed.
Therefore, we recommend programmed on/off operations.
Page 11 / 20

VA-IMS-0-R1

1.5.0

OPERATION

1.5.1 

Gate Valve

In these valves, the flow is enabled by the movement of the slide (3)* between two seats(2).
Bottom end of the stem (4) is connected to the top side of the slide (3); this enables the required
resistance for maneuver.
All movements of the slide (3) are directed to the channel on the valve body (1).
The seats (2) are fixed to the body with an angled position.
The gasket socket that contains gasket rings (6) is on the cap (1a).
The gasket (6) is tightened in the gasket socket by gland (7) and gland flange (8), by providing the
required pressure with four gland nuts (10) and two gland bolts (9).
Cogged top of the stem (4) is fixed to its position with fork nut (12a) by connecting with stem nut
(11).
The valve is opened by turning the flywheel (17) counterclockwise.
After the valve is fully opened, turn the valve a quarter round towards the closing direction, so that
the valve does not stay in ring pressure "BACKSEAT" (5) position.
Do not reduce with gate valve, it may damage the tightness surfaces.
(* : These numbers show the related part in figure 4.)

Never over-power the flywheel, (if there are any foreign substances) stem and tight
surface may be damaged.
The following figure shows the normal mode of operation of Gate valve
Close

Open
17a
18

17

11
10
8
7
9
6

4
14

1a
13
1
3,3a
19a

2,2a

Figure 4 Open and closed positions of Gate valve

1.5.2 

Globe Valve

The structure and operation mode of globe valve are similar to gate valve. The difference is the
flow control system and this is performed with a disk (3) in globe valves. It may be provided in
parabolic form, as Teflon or with needle-disk upon request. The disk (3) is connected to the stem
(4) with flexible connection. Since the fluid does not have a direct flow, significant load loss occurs
in the globe valve. This means a perfect flow control, especially reducing and full transition control
can be obtained. Similar to gate type, these valves are also opened by turning the flywheel (17)
counterclockwise. After the valve is fully opened, turn the valve a quarter round towards the
closing direction, so that the valve does not stay in ring pressure "Backseat" (5) position.

Page 12 / 20

VA-IMS-0-R1

Never over-power the flywheel (17), (if there are any foreign substances) stem (4)
and tight surface may be damaged.

The following figure shows the normal mode of operation of Globe valve
Close

Open
17a
18

17

11
10
8
7
9
6

4
14

1a
13
1
3,3a
19a

2,2a

Figure 5 - Open and closed positions of Globe valve

1.5.3 

Lift Check Valve

The body of lift check valve (1) is the same as the body of the globe valve. This
mechanism consists of a free or spring-loaded disk (3), which is guided in the body to sit
on the body seat (2). The disk (3) remains in contact with the seat (2) by means of gravity
or spring strength and opens itself when the fluid passes through its bottom.
Fluid entry from the reverse direction pushes the disk (3) against the seat (2) and stops
the flow. Lift check valve is generally used in horizontal lines.
It may also be used in vertical lines by placing a return spring. (If specified, return spring
is placed.)
The following figure shows the normal mode of operation of Lift check valve
Close
14
1a

Open
13

3b
1
2a

Figure 6- Open and closed positions of Lift check valve

Page 13 / 20

b
1.5.4 

VA-IMS-0-R1

Check Valve with float type disk (clack type flap type)

Direct flow in this type of check valves is provided by the floating disk (3) that is placed
against seat (2).
The floating disk is tied to the handle loosely and the seated to the body by pin (3d) on the
handle. If the disk is pushed by fluid, the handle acts as hinge and enables proper and
free flow by opening in circular way. In reverse flows, the disk (3) free-falls towards the
seat (2) and prevents the flow. Check valves are preferred on horizontal axis, however,
they are used in vertical lines, provided that the flow direction is upwards.
The following figure shows the normal mode of operation of Floating type check valve
Open

Close
13

14

1a
3d
2

3
1

Figure 7 - Open and closed positions of check valve

1.5.5 
Ball Valve
The valve is opened and closed by turning the positions of Ball type disk (3) surfaces 90
degrees that are placed between the seat rings (2) placed in the body in adjusted
sequence. The globe will be moved by turning the stem (4) and the rotator handle (17) or
the reducer. On/off directions are stated on the handle (17) or the reducer. At the end of
each move (on/off), the applied force will prevent movement since the mechanism is
restricted. In addition, the end of the operation will be understood by checking the
significant markings. In Ball valves with handles, the handle (17) is on the same axis as
the pipeline in open position.
The compatibility of the valve with single or double direction flow is specified on the label.
The following figure shows the normal mode of operation of Ball valve

Open

Close

7
6
5
4
3

11

10

12
9

2
1

Figure 8 - Open and closed positions of Ball valve

Page 14 / 20

VA-IMS-0-R1

PERIODIC CONTROL and GENERAL MAINTENANCE

1.6.0

Valve control,
Stem and stem nut cleaning and lubrication,
Gasket addition,
Tightness control,

1.6.1 

In PERIODIC Controls, generally the stem/piston is lubricated, gasket/o-ring

tightness is checked, brake wheel/handle operation is checked and end connections cap/body
washer leakage is checked. If there are any improprieties, maintenance record is processed into
the report.

1.6.2 
Lubrication of the stem and cleaning,
Stem nut and stem gears must be lubricated periodically depending upon ambient conditions, no
less than one year. We recommend you to select the lubricant type in accordance with the
ambient conditions. The important factor is that it is reducing the lubrication and friction. Some
small-diameter valves might not have lubricators, in this case, graphitic spray or dry lubrication
may be used, and it may also be applied by brush. The o-rings in the stems of the ball valves must
be protected from foreign substances and must be cleaned.
Gasket addition, O-ring change
1.6.3 
If a valve makes way for a high-temperature fluid, it may leak from the gasket in open position. Do
not tighten the gasket adjustment nuts immediately, wait for the valve to reach operational
temperature. The time that is lost in this situation does not usually exceeds couple of minutes.
If the leakage continues, see the remaining part of this section. The loss in gasket socket does not
indicate that the valve is damaged; a stem, which is over-tightened with gasket, will cause
operational difficulties and shortening of gasket life. In this case, it will be enough to increase the
tightness of the nut one round at max. after preventing the leakage.
If you go all the way to the end of the gland part that goes into the gasket socket and the leakage
still continues, now it is required to make a gasket addition. The leakage from the stem in globe
valves shows that the O-ring is damaged. It needs to be changed.
Isolate the line from pressure and decrease the valve pressure. It is not enough to dismount Gate
and Globe valves from the line, the valve should not be operated and the stem must be in
BACKSEAT position. O-ring cannot be changed unless the globe valve is dismounted from the
line.

8
9
10

Figure 9 Packing change

Before performing this for Gate and Globe valves, especially when working with hazardous fluids,
make sure you decreased the pressure of the operating part of the line and cautiously discharge
the gland nuts (8) that hold the gasket. Do not remove the nuts completely before the trapped
pressure is released and gland (7) becomes free.
Remove the gland nuts and open the gland and gland flange (9) to the maximum distance. Place
gasket rings (6) directed to each other at 90 degrees until they completely fill the gasket socket
and try to properly place it.
Page 15 / 20

VA-IMS-0-R1

If you encounter over-smeared gasket traces on the stem, clean the stem thoroughly and make
sure there are no scratches or porosity. In this case, it is understood that the entire gasket should
be changed at first. If the scratch and porosity is about 250 Rms (6.3 Ra) according to stem
measurement (rough turning surface) it must be reported that the stem must be repaired or
changed as soon as possible.
Remove the old gasket with proper tool. Any remaining gasket residue must be cleaned out from
the stem. After ensuring that there are no damages in the stem and the gasket socket, place the
new gasket rings one by one and in such a way that one ring will be directed 90 degrees from the
other.
Before placing each new ring, they should be properly pushed into the seat. Place the gland
flange, gland and bolts, tighten the gland nuts mutually.
In Ball valves, the valve that is removed from the line is removed from the body connection spot
and divided into two. The valve is fully opened and the ball is removed from the body. The nut on
the handle is removed and the handle is separated from the stem. The stem is pulled out by
pushing into the body. O-ring is taken from the stem and the o-ring socket on the stem and the
body is cleaned and the new o-ring is placed and assembled.

1.6.4 

Gasket Change

The gasket change procedure (13) if available must be as follows. The phases
that are specified on the figure belong to Gate valve, but this information can also be used
for check and Globe valves;
1. Isolate or cease the pressure, operate the valve in nearly open position.
2. Mark the body (1) / cap (1a) with a fixed paint or mark from the top to the bottom,
so that you can tie these Marks at the same position when reassembling. This
process is very important, since it guarantees tightness on the same surface.
Disassemble and remove body bolts (15) and nuts (14).
3. Remove the cap and make sure that the disk is also position-marked in
accordance with previously marked side (not on the tight surface). Remove (13)
and dispose the old Gasket.
4. Check the washer contact surface against damage and corrosion. Clean the
surface and take any foreign substances and/or residues. Clean the gasket socket
with a rough ragged cloth. Any type of leakage on the gasket may cause damage.
In order to ensure a good tightness, the contact surfaces must have 1.6 3.2 Ra
slickness.
5. Assemble the new gasket without using any kind of filling materials during this
operation.
6. Assemble the valve lid (1a) with the body (1) and make sure that the disk is not in
closed position (half-open).
7.
Washer change in globe valves: the two-piece body is assembled with a screw
thread and it may be spot-welded in order to prevent disassembly. If it is so, first of all, the
spot-weld is removed by grinding. The body is tied to a clamp and the body part, which is
shorter and which has the key inlet, is disassembled with open ring wrench or with pipe
wrench counterclockwise. The washer is removed and the new one is assembled after
cleaning the residues. The body part is tightened until the spot mark and the part is spotwelded again in order to prevent disassembly.

Page 16 / 20

VA-IMS-0-R1

11
17
16
12a
8
9
10

1a

7
6
7e

1a

14
15

14

15

13
3

13
1
2

Figure 10 Gasket Change

1.7.0

EMERGENCY MAINTENANCE

The procedures described in this section must only be used if required. If the
following repairs do not meet the emergency requirements, send the damaged valve back
to the factory.
1.7.1 

Body/Cap Disassembly

In the following lines, the disassembly of body/cap of Gate-Globe and check valves are
described. Note that this process should only be applied in case of emergency by
experienced and qualified personnel.
-

Cap disassembly with screw: Paragraph 1.6.4 Washer change procedure is

applied.
WB Welded cap disassembly:
A portable spiral grinding or similar nipping equipment are used to remove the
weld. Weld removal must be reduced as much as possible. Remove the cap
without damaging the disk. Note that the cap will be removed by turning
counterclockwise.

1.7.2 Seat change

Note that the valve must be disassembled from the line in order to place new valve seats.
We recommend you to send the valve back to the factory for change and repair. The
following part change and/or repair information is provided for emergency cases.
1. Thread type strings (including PTFE rings) can be removed by hitting the transition
opening with a special tool.
2. Welded rings are removed by cutting processing the weld on machining bench and
the new one is welded after checking the size. It is recommended to perform this
process in Vasta service and factory.
3. In order to work on the line without any problems, there should be adequate space
around the valve body.
Page 17 / 20

b
1.8.0

VA-IMS-0-R1

SPARE PART ORDERING

The parts, which have been changed during general maintenance service, are gaskets
and washers because of their material structure.
If they are within the general product range, they may be sent from the stock.
Many of the valve parts can be used interchangeably, within the allowable frame.
If you order a change component, we will ask you to provide the following information:
-

Catalog number
Type, size, serial
Material
Your product number, if available (tag no. Stock no. etc. )

If this is a spare part order for a Vasta originated order, it helps material identification
especially for custom-made valves.
Production series show differences in accordance with many orders. It will be helpful to
provide order date and number for us to supply spare parts in compatible materials and
designs.
1.9.0

PERSONNEL QUALIFICATION

1.9.1 These procedures herein can only be implemented by expert and authorized
personnel.
1.9.2 Personnel Qualification certificates must be approved by the institutions with
accreditation authorization for these procedure types.
1.9.3 Vasta offers service with personnel, whose service competence can be verified by
educational level, certificate and implementation records.
1.9.4 The personnel, who is specified as level 1 in the certificate, can perform
implementations and take photo-records.
1.10.0

CALIBRATION

Calibration must be performed as the verification of measurement devices. For this, all
pressure-temperature-size measurement devices are examined with accurately, validly
and effectively certificated devices or calibrators and the reliability of the information will
be ensured. We especially recommend calibration of the manometers at least once a
year.
Vasta service team can perform the verification of the measurement at the facility with
calibrated devices upon your request.

Page 18 / 20

VA-IMS-0-R1

Gate valve Part list & Service Type

Srgl Valf para listesi ve Servis tipi
tem PART NAME
Para no Paa adi
BODY
1
Gvde
BONNET
1a Kapak
BODY SEAT RNG
2
Gvde ringi
Seat Face
2a Ring yzeyi
WEDGE
3
Srg
Wedge Seat Face
3a Srg yzeyi
STEM
4
Mil
BACK RNG
5
Geri ring
PACKNG
6
Salmastra
GLAND
7
Salmastra baskisi
WHASHER
7e Pul
GLAND FLANGE
8
Glend flani
GLAND BOLT
9
Glend saplamasi
GLAND NUT
10 Glend somunu
STEM BUSHNG
11 Mil burcu
BUSHNG NUT
12 Bur somunu
FLANGE
12a atal flani
BOLT
12b Civata
GASKET
13 Conta
STUD BOLT
14 Saplama
NUT
15 Somun
GREASE FTTNG
16 Gresrlk
SET SCREW
16a Setskur
HANDWHEEL
17 Volan
WHEEL NUT
17a Volan somunu

Globe valve Part list & Service Type

Glob valf para listesi ve Servis tipi

Control
Kontrol

Maintenance

Repair
Onarim

Spare part

Bakim

Y.Para

tem PART NAME

Para no Paa adi
BODY
1
Gvde
BONNET
1a Kapak
BODY SEAT RNG
2
Gvde ringi
Seat Face
2a Ring yzeyi
DSC
3
Disk
Disc Seat Face
3a Disk yzeyi
DSC NUT
3b Disk somunu
STEM
4
Mil
BACK RNG
5
Geri ring
PACKNG
6
Salmastra
GLAND
7
Salmastra baskisi
WHASHER
7e Pul
GLAND FLANGE
8
Glend flani
GLAND BOLT
9
Glend saplamasi
GLAND NUT
10 Glend somunu
STEM BUSHNG
11 Mil burcu
SET SCREW
12c Setskur
GASKET
13 Conta
STUD BOLT
14 Saplama
NUT
15 Somun
HANDWHEEL
17 Volan
WHEEL NUT
17a Volan somunu

Check valve Part list & Service Type

ek valf para listesi ve Servis tipi

15

BODY
Gvde
BONNET
Kapak
BODY SEAT RNG
Gvde ringi
Seat Face
Ring yzeyi
DSC
Disk
Disc Seat Face
Disk yzeyi
DSC NUT
Disk somunu
Disc Hinge
Kol
Disc Pin
Pim
Disc Washer
Pul
Plug
Tapa
Plug Seal
Tapa salmastrasi
GASKET
Conta
STUD BOLT
Saplama
NUT
Somun

:Supplied by Vasta or customer

Vasta veya mteri temin edecek

1
1a
2
2a
3
3a
3b
3c
3d
3e
3f
3g
13
14

1a

1e

1g

2a

2b

2c

2e

3a

4a

4b

4c
4d
13
14

:No need
Gerekmez

Maintenance

Repair
Onarim

Spare part

Bakim

Y.Para

Ball valve Part list & Service Type

Kresel valf para listesi ve Servis tipi

:Supplied by only Vasta

Yalnizca Vasta tarafindan temin edilir

Control
Kontrol

15
17

Body 1. Part
Gvde 1. Para
Body 2. Part
Gvde 2. Para
Seat Lubr.plugs
Yalama tapasi
Lubrication
Sizdirmazlik yai
BODY SEAT RNG
Gvde ringi
Seat Face
Ring yzeyi
Seal Ring
kincil ring
O-ring
O-Ring
Spring
Yay
Ball
Kre
Ball face
Kre yzeyi
STEM
Mil
Bearings
Yatak
Washer
Pul
O-ring
O-Ring
Bushing
Yatak
GASKET
Conta
STUD BOLT
Saplama
NUT
Somun
Wrench
Kol

Page 19 / 20

1.11.0

VA-IMS-0-R1

DOCUMENT REVISION HISTORY

The following table gives the revision history of this document:
REV.
NO.

EFFECTIVE
DATE

01.12.2006

REMARKS

First Edition

Page 20 / 20

Operating Instruction Manual

for
Full Welded Ball Valves

VA-IM-E63.3R0/2013

VA-IM-63-3R0

Index

1.0.0

BS6683 COMPARISION

1.1.0

INTRODUCTION

1.2.0

PURPOSE

1.3.0

GENERAL

1.4.0

PACKING, STORAGE AND TRANSPORT

1.5.0

MARKING

1.6.0

ERECTION IN LINE

1.7.0

RISK ANALYSIS

1.8.0

START-UP AND LINE TEST PROCESS

1.9.0

OPERATION

1.10.0 PERIODIC CONTROL AND GENERAL MAINTENANCE

1.11.0

VALVE PROBLEMS AND SOLUTION SUGGESTIONS

This index complies with the sequence indicated by the standards. If any approach you
make does not answer to your question, please search for correct answer under another
title.

Page 2 / 40

VA-IM-63-3R0

1.0.0 COMPARISION BS 6683:1985 WITH VA-IM-63-3R0

BS 6683:1985 ITEM
VA-IM-63-3R0 ITEM
1.0 General
1.0 General
1.1 Purpose
1.2 Purpose
------2.0 Service and Environmental Factors
2.1 Fluid
2.2 Pressure-Heat Rate
2.3 Layout
2.4 Distortion Test
2.5 Fire test
introduction
2.6 Pressure Fluctuation and Circuit
------2.7 Throttling
1.5.1,1.5.2
2.8 Flow Coefficient
Kv table(Table 1)
2.9 Temperature Effect
------2.10 Jammed Pressure
------2.11 Corrosion
1.1.4
2.12 Stem Tightness
1.8.2.3
2.13 Cryogenic services
------2.14 Operating Force
Torque table (Tablo 2)
2.15 Vibration
-------

3.1 General

1.4.0 PACKING, STORAGE AND

TRANSPORT
1.4.1, 1.4.2, 1.4.3

3.2 Handling

1.4.5, 1.4.7, 1.4.8

3.3 Storage

1.4.4,

4. Assembly in line

1.6.0

3. Storage

4.1 General
4.2 Inspection

Page
4
4
8

4
13, 18
14

6
16-17-18
15-16 17

7
7
7
7
9

------1.6.0

4.3 NPT valves/pipe assembly

-------

4.4 Assembly of flanged valves

4.5 Assembly by welding
4.6 Test and adjustment
5. Operation and maintenance

1.6.3-1.6.4-1.6.5-1.3.6-1.3.7-1.6.8
1.8
1.9.

5.1 General

11
12-13

------12-13-14-15-16-17
18

5.2 Operation of manual valves

1.9.1-1.9.2

5.3 Operation of actuated valves

5.4 Quarter turn Valves

10-11

------1.9.2

5.5 Noise

17-18

-------

5.6 Maintenance
1.10

19-20-21-22-23-24-2526-27-28-29-30-31-3233-34-35

Page 3 / 40

VA-IM-63-3R0

1.1.0 INTRODUCTION

Do not take any action related with the valve we supplied without reading the information

given in this manual, across this symbol

 Do not initiate the related operation without reading the information given in this manual
across this symbol.
1.2.0 PURPOSE:
To make valves do their functions perfectly and obtain long operating life for the valves produced
according to API6D standard.
Giving information and procedures in order to obtain suitable conditions and not to do same action
that are prohibited.
User himself is responsible if he does not fulfil the instructions mentioned.
Valves are in the pressured vessel class. Because of this feature giving importance to human health
, recommended precautions are completely important.

Special Note:

This procedure can be applied to all kinds of ball valves. We kindly request you to pay attention to

our comments and suggestions. If our procedure or suggestions are against your company policy,
we suggest your management or supervisors can discuss the differences and the maintenance
procedure to be followed.
Explanation:
Vasta Ball Valve specifications:

Designed according to API6D standard

All sizes between NPS2 and NPS60 are API monogrammed.

API 6FA fire certificated.

Anti-static designed.

Suitable with the ISO 14313 and TS 7843

Steel structured. The safest material against frost, earthquake, stroke and accidents cause
deformations.

Trunnion ball designed.

Floating seated.
Page 4 / 40

Sealant power which is directly proportional to pressure spring supported

Optional:

VA-IM-63-3R0

(DES) Double sided tightness rings (Double sided tightness rings can not discharge the pressure
and adjustable relief valve must be added to the body cavity.)
(SES) Single sided tightness rings can be used. (Single sided tightness can be discharge the
pressure by itself.)

DBB featured. When there is pressure both on the entry and exit sides, it can discharge the
body cavitations and leakage can be checked. This feature also allows working safety in the
other parts when the valves body discharged.

Full welded-FW- Valves. These valves are used without dismantling from the line in order to make
periodic maintenance during their operating life. The sealing control can be done by utilizing DBB
feature. When necessary or once at the latest of 14 months, periodic maintenance should be done.
During maintenance,sealant injection should be done in order to provide cleaning and tightness
after leakage control.
VASTA types;
1. E63: It is the unique type for 150#, 300# and 600#. (Suitable for using with different
operating pressures.)
2. E63U: Same with E63 but extended stem is for underground applications.
3. E63F: Flange welded type of E63. Flange can be welded according to pressure classes
(150#,300# and 600#) upon request, But FTF dimension will be according to 600# for each
case.
As the valves are manual py opearated, they are equipped with operator types, are according to
MSS SP91 standard therefore manual operating type which is suitable with the standart is
recommended. But differnt operators can be applied upon customers request despite the
precaution.

Page 5 / 40

VA-IM-63-3R0

1.3.0 GENERAL:
1.3.1 This manual is applicable to full welded ball valves manufactured by VASTA.
1.3.2 The user will find compliance of any products covered by this manual to API 591 standard
Acceptance Requirements
1.3.3 This manual is conforming to BS 6683 Maintenance & Operation Procedures
1.3.4 If there are special conditions in the order, those conditions will be valid, and this manuel
will be its complementary.
1.3.5 In the case of valves driven by actuator or manual gear box, the declaration of conformity
by Vastas, is limited only to the valve including its coupling connection with the actuator or
manual gear box.
1.3.6 The valve has been designed for a minimum life as defined in the contract. If such
information has not been specified, Vastas will guarantee a minimum life of 30 years. This
period can be ensured by correct use of the item, following project parameters, and by
applying a maintenance/inspection procedure as indicated in this manual.
1.3.7 If the valves is used in the creep range, it has been designed to function for a period of
100000 hours.
1.3.8 Vasta warrants that its product would serve along with the economical life of the plant
provided procedure in the manual is strictly followed.
1.3.9 If the process fluid has not been clearly defined in the order, it is the reponsibility of the
owner of the plant to verify its compatibility with the materials of the valve. Vastas
declines all responsibility for any detrimental effect on the valve due to the presence of
contaminating agents in the fluid.
1.3.10 The valve has not been designed to be used in subsea service or subject to an external
pressure greater than atmospheric pressure.
1.3.11 Whenever overpressure & temperature rates or contamination of line with solid & metallic
parts are observed with resulting defects, the valve should not be forced to further operation
but field service should be required / applied, immediately.
1.3.12 Any defective part has to be renewed by application to Vasta field service for their support
of spares.
1.3.13 Vasta suggest the user to send the defective valve to its plant without considering the
valve is under Vastas guarantee or not. The report of the inspection will be informed to
the user and the valve will be repaired and tested after users approval.
1.3.14 New valve would be suggested if the repair cost would not be economic.
1.3.15 All defects found within the guarantee coverage would be removed on free of charge.
1.3.16 Valves covered with Vastas guarantee shall only be handled by authorized Vasta team /
operator.
1.3.17 Vasta shall not be responsible for the performance failure resulted by unauthorized
interventions other than the actions permitted in the manual.
1.3.18 Do not hesitate to contact Vasta through the contact information given below:

VASTA Valf Armatur Sanayi Ticaret A.

.O.S.B Sabanci cad. No:22 Cerkezkoy 59500 Tekirdag / Turkiye
Tel: 0 282 758 36 50 (pbx) Fax: 0 282 758 36 59
www.vastas.com

[email protected]

Vastas servis team serves as 7/24.

Page 6 / 40

VA-IM-63-3R0

1.4.0 PACKING, STORAGE AND TRANSPORT

1.4.1 Vasta valves are protected with connection end covers
1.4.2 Standard deliveries are made as the valves fixed on wooden pallet and packed unless
otherwise indicated by the order.
1.4.3 Fixing the valves safely on pallets is suitable for ground/air transport
1.4.4 Wooden cases are not suitable for outdoor storage, unless they are covered and protected by
a suitable sealed weatherproof barrier. All mechined ferritic surfaces without permanent
coating shall be protected with an appropriate anti-corrosion product and with external
protections to prevent damage and/or the ingrees of impurities. All such connections shall
be taped with waterproof adhesive tape around the blank/flange circumference as a
precaution against the moisture.
1.4.5 The storage period is two years if none of any sea transport made. It is recommended to
open and close the covers each 12 months and lubricate the machined faces, than replace
the covers
1.4.6

 Compulsory storage n open area should be supported by elevating the valves from

earth and by wrapping to protect from water and moisture .

1.4.7




Valves should be inspected for any defects caused by transport after such activities.

1.4.8

Compliance to the requirements should be checked during handover using packing

list, operating instruction and manufacturers certificate.

1.4.9

Weight list should be checked and suitable vehicle has to be prepared before
handling the goods.

1.4.10

 Use reinforced cloth slings for handling of the product and take care of the paint of
valve. Never hook the valve through its wheelhand or its actuator.

1.4.11

1.4.12

Ball valves should be handled and storaged in open position. Painted with different
colors for under and above ground. Under ground valve paints are not resistant for UV rays,
and should be protected from sunlight. Closed area should be chosen for long storage
period.

In case of any damage, suitable repair procedure should be applied according to

paint type or coating type.

1.4.13  Accessory equipments (vent and drain valve-pipe-fittings, operating system gear
box-actuator, grease fittings-pipe-indicator ...etc) should be protected from stroke, crush or
jamming.

1.4.14

If accessories cannot be protected, they should be disassembled and separate

package should be requested for transport and storage.

1.4.15

It is recommended that the disassembled parts should be assembled by Vasta

personnel or experienced personnel.

1.4.16
1.4.17

Prevent valves and accessories against dirt. (Affecting from external elements like
dust, sand and mud)

Suitable package should be used according to transport type, storage place and period,

if it is unpacked, precautions should be taken in order to prevent overturning in the vehicle

(container-truck case).

Page 7 / 40

b
1.4.18
1.4.19

VA-IM-63-3R0

Valves should be protected against weather conditions such as rain water , moisture
etc.., during storage. Storage in closed, well vantilated and dry areas is recommended.

Valve should be kept with suitable cleaner and valve-flush injected during storage
period including transport. Sealent lubricant should not be used till the operation and test.

1.5.0 MARKING:
1.5.1 Each valve has a nameplate, which might be simply attached with a wire if the size is too
small.
1.5.2 Info given on nameplate is as shown below.

VASTA
Trim material

FIGURE No.
Design
Standartd

Manufacturing
Date and Serial
Numaber

SIZE
End Type and
Standard

CLASS
MOP primary
max. operating
pressure

Body Material
MOT max.
Operating
temperature

Customer Marking Instructions

Read the label information and do not use the valve under higher temperature/
pressure conditions, compare this information each time when handover, assembly in
line and commissioning of the valve.

Check the suitability of valve materials for the flowing fluid and do not assemble the valve
without approval of the manufacturer whenever any confusion occurs.

1.5.3

Integral marking on the body is as follows.





Vasta
Size
Class
Material
Standard logos
Flow-cut Signs
Charge no.

DBB Tightness at Double Direction

Tightness at one Direction
Flow Direction

Page 8 / 40

VA-IM-63-3R0

1.6.0 ERECTION IN LINE:

1.6.1 Preparation;
-

Supply the suitable tools.

Control the line properties and the compliance of the valve.

If there are, determine the flow direction or flow cut off direction. If there is no flow

direction or closing direction signs on the valve used, both ways can be connected.
-

In the case of a valve supplied BARE STEM the fitting of the actuator and/or the gearbox,
must follow the installation instructions supplied by its manufacturer. If the valve is
motorised, before operating it, carefully read the instructions specific to the actuator.

If the actuator is installed on the valve, the limit switches have been adjusted in vastas factory
during functional tests to ensure correct operation from the fully open to fully closed
positions. If the actuator is electrical, the torque switches have been adjusted in vastas
factory during the functional tests and must not be modified. In case of a pneumatic or
hydrolic actuator, if the maximum actuator torque /thrust exceeds the maximum permissible
values for the valve stem, it is strongly recommended to install a pressure regulator on the
actuator.

Clean the erection area, the fittings & fasteners

Always considers the heat resistance of the gaskets if the valve would be welded to the
line together with counter flanges fixed. Never weld such a complete valve if the counter
flanges are not welding neck type.

With flat or slip on type counter flanges, use only tacks welding to adjust the centerline,

than disassemble the valve and end gaskets for further procedure of welding. Clean the
welding area properly after welding procedure is completed.
-

Select the correct electrode for welding and check the compliance of welding

procedure.
-

Welding procedure instruction should be followed with care

1.6.2 Pre erection controls and review of assembly criteria.

- 

Easiness of the assembly position for operation.?

- 

Easiness for maintenance & inspection?

- 

Suitability of space left for disassembly of the bonnet?

- 

Suitability of space left for control & addition of packing?

- 

Cleanness of valve internals when the protective end covers are taken out. Any
pollution might be removed by pressurized air

- 

Precautions for preventing of any residual metallic parts in the line?

Page 9 / 40

VA-IM-63-3R0

- 

Requirement for maintenance of the filters after first cleaning of the line?

- 

Proper positions of erection. ( see the following sketches)

- 

Vastas E63 series ball valves which have weld ends as per ASME B16.25 are suitable
for field welding process.

OK

Not recommended
(Drain cannot be done, line wastes can
give damage to valve)

OK

Not recommended
(Drain cannot be done, line wastes can
give damage to valve)

figure 1-Acceptable operating positions for ball valve

Page 10 / 40

VA-IM-63-3R0

1.6.3 A clearance of 1,6-3,2mm has to be kept between the ends of valve and pipe during
welding root layer.
1.6.4 Erection of valve to pipeline by welding should be executed by qualified personnel using
welding procedure approved for related codes & standards and regulations.
1.6.5 Ball valves have to be full open during welding.
1.6.6 Post welding heat-treatment has to be applied on limited areas of the weld for the same
reasons
1.6.7 In the event of damage to external painting, it is essential to quickly repair any defects.
1.6.8 The body itself should not be heated over 100 degree C for protection of the closure seats
on both the body & the disc. Care should be taken to prevent heating over 80 degree C in
order to protect soft seat-rings, the bonnet gasket and the packing.
1.6.9 Check the convenience of seat materials to the ultimate temperature of the valve
approached.
Table below indicates border lines for most common used materials.

MATERIAL

TYPE

MAX. TEMPERATURE

MAX. PRESSURE

PTFE

PTFE

260C

100

Buna-N

NBR

130C

100

Viton

FP

220C

100

1.7.0

Risk Analysis

1.7.1

General

The valve must be used within the operating parameters stated on the nameplate,
exceeding even only one of the stated limits may be hazardous. The following is a list of
possible hazardous condition that, are not completely eliminated even though evaluated and
recorded in the risk analysis of the component, Possible hazardous conditions:
Wind, snow, ice;
Acoustic vibrations and/or flow induced vibration;
Water hammer;
Chemical attack;
Decomposition of fluids;
Uncontrolled chemical reactions;
Stray electrical currents;
Shock waves.
Pressure compensation;
Adiabatic compression;
Induced current;
Acoustic energy emission;
Flame;
Lightning;
Page 11 / 40

VA-IM-63-3R0

Pollution;
Interruption of current;
Electromagnetic waves from 3*10^11 Hz to 3*10^15 Hz ;
Radio frequency (RF) electromagnetic waves from 10^4 Hz to 3*10^12 Hz;
Ionizing radiation;
Optical radiation;
Thermal reaction;
Eddy currents;
Humidity;
Ultrasound;
Environment variations;
Other external disturbances;

1.7.2

Required Information to be Specified by the User

The following is a list of the possible hazardous conditions that, if not previously specified
in contract documents, have not been considered during the design phase.
Possible hazardous conditions:
Thermal fatigue;
Seismic loads;
Creep;
Vacuum collapse;
External corrosion;
Contaminated fluid;
Abrasion;
Cavitation and flashing;
External fire;
External pipe loads differing.

1.7.3

Precaution And Conditions to be Considered

The installer and/or the end user shall analyse the possible hazardous situations initiated by
one or more of the following causes and take appropriate protection measures:

The surface temperature of the valve is a function of the temperature of the process
fluid, the maximum allowable surface temperature is shown on the name plate.
External solar radiation with the line at atmospheric pressure causes the internal
temperature of the line to increase.
External temperature will redound the Valve internal pressure.
None of the pressure containing parts shall be changed when the Valves is under
pressure.
If it is necessary, Valve shall be dismantled in half open position otherwise there
can be pressure jamed in Valve while dismantling in closed position.
Deposits of flammable dust may form on the valve. Vastas recommends limiting the
thickness of dusts deposits by periodically cleaning the external body of the valve,
and in particular the areas near moving parts (stem).

Page 12 / 40

VA-IM-63-3R0

The frequency of this operation shall be so as to prevent dust deposits greater than 5
mm. Wastes resultant because of cleaning must be checked environment expert and
must be eliminated properly.
The valve may release to the atmosphere gases and/or flammable dust that, in
extreme cases, can cause an explosive atmosphere. The probability of the formation
of an explosive atmosphere is greater during venting and draining operations.
Wastes accured because of Valve repair and maintenance, must be properly
eliminated according to environment standards and regional reguletions.
After completion of service life of Valve parts can be delivered to recycling by
decompasing the hazardus wastes.

1.8.0

Start-up & Line Test Process

1.8.1

Inspection and Control

Depending on the valve type and the installation conditions, after installation in the
line and before pressurizing the line, perform all or part of the following activities:
Check the presence of plugs, drains, vents, and verify that they are tight.
Verify the tightness of the bolting on the packing ring, the body/end flange
and body/bonnet
Grease stem bearing and threads
In case of actuated valves, read the instructions relating to the actuator.

1.8.2
Release the flowing fluid or pressurized air through the line by open/close cycles of
valves in order to drag out the solid contaminations of the line. This should be executed
after completing all connections. Waste in line shall accumulate within filters after this
procedure.
1.8.3 The fluids used to perform the pressure test of the line and successive operations during
startup must be compatible with the soft and metallic components of the valve.
The use of the following products/fluids may cause problems to the valve:
Amine corrosion inhibitors could damage fluorocarbon O-rings
The use of methanol to dry the piping could damage O-rings.
Water without inhibitors could increase corrosion of carbon steels parts;
Contact with fluids containing chloride and/or chloride compounds, may induce corrosion
of stainless steel parts.
1.8.4 

Fill the line completely with the test fluid.

1.8.5 

Make the valve and open position while doing line test.

1.8.6 

Relief any entrapped air by means of the vent connections.

1.8.7 

Inspect all connections after pressurizing the system in order to be sure of their

tightness.
1.8.8 

Reduce the difference to 7 bar and less in order not to damage the sealing surface

during opening and closing. By-pass should be used for this. It is not important for valves
that do not need by-pass.

Page 13 / 40

b
1.8.9 

VA-IM-63-3R0

Operational handicap may be faced if the valves stay for a long period at the same

position. De-greasing may occur or seat materials surface contact dimensions can be
changed. We suggest periodic open / close operations within a program. In order to be sure,
suitable grease should be given through grease fitting that greases stem and seat rings.
1.8.10

Test pressure can not pass 1,5 times of the highest operating pressure when the

valve is in half open position.

1.8.11 

1.1 times of operating pressure should not be passed during closure test

1.8.12 

Pipeline should be physically cleaned before test and test water should be less

chlorinated than 2ppm. Valve should be full open during test waters purification.
1.8.13 

Valve drain should be used for accumulated test water in body cavitations in full

open position.
1.8.14 

Valve flush should be used for cleaning lubricant holes fittings and pipes after test.

After cleaning lubricant holes with valve cleaner, enough greasing should be done with
suitable lubricant.
1.8.15 

The quantities given on the table are minimum quantities. Additional to these, more

grease should be added for extension pipes and additional grease installments.
1.8.16 

See operating system breakdowns section for troubles of the actuator and gear box

settings.
1.8.17 

See leakage troubles section if you have tightness problems.

1.9.0

Operating:

1.9.1

Trunnion Ball Valve.

The flow in these valves will be provided by the motion of ball (3)* between the two seats (2)*.
The stems bottom head (4)* is connected with the top of ball (3) with motion transmitter provides
the required strength for the motion.
All movements of ball (3) are fully guided to the seats within the valve body (1)*. The seats (2) are
placed to the body flexibly. O-ring (4) slot is on the stem, placed into stem gland flange (12a)* and
body (1).
(*) : Please see figure17 for the related part.

Do not overload the hand wheel with arm, while you may destroy the stem and seat faces if
there is any obstruction on the way of flow.

Page 14 / 40

VA-IM-63-3R0

Figure 3 indicates on / off operations of the ball valve.

Closing way
(clockwise)

Opening way
(Counter clockwise)

OPEN

CLOSE

Kv / Cv Coefficients
Cross Section Diameter and Cross Section Area

NPS in
2
3
4
6
8
10
12
14
16
18

ID mm
49
74
100
150
201
252
303
334
385
436

Dm
0,2
0,4
0,8
1,8
3,2
5,0
7,2
8,8
11,6
14,9

Kv
326
816
1540
3720
6800
11950
18600
23500
30900
40900

NPS in
20
24
28
32
36
40
42
48
56
60

ID mm
487
589
684
779
874
976
1020
1166
1360
1458

Dm
18,6
27,2
36,7
47,6
60,0
74,8
81,7
106,7
145,2
166,9

Kv
49300
78000
102000
141000
178500
225500
252000
301500
442500
509500

Table 1- Kv table

Kv
Q
P
S

: Flow Factor
: Flow
m3/h
: Pressure Decrease Kg/cm2
: Specific gravity (water 1)

Kv =

Q
P
S

Cv =

Kv
0.865

Page 15 / 40

VA-IM-63-3R0

Ball Valves Open (Breake) Torque Values

Table 2- (Ball Valves) Torque Values

Page 16 / 40

VA-IM-63-3R0

1.9.2 Operational Problems and Maintenance

1.9.2.1 Icing. For ball valves, after test of pipeline, because of no discharging and drying,
external weather conditions and fast discharging icing can be occured. Under this
circumstance, operation of valve can be difficult or completely locked. You shall wait if the
temperature is enough for removing icing. If the temperature conditions are not suitable,
you should make service with using valve-flush and you must heat. Never try to open the
lock occurred by icing, with exceeding torque values. If the valve is not greasing type and
icing is not thawed, the valve should be extracted from line and should have maintenance.
1.9.2.2 Sticking of ball and seat: Seat ring and ball could be stuck when ball valve left
without using for a long time. Same situation will occur for o-rings, which are between
body couch and o-rings. Valve cannot be operated during sticking like icing. It can be
locked in open or close position. Try to do opening or closing with the top limit of torque
values. If it does not help, immediately maintain the valve. In order to eliminate sticking,
pump valve-flush slowly from all grease fitting entrances. Avoid excessive grease pressure
otherwise damage can be occurred. Reopening and re closing should be made after reaching
grease flow mentioned for valve. Proceed on pressing valve-flush till the relief. After
having desired result, lubrication should be done with the lubricant suitable for the fluid
upto sufficient flow. If the valve is not Lubricated type and is not relieved, the valve should
be taken from line and should have maintenance
1.9.2.3 Stem leakage: Greasing should stop leakage observed from ball valve stem.Again
lubricant should be injected carefully, pressure should be increased and decreased after
leakages stop. Excessive greasing can damage tightness. If the valve is not Lubricated
type, the valve should taken from line and should have maintenance.

Maintenance of Stem Under Line Pressure

When any stem leakage is observed which might create mal-functions of any sealing
elements releated the stem, it is recommended to remove this leakage by repacking under
pressure. General Stem maintenance, however should be made during to line breaks.

Page 17 / 40

VA-IM-63-3R0

17c

12b
4d
12a
12d
6

1e

figure-3 Dissambly sketch of stem maintenance under pressure for gear operated valves.

Page 18 / 40

VA-IM-63-3R0

17a
17g

12b

17

12a
6
4

1e

figure-4 Dissambly sketch of stem maintenance under pressure for lever operated valves.

Page 19 / 40

1
2
3

4
5
6
7

VA-IM-63-3R0

This procedure is applicable to full welded valves having anti-blowout type stem.
Gear box is taken out by unscrewing the screws 12c and lever can be taken by
screw17a.
The key 4d is taken from its housing by light strokes with a chisel & hammer in the
direction of the stem side, otrherwise the shape of key would be deformed and can not
be re-used. Key application is not used on lever operated valve . Instead of key,canals
on the stem transmit the motion from lever to ball.
Screws 12b are taken and 12 a connecting flange should be removed by light blows of
plastic hammer at the back side.
Packing 6 is taken away from its housing and renewed.
Assembly is executed by reverse steps indicated above.
Val-tex sealent lubricants should be filled under suitable pressure through grease fitting
1e, before operation.
1e

Scale
figre-51:1
stem

lubrication fittings

1.9.2.4 Closing leakage:

If there is a leakage to body cavitation and can not be stopped, when ball valve
is in open or close position, suitable Lubricant should be injected from grease fittings.
Lubrication should be proceeded by opening and closing till leakage stops. If the leakage
does not stop, this means there is damage. In this case call service for damage removal or
use damage remover lubricant by help of a specialist. This operation should not be mixed
with open-close position fault. Otherwise procedure will not work.
1.10.0

Periodic Controls &General Maintenance:

1.10.1

 Inspection
To verify the correct functioning of the valve, the following checks must be made on
site, all or in part, depending on the frequency of valve operation and service
conditions:
Integrity of the paint;
Dust deposits;
Signs of rust, external corrosion, oxidation;
The tightness of bolting on body-bonnet, flange-line, packing ring, the condition of
vent and drain devices;
Greasing of stem thread and bearings (valves with handwheel/gearbox);
Internal or external leakage.

1.10.2

 Periodic control, covers

Routine maintenance interventions must be performed at a maximum of every two
years, as from delivery date. Vastas trained personnel, according to the modes
scheduled by applicable documents, shall perform the above-mentioned
Page 20 / 40

VA-IM-63-3R0

interventions. As for the valves that are completely underground, ordinary

maintenance cannot be carried out; however, a yearly (at most) preventive
maintenance and inspection programme is required.
Generally, lubrication of the stem &seat ring, hand wheel, gear box or actuator
operation control and end connections, body flanges gasket leakage control, leakage
control through relief vent-valves and drain plug where applicable. Any
nonconformance faced during control should be recorded to registry if applicable.
Forwarding to dealers and calling defect removal service shall be obtained.
1.10.3

1.10.4

 Supplementary maintenance
Supplementary maintenance interventions cannot be scheduled; they are carried out
when there are failures that partially or totally obstacle valve operation. Vastas trained
personnel, according to the modes scheduled by applicable documents, shall perform the
above-mentioned interventions.
Before starting any maintenance operation, depressurize, drain and vent the line on
which the vailve is connected; check that the line is not at operating temperature,
disconnect any electrical equipment and decontaminate the valve. The non-observance of
any one of the above mentioned regulations might cause a serious danger for personnel
health and safety.
 Cleaning & Lubrication of the stem.
Stem shall be cleaned and lubricated at least once a year. VASTA recommends the
selection of lubricant according to the operational conditions. Important point must be
lubricating fitting and reducing the friction. Where lubricant injection is not convenient,
grease fitting should be renewed. If there is stem protector, this shall also be cleaned and
the position indicator shall be adjusted if applicable. If leakage occurs from stem, procedure
mentioned in this section should be applied for emergency cases. If scratch and porosity
size is like Rms 250 (6,3 Ra) according to stem size, necessity of stem repairing or
renewing should be noted to report.

1.

2.
3.
4.
5.
6.
7.
8.

1.10.5 Maintenance Preparation

Find the instructions of the valve with DS or DSWG drawing number reference number
that will have maintenance. Maintenance shall not be done without instructions and
drawings.
Check the security of the maintenance area.
If there are flammables, explosives, electric currents, pressure, air polluters or toxics in the
area, tell authorized person to eliminate them.
Provide the maintenance equipments-tools which are seen on the drwg and which can be
necessary.
Check if you have enough equipment for assembly and disassembly torque.
Provide enough lubricant of necessary kinds. (See Val-tex range of products)
Provide enough valve flush of necessary kinds. (See Val-tex range of products)
If there are gearboxes or actuators, their catalogues and maintenance instructions must be
followed.
1.10.6 Maintenance and Lubrication Procedure:
Emergency sealing system made of steel with large and proper type connecting head
of NPT are located on both body ends cover flanges.(See figure-5)
Seats of Vasta E63 series are designed as being full tight without neccesity for any
addtional tightness materials. Solid particles left in pipeline system, however, may enter
Page 21 / 40

VA-IM-63-3R0

between seat and ball creating damage of seat faces. Defected faces results leakage of fluid.
Solid wastes in the line might also create erosion of valve walls due to defective seat faces
may be prevented temporarily using proper val-tex sealents through emergency sealing
heads.
1
Cleaning should be done after approval of safety precautions.Keep cleaning wastes
in proper container to prevent scattering the same around.
2
Inject proper & qualified Vasta seat flush material through the emergency sealing
system, which enable the old sealent and foreign materials be flushed away from the
seating area.
3
Inject Val-tex sealing lubricant appropriate for the flowing fluid through emergency
sealing system at the high pressure side of valve being full closed position.
4
Follow the lubrication procudure and related valve drawing or datasheet during
execution.
5
If possible slightly move the ball in order to distribute the additional lubricant
evenly on the ball surfaces.
6
Demaged or defective emergency sealing fittings can be renewed under line
pressure, but be sure that the check valve of the fittings operates well.
Lubricantion wastes should be cleaned and disposed in proper containers.

1.
2.
3.
4.

5.

1.10.7 Control Procedure

Security precautions shall be approved for the control and live test.
Get information from sources about measuring system pressure for test.
For DBB type, start to discharge the pressure from body cavitation by opening drain and
vent valve.
Make leakage measurement according to API 6D leakage tolerances if pressure in body
discharges. Bubble measurement by using tube will be enough.
Make leakage record and recommend your repair procedure if there is a measurement
higher than standard values. (Gear box adjustment, actuator adjustment, seat, stem tightness
adjustments or seat repair lubrication etc)

1.10.8 Removal Procedure

1. After approval of security cautions, cleaning will be done. Take precautions for cleaning
wastes dispersion to the environment.
2. Especially parts for maintenance should be cleaned properly.
3. Use lifting equipments for big and heavy valves whose lifting or removal is not possible by
using hands.
4. Follow the recommended procedure by looking to detailed drawings for decided removal
type. During removal, mark with paint, sign or numerate with pen by not separating the
pieces from each other, for understanding direction easily and to find same direction while
fastening.
5. During removal, as soon as take photo if any damage like corrosion or deformation should
be seen.
6. Record the operations to eliminate the damage and attach the photos as a proof.
7. Clean abbreviation and/or spots from removed pieces without making damage.
8. Separate the pieces which will be changed and check the conformity with the spares.
9. Check the measures and tolerances written on drwg and DS or instruction, record measures
or make report.
10. Take the valve from line if tightness could not be achieved.

Page 22 / 40

VA-IM-63-3R0

1.10.9 Assembling:
Apply the reverse of removal procedure. Absolutely consider warnings written on related
Drwg, DS or their attachments for body assembly. If there are any doubts, consult to
VASTA Technical Service or call service.

1.10.10
Final Settings and Controls:
Check the correctness of opening-closing direction marks.
Measure and record of opening-closing torque.
Full opening-closing control (can be done with tightness control)
Approve security cautions for control and live test.
Get information from attendants if there is condition to test system pressure.
For DBB type valve, start to discharge the pressure from body cavitation by opening drain
and vent valve.
Make leakage measurement according to API 6D leakage tolerances if pressure in body
discharges. Bubble measurement by using tube will be enough.
Make leakage record and recommend your repair procedure if there is a measurement
higher than standard values. (Gear box adjustment, actuator adjustment, seat, stem tightness
adjustments or seat repair greasing etc)

1.
2.
3.
4.
5.
6.
7.

8.

1.10.11

Maintenance Marking:

Copy the records that you made in maintenance document to valves file. Attach to service
attachment if service made. Record and sign the maintenance approval on Drwg and DS.
If there are used spare parts, attach spare parts input to valve file and service forms attachment.
Adjustment, measurement records, opinions and recommendations for the next maintenance
should be written on service form.

Make labeling about site service and record the latest maintenance date. Period can
not be more than 12 months.

1.10.12
Removal and Disposal.
At the end of its operating life, the valve can be removed from the line by using a suitable
procedure according to its kind and installation conditions. After removing the valve, immediately
position suitable snugs at its ends and openings (e.g. drainage, vents), in order to avoid the leakage
of contaminants in the environment. Bring the valve to a place in compliance with the requirements
of the European, national, regional, municipal environment and safety rules, and store it there
waiting for its reclaim.
As the valve can contain toxic, corrosive and/or noxious substances, clean and reclaim (e.g. using
high pressure steam) before disassembling. The staff carrying out this operation shall have suitable
protective equipment, according to the kind of pollution.
The residuals of the reclamation must be collected and eliminated in compliance with the
requirements of European, national, regional, municipal directives and/or laws concerning rubbish
and/or dangerous substances.
Remove any paint coat on the valve (e.g.sandblasting). Eliminate the paint removed in accordance
with the related legislation in force. Metallic parts can now be transported to a steel plant to be
reused. Plastic parts (O-ring, packing rings, etc...) have to be disposed of in compliance with the
dispositions established by European, national, regional, municipal directives and/or laws
concerning rubbish and/or dangerous substances.

Page 23 / 40

VA-IM-63-3R0

Attached Documents:
Hand operated/Actuator Assembly Drawings
Part list and Descriptions

1.11.0

Valve Problems and solution suggestions:

There are 3 types of ball valve problems and procedures in order to solve them are listed below.
Working hard or not working at all
Stem leakage
Seat leakage
If you have valve problem, always inspect from top to bottom. Start to check from operator
to valve adjustment.
Operating type should be determined;

Manual operating ball valves

1.10.1 
As a rule, external subjects can hinder working of valve, which can be corrected or can be
changed. After corrective acts if there is still difficulty for working, then this means there is a
problem inside the valve.
1.10.2 
Gearbox operated ball valves
Check all internal parts of gearbox:
Bearing control
Gearwheel control
Fasteners control and adjustment
Greased gearwheel and coated surfaces that touch metal to metal with grease should
also be controlled.
Grease that is used for these surfaces is oil based and water can contaminate. Water can freeze in
cold weather conditions and valve cannot operate. In this case remove gearbox, clean ice, water
and water contaminated grease. Renew the grease. If the working environment is so cold, choose
glucose-based grease because of its durability to cold weathers. Be sure of gearboxes tied to valve
properly and fasteners are not loosened.
1.10.3 
Actuator operated ball valves
Check Actuator maintenance instruction for suitable inspection.
Check power supply, electrical, air or hydraulic liquid connections as they can give necessary
supply. Make corrective actions if necessary.
Check all moving part with necessary adjustment level. Make corrective actions if necessary.
Check valve actuator for movement. (Under high torque, torque loss can inhibit valves full
opening and closing) Separate actuator from valve and confirm its regular working if necessary.
This operation will isolate probable problems.
1.10.4 

Working hard or not working valves- Internal Causes

After revising all external causes that can inhibit valves operation, also 4 internal reasons
should be checked as indicated below.

Page 24 / 40

VA-IM-63-3R0

Icing
If your valve is on a gas line; most of gas lines consist a little amount of water (condense). Water
will accumulate on the lowest part of valve. During cold weather conditions this will turn into ice.
Corrective actions;
From body bleed fittings to body cavitations, block valve and make water go out. (Opening drain
valve can discharge water)
OR: if icing occurred, suitable and acceptable method can be used for melting.
EX: Apply a heated piece to valve or inject a liquid that prevents forming of ice within valve
(Alcoholetc).
Seat-Ball Sticking
Seats can make a set to ball for free seated valve in long term stable lines. Because of this situation,
more force is needed for leaving ball free and continue of work. This will increase necessary
working torque for high line pressure.
Corrective action:
Operate valve by using more suitable force. If valve is lubricated type, inject valve flush in order to
separate tightness element and seats from ball and also if possible open and close valve for many
times.
Seat ring
Sticking of wastes coming from line, such as dirt, sand or old rough greases can accumulate in seat
ring area and inhibit seats movement. Sticking of seat rings can cause leakage between seat and
ball.
Corrective action:
If valve is lubricated type; inject valve flush as much as you can into valve in order to solute and to
break wastes into pieces. Open and close valve to break further these wastes if possible.
If valve is not lubricated type, valve shall be disassembled, rings should be removed and necessary
cleaning should be done. O-ring and TFE rings might be changed.
Note: VASTA suggests calling service.
Stem leakage
Vastas ball valves are designed with 3 steps stem sealing. If there is no leakage through to stem, do
not proceed with the stem which might create otherwise some problems. Generally, If stem
leakage is observed, this might be created from seat leakage, hence line pressure reaches to upper
stem sealing element. When the valve is lubricated type, inject sealing lubricant through the proper
fitting until leakage stops.
CAUTION: Over pressure around stem area might block the valve. Procedure should be allways
applied giving attention to line pressure.
If leakage does not stop, the valve should be taken from line for maintenance,
following the below procedure.

Page 25 / 40

VA-IM-63-3R0

17c
12b
4d
12a

12d
6
4e
12c
7
7a
7b

1e
4c

4b
4

3c

Figure 6 Stem maintenance, dismounting procedure for gear operated valves(Line without Pressure)

Page 26 / 40

VA-IM-63-3R0

17a

17g

12b
17

12a

12c

4e
6
7
7a
7b

1e

4c
4c
4c
4b
4

3c

figure 7 Stem maintenance, dismounting procedure for lever operated valves(Line without Pressure)

Page 27 / 40

VA-IM-63-3R0

The process should be carried out by a qualified technician for valve maintenance or
better by Vastas service team .
2 Valve is closed and drained.
3 Screws 12c is taken out for dismantling the gearbox or screw 17a has to be unscrewed
for taking the lever out.
4 Key 4d has to be slid up by slow blows with a chisel and hammer on its face of stem
direction. Strong blows might destroy the form of key, preventing re-use of the same.
Lever operated valves have grooves on circumferences of stem instead of key, to carry
off the movement of lever.
5 Screws 12 b are taken out and connecting flange12a is slid up by slight hammer blows .
6 Packing 6 is removed and renewed.
7 Gland 7 is dismantled by removing 12e bolts and centering pin 4e.
8 Gasket (SWG) 7a and O-ring 7b on the gland are repalced by new ones.
9 Grease fitting 1e on the gland is unscrewed and lubrication groves are cleaned.
10 Stem is taken out and its accesories, 3 pieces O-rings 4e and PTFE washers 4b are
renewed
11 Assembly is made by reverse action, taking care for suitable positioning of anti-static
device 3c
Finaly, Proper sealing lubricant is injected through 1e fitting under suitable pressure.

Seat leakage

The other general ball valve problem is leakage from seats. Seats of Vastas ball valves are against
passing side.
Seat leakage can be seen while valve is in open or in close position. Because of this, valve seats
can be controlled in both positions.
Test procedure for seat leakage
1. For fast control, be sure that valve is fully opened. This cause decreasing of pressure in
body and shortening the necessary time for drain. Repeat the same action for opposite
direction without doing anything when valve is in closed position.
2. Confirm balls full turn and do not forget full turn is 90 degree If any turn left 3 degree
open, without looking to open or close position, leakage will be occurred. Your mistake
ratio must be minimum.
3. In manual operated ball valves, you can confirm the tour of ball from the indicator on
valve.
4. Check stem stopper;
a) In small size ball valves stem stopper can be seen.

Page 28 / 40

VA-IM-63-3R0

b) Check jammed or accumulated materials between stem stopper and stem in big size
ball valves. Dust formation inhibits valves full turn and cause leakage. If valve is
buried, dust can be filled from extension and this cause leakage. If you cannot see
stem stopper and stem head, sometimes listening voice that comes from valve can
be useful in order to understand completion of 90 degree turn.
5. For valves with actuator or gear box, balls settling to its place can be checked for many
times. While putting actuator to valve, stem stoppers are removed from valve. For some
cases stoppers are in valve. Wrong adjustment of stoppers can cause leakage.

Seat Leakage- Internal causes

Seats in valve stuck to each other and cannot move. There may be leakage and seat cannot move
because of old rough dirt on line and waste combination in line.
Wastes originate from same causes may result leakage between ball and seats.

Ball and/or seats can be scratched and damaged. In these conditions repair and renewal can
be done after inspection of VASTA personnel.

Repair of seat leakage and general maintenance

Page 29 / 40

VA-IM-63-3R0

17a
17g
12b
17

12a

4d
6
7

4e
7b

7a
4c

4b

4c

3c
3f

2i

2c

1e
1

4 2e
2c

3g
3h
2

1a

2e

2c

2c

2b

2
2b

2i
3
3g
3h

3f

Figure-8 Dismantlig sketch for lever opearated valve having no lubring.

Note:The valve has to be taken away by cutting the pipe and one side should be machined as per
instructed in order to sperate from weld connection.

Page 30 / 40

VA-IM-63-3R0

17c
12b
4d
12a
12d
6
4e
3c
12c
7
7b

2e

7a
1e

2c
2i

4c

4b

4
2g
3c

3c
3

3f
3g
3h
2b

2e
2c
2d

2b
2d
2c
2e
2g
2

3g
3h
3f

2i
2c
1a

2e

Figure-9 Dismantlig sketch for gearbox opearated valve, having lubring

Note:The valve has to be taken away by cutting the pipe and one side should be machined as per instructe in order to sperated from weld connection.
Page 31 / 40

b
1
2
3

VA-IM-63-3R0

This process has to be carried out by vastas service personnel at vastas plant
Procedure for stem leakage is applied, if any stem leak occurs .
One of body parts 1a is separeted from body 1 at weld area by cold cutting or by machining
at lathe. Cutting process should be step-wise as per seen on figure10, having max cutting
width of 10mm by each step. Cutting should go down to root of weld and depth of cut is
tabulated on the table 3. valve shoud be full open during the process.

Valve size
NPS 2
DN50
NPS 3
DN80
NPS 4
DN100
NPS 6
DN150
NPS 8
DN200
NPS 10
DN250
NPS 12
DN300

Depth of cut
11,7
13,6
12
13
15
18
21

Valve size
NPS 14
DN350
NPS 16
DN400
NPS 20
DN500
NPS 24
DN600
NPS 30
DN750
NPS 36
DN900

Depth of cut
21
25,5
32
41
50

Table 3: Dimesion of cutting depth at connection welds for ball valves

Note: Values given on Table-3 are general averages. Apply dimensional instructions stated on valve drawings for
definite dimensions.

12

Max 10mm

Figure-10: Separation skecth of body part 1a from body 1

4
5
6

Each part dismantled should be cleaned from dirt and/or grease, if it is re-used
Springs 2e dismantled should be renewed, if they are deformed.
Fire safe rings 2i located on seat rings for smaller size valves than 30 and on lubrings for
larger size valves

Page 32 / 40

VA-IM-63-3R0

2b
2d
2c
2e
2g
2

2i
2c
2e

Figure-11 schematic view of lubring+seatring application for valves larger than 30

2b
2
2i
2c
2c
2e

Figure-12 schematic view of seatring application only for valves smaller than 30

Page 33 / 40

VA-IM-63-3R0

a)

b)
Figure-13 a) visual view of seatring application only for smaller valves than 30
b) visual view of seatring+lubring application for larger valves than 30

7
8

O-rings 2c located on lubring & seatring have to be renewed.

PTFE seat face 2b over seat ring only for smaller valves than 30 and both 2b and PTFE
secondary ring 2g over lubring for larger valves than 30 have to be replaced. If
deformation observed replacement should be executed by hand without use of any tool
which might demage ring housing
After O-rings and felts of valve seats are replaced, drybearing 3g and washer 3h have to
be
also
renewed.
3f
3g
3h
3c
3

3g
3h
3f

Figure-14 Ball group of valve

10 Grease fitting 1e should be unscrewed and lubrication grooves on 1a part are cleaned.
11 Re- assembly is achieved by reverse action described above.

Page 34 / 40

VA-IM-63-3R0

12 Weld ends of parts should machined complying with criteria indicated on figure 15, before
re-welding
12
1

5,9

R6

1.6

5,9

Figure-15 Welding end shapes&dimensions of body parts1&1a

13 Connection welding has to be executed by qualified personnel, according to approved

welding procedures complying with related codes, standards and regulations
14 Suitable NDT methods shall be used for acceptance of the applied welds.
15 Finaly, proper Val-tex sealing lubricant is injected through grease fitting 1e located on body
part 1a, into lubrication grooves of seat assembly
1e1e

Figure-16 Seat lubrication fitting

Problems appeared from blunt plug

Sometimes VASTA valves shipped with blind plug fittings affixed or blind plug fittings in box
or in bag according to customers request. Fittings must be affixed before valve attached to line.
Reason of shipping like this is to prevent the brake of fittings during transport.
If fittings attachment is forgotten and blind plug left on its place, procedures written below should
be applied.

NOTE: Blind plug should be changed when there is no pressure on line according to VASTA
suggestion.
Page 35 / 40

VA-IM-63-3R0

You must be so careful while removing plugs when valve is under pressure. In this case and while
attaching body bleed fittings you will be exposed line pressure directly. Do not attach fittings when
valve is under pressure. Do the operations written below after reading your companys instructions
and policy: In some cases, isolating line completely is needed for attaching fittings.
This is the safest and always suggested method. If blind plug will be changed under pressure;
a) Be sure of you, your personnel and your surroundings will not be hurt because of a
piece that gets out from valve.
b) Do not stand across blind plug.
c) Against continuing of body pressure because of seat leakage, keep a valve on hand
in full open position, which has fittings on one side and has same disc.
d) Discharge pressure in body. Open blind plug with wrench and let pressure get out.
Do not open blind plug fast. This procedure needs to be patient and care. When
pressure becomes less, open plug slowly so that left pressure gets out from threads.
e) After opening plug, attach valve mentioned in item c.

Draining and venting VASTA ball valves:

Venting the valve body cavity while it is pressurised, is a dangerous operation requiring
trained personnel. Vastas strongly recommends the use of a vent with a bleed port for the
safety of the operator.
Draining the valve body cavity while it is pressurised, is a dangerous operation requiring
trained personnel. Vastas strongly recommends as a minimum the use of a drain with a
bleed for the safety of the operator.
In both cases, as the fluid in the pipeline may be toxic, corrosive or cause burns, the valve
must be decontaminated to an appropriate standard procedure, before an operator starts
working on the valve. The staff carrying out this operation shall have suitable protective
equipment, appropriate to the type of contaminant present.
If a safety relief valve is present, to avoid the uncontrolled release of fluids that may be at
very high temperature and pressure and also dangerous for heath and safety, it is strongly
recommend to connect these safety devices to an appropriate manifold to contain the
released fluid. If there is not a bleed fitting, do not use the vent or drain plug to bleed
pressure from body cavity.
The tools used for working the on the valve body externals, during grinding, welding,
cutting, disconnection form the line etc, must comply with the anti-sparks requirements.

Page 36 / 40

VA-IM-63-3R0

1 2a

3c
3g

18
1e

3f

1e

3h

1m

1i

3 , 3a

1a

1b

19

1g

2d
2b

2c

2, 2a

Figure17-Part list for full welded,lubricated type ball valve

1 Body

3g (Trunnion)

1a Body parts

3h Pul (PTFE)

1c Pups

4 Stem

1e Grease Fitting

4b Washer (PTFE)

2 Seat ring

4c O-Ring

2a Seat ring face

6 Packing

2b PTFE ring

7 Gland

2c O-Ring

7a Gasket

2d Spring

7b O-ring

3 Ball

12a Reductor connection flange

3a Ball Face

18 Valve Label

3c Anti-static device (ASD)

19 Paint

3f Retainer

19a Bonnet

Page 37 / 40

VA-IM-63-3R0

Declaration of conformity
According to Directive 97/23/EC for a pressure equipment
The manufacturer herewith declares, that the pressure equipment
Description: Ball Valves; Split body and Full welded, Floating and Trunnion type, Top entry & side entry,
Soft seated & metal to metal seated, from Class 150 upto Class 2500.
Type-, Serial-, Identification-No: E610-E61 / E620-E62 / E630-E63 / E640 / E650 / E660
max. allowable pressure PS: 20 bar / 51 bar / 102 bar / 153 bar / 255 bar / 425 bar
Allowable min. / max. temperature TS: - 46 / +100 C
Volume V: 0,4 to 3.500 Liter
Year of manufacturing: 2010 & following years
Test pressure PT: 30 bar / 77 bar / 153 bar / 230 bar / 383 bar / 638 bar
Test fluid: Water
Corresponds to the Pressure Equipment Directive 97/23/EC.
Applied conformity assessment
procedures:

Module H+H1

Applied standards and technical

specifications:

API 6D

Other applied EC-Directives: NA

Engaged notified bodies:
Surveillance of the QS-System: TV Rheinland
Examination / inspections / test
during manufacturing:

TV SD, Bau und Betrieb GmbH

Certificates which are included

EC- modul H/H1 Full quality assurance / Full quality assurance with design examination and special
surveillance of the final assessment.
Cert. No: DGR-0036-QS-1072-12
Location, Date: Tekirdag / Cerkezkoy, 01.04.2013

Signature

Page 38 / 40

VA-IM-63-3R0

Page 39 / 40

Signature/mzalanmtr

30.08.2013

A.KARADAG

K.KORKMAZ

N.ERGN

REV

Explanation/Aklama

Date/Tarih

Prepared By/Hazrlayan

Checked By/Kontrol Eden

Approved By/Onaylayan

DUAL DISC WAFER TYPE CHECK VALVE

INSTRUCTION MANUAL

FT DSKL WAFER TP EK VALF

KULLANIM KILAVUZU
E40D

Location

DES

Doc. No & Rev.

VA-IM-E40D-3R0

Scale
Page

A4

Valf Armatr Sanayi Ticaret Anonim irketi

.O.S.B. 59500 Tekirda-TRKYE Tel: 0282 758 36 50 Fax: 0282 758 36 59

1 /16

VA-IM-40D-3R0

INDEX / NDEKLER
ITEM /
ARTICLE

SUBJECT / BALIK

PAGE/ SAYFA

1.1

INTRODUCTION / GR

1.2

GENERAL / GENEL

1.3

PACKING, STORAGE & TRANSPORT / AMBALAJ, DEPOLAMA ve TAIMA

1.4

MARKING / MARKALAMA

1.5

DESCRIPTION / AIKLAMA

1.5.1

FEATURES & BENEFITS / ZELLKLER ve YARARLARI

1.5.2

APPLICATIONS / UYGULAMA ALANLARI

1.6

OPERATION / LETM

1.7

INSTALLATION / KURULUM

1.8

DIMENSIONS / LLER

10

1.9

TABLE 1 FLANGE BOLT TORQUES / TABLO 1 FLAN CVATA TORKLARI

12

1.10

MAINTENANCE / BAKIM

13

1.11

TROUBLESHOOTING GUIDE / SORUN GDERME REHBER

13

1.12

DISASSEMBLY / SKME

14

1.13

REASSEMBLY / TEKRAR MONTAJ

15

1.14

SPARE PART and SERVICE / YEDEK PARA ve SERVS

16

1.15

REVSON HSTORY / REVZYON TARHES

16

REFERENCE STANDARTS / REFERANS STANDARTLAR

1.

API 6D

2.

API 598

3.

API 594

4.

ASME B16.34

Page 2/15

VA-IM-40D-3R0
1.1 INTRODUCTION /GR

Do not take any action related with the valve we supplied without reading the information given in this manual,
across the symbol
Bu kitapta sembol karsndaki bilgileri okumadan Valfle ilgili hibir ey yapmaynz
Do not initiate the related operation without reading the information given in this manual across the symbol.
Bu kitapta sembol karsndaki bilgileri okumadan ilgili operasyonu yapmaynz

1.2 GENERAL / GENEL

1.

This manual is applicable to all Dual Disc Check Valves manufactured by Vasta
Bu el kitabi Vastas tarafindan retilmis olan tm Dual Disc Check Valflere uygulanabilir.

2.

Special requirements in the purchase order have preference to this manual

Msteri zel kosullar ile siparis etmisse o kosullar geerlidir. Bu kitap onun tamamlayicisidir.

3.

Vasta warrants that its product would serve along with the economical life of the plant provided the procedure in
the manual are strictly followed.
Vastas, bu elkitabindaki prosedrlere uyum halinde Tesisin Ekonomik mr boyunca valflerin hizmette kalacagini
garanti eder.

4.

Whenever overpressure & temperature rates or contamination of line with solid & metallic parts are observed with
resulting defects, the valve should not be forced to further operation but field service should be applied / required,
immediately.
Valfler, basin ve sicaklik degerlerinin asilmasi veya hat kirliligi ve metal paralari hasarlari olusmasi halinde
zorlanmamali ve derhal bakim yapilmali ve servis istenmelidir.

5.

Any defective part has to be renewed by application to Vasta field service for their support of spares.
Istenmeyen sartlarla hasar grmesi halinde Vastas servisine basvurularak yedek para destegi istenmelidir.

6.

Vasta suggest the user to send the defective valve to its plant without considering the valve is under Vastas
guarantee or not. The report of the inspection will be informed to the user and the valve will be repaired and tested
after users approval.
Garanti kapsaminda olsun veya olmasin Vastas tm valflerin ariza halinde Vastasa ulastirilmasini nerir. Bu
durumda valfte yapilacak kontroln sonucu tarafiniza bildirilecek, mutabakatinizla bakim ve tamiri yaplacaktr.

7.

New valve would be suggested if the repair cost would not be economic.
Tamir ekonomik degeri asacak boyutta ise yeni valf nerilir.

8.

All defects found within the guarantee coverage would be removed on free of charge
Garanti kapsaminda kusurlar tespit edilir ise bedelsiz olarak giderilir.

9.

Valves covered with Vastas guarantee shall only be handled by authorized Vasta team / operator.
Garanti kapsamindaki valflere yalnizca yetkili Vastas servisleri tarafindan hizmet verilebilir.

10. VASTAS shall not be responsible for the performance failure resulted by unauthorized interventions other than the
actions permitted in the manual
Kullanma klavuzunda belirtilen hususlar dnda yaplacak yetkisiz mdahaleden ve bunlarn olumsuz
sonularndan VASTA sorumlu tutulamaz.

11. Do not hesitate to contact Vasta through the contact information given below:
Her istendiginde asagidaki kaynaklara basvurulabilir.

Vastas A.S. .O.S.B 59500 Tekirdag Trkiye

0282 758 36 50 Fax. 0282 758 36 59
http://www.vastas.com , [email protected]

Page 3/15

VA-IM-40D-3R0

1.3 PACKING, STORAGE & TRANSPORTEMBALLAGE/AMBALAJ, DEPOLAMA ve TAIMA

1.

Vasta valves are protected with connection end covers or packing.

Vastas valfleri agiz kapakli veya ambalajl olarak korunmustur.

2.

Standard deliveries are made as the valves fixed on wooden pallet and shrink wrapped with polyethylene unless otherwise
indicated by the order
Sipariste aksi belirtilmedike vanalar palet ve polyethyleneli shrink ambalajli olarak teslim edilir.

3.

Fixing the valves safely on pallets is suitable for transport

Palet zerine emniyetle yerlestirilmis olup tasimaciliga uygundur.

4.

The storage period is two years if none of any sea transport made. It is recommended to take the covers each 6 months
and lubricate the machined faces, than replace the covers
Depo muhafaza sresi denizasiri tasima yapilmamis olmak zere 2 yildir. Bu sre iinde depo kosullarina gre her 6 ay
iinde agiz kapaklarinin ailip boyasiz yzeylerin yeniden yaglanmasi ve tekrar kapatilmasi tercih edilmelidir.

5.

6.

7.

8.

1.

Each valve has a name plate which might be simply attached with a wire if the Valve size is too small.There are necessary
informations of valves with packing on the packing.
Her valfin bir tanitma etiketi vardir. Boyutu etiketin takilmasina uygun degilse atalanmis olabilir. Ambalajl olanlarn
ambalajnda gerekli bilgiler mevcuttur.

2.

Info given on name plate is as shown below.

Etiket bilgileri asagidaki gibidir.

Valves should be inspected for any defect arised by handling / transport after such activities.
Istenmeyen sartlarla hasar grmesi halinde Vastas servisine basvurularak yedek para destegi istenmelidir.

Compliance to the requirements should be checked during handover using Packing list, operating instruction and
manufacturers certificate.
Teslim alma sirasinda Ambalaj listesi, Kullanma talimati ve Sertifikasi ile uygunluk kontrol yapilmalidir..
Weight list should be checked and suitable vehicle has to be prepared before unpacking the goods.
Ambalaj sklmeden agirlik bilgilerine bakiniz ve uygun tasiyici temin etmeden ambalaji skmeyiniz..

Use reinforced cloth slings for handling of the product and take care of the paint of valve.
Tasima iin bez sapanlar kullanin, boyanin hasar grmemesine zen gsterin

1.4 MARKING /MARKALAMA

VASTAS

FIGURE

SIZE

CLASS

TRIM MATERIAL

DESIGN STANDARD

END STANDARD

Max. Oper. Pressure

Date of Mnft.
Serial No

SHELL MATERIAL
Max. Operation Temperature

Marking info required by the customer

Read the label information and do not use the valve under higher temperature / pressure conditions, compare this
information each time when handover, assembly in line and commissioning of the valve.
Etiket bilgilerini okuyun ve bu deerleri aan artlar iin kullanmaynz. Bu bilgiler teslim alnrken, boru hattna baglanrken,
yol-verme baslangcnda ayr ayr kontrol edilmelidir.

Check the suitability of valve materials for the flowing fluid and do not assemble the valve without approval of the
manufacturer whenever any confusion occurs.
Akkan cinsi ve vana malzeme uyumunu kontrol edin, pheye dlen konularda reticiye danmadan montaj yapmayn.

Page 4/15

VA-IM-40D-3R0

Integral marking on the body is as follows.

Gvde zerinde markalama bilgileri aadaki gibidir.

Vasta
Size
Class
Material

Standard logographs
Flow-stop directions
Heat No

 Tightness at one direction

Tek ynde szdrmazlk

 Flow direction
Ak Yn

1.5 DESCRIPTION
AIKLAMA
The Dual Disc Check Valve is designed to open fully to provide flow in the forward direction
and close rapidly upon flow reversal. and designed to prevent reverse flow automatically. On
pump start-up, the flow of water enters the valve from the seat end
(in Figure 1) and
forces the two discs open until they strike the disc stop pin. On pump shut-down, valve
closes with help of the torsion springs.The valve should be installed in horizontal or vertical
flow up pipes carrying clean flow. This valve is not intended for fluids containing suspended
solids such as wastewater.

Dual Disk ek Valfler ileri ynde ak salamak ve ak terse dndnde hzlca

kapanabilmek iin tasarlanmtr ve otomatik olarak geriye ak nler. Pompa knn
ucuna taklr ve akkann ak kuvvetinin etkisiyle iki diski de pime kadar iter ( Figr 1) ve
diskleri ak tutmaya zorlar. Pompa kapandnda yaylarn yardm ile kapanr. Temiz
akkan tayan borularda yatay veya dikey pozisyonda kullanlmaldr. Bu valfler atk su gibi
kat paralar ieren sistemlerde kullanma uygun deildir.

Page 5/15

VA-IM-40D-3R0

FLOW
AKI

Open Position
Ak Pozisyon

Close Position
Kapal Pozisyon

Figure 1 / ekil 1

Page 6/15

VA-IM-40D-3R0

1.5.1 Features & Benefits/ zellikleri ve Yararlar

A-

Dual-plate designs that are compact and lightweight for efficient seating, operation and lower
installation cost.
Dual-plate dizaynlar verimli seating operasyon ve dk kurulum maliyeti iin kk ve hafiftir.

B-

Spring action closes plates independently.

Yay hareketi diskleri birbirinden bamsz kapatr.

C-

Hinge support sleeve reduces friction and minimizes water hammer through independent plate
suspension(larger sizes)
Mentee destek kolu srtnmeyi azaltr ve bamsz disk sspansiyonu sayesinde su darbesini en aza
indirir.(byk boyutlarda)

D-

Independent springs with long legs to prevent seat scrubbing and provide non-slam performance
Uzun bacakl serbest yaylar arpmasz performans salar ve seat yzeyinin anmasn nler.

1.5.2 Applications/ Uygulama Alanlar

Petroleum Refinnig/Petrol Rafineleri

Oil and Gas Production/Petrol ve Gaz retim
Chemical and Petrochemicals/Kimya ve Petrokimya

Power Generation/G retim Tesisleri

Steel/Primary Metals/elik/ Temel Metaller
Marine/Denizcilik
Water/Su
C

API 594
API 598

PRODUCT STANDARDS/RN STANDARTLARI

Valve Design/Valf Tasarm
Valve Pressure Testing&Inspection
Valf Basn Test&Muayene

ASME B16.5&B16.47 Flanges/Flanlar

Pressure / Temperature Rating
ASME B16.34
Basn / Scaklk Deerleri
API 6D

Pipeline Valves/Boruhatt Vanalar

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VA-IM-40D-3R0

* Dual Disc Check Valve (wafer) design is generally stronger, lighter, smaller, more efficient and less

expensive than conventional swing check valves.Bolts are montaged to tighten cross over
between two flanges (See. Figure A)
Dual Disk ek Valfler (wafer) tasarm, geleneksel yzer tip ek valflerden daha gl, daha hafif,
daha kk, daha efektif ve daha ucuzdur. ki flan arasnda kardan karya saplamalar arasnda
sklarak monte edilir. (Bak. Figr A)
* Its design meets API 594 which is

approximately one fourth the face to face dimension and 15% to 20% the weight, on
most popular sizes, making them less expensive than a swing check valve.
API 594 e uygun, yzeyden yzeye uzunluun yaklak 1/4 olmas ve arln %15 ve %20
arasnda daha az olmas, bu vanalar yzer tip ek vanalardan daha ucuz yapar.

* It is much easier to install between standard gaskets and line flanges

Standart contalar ve hat flanlar arasnda kurulum yapmak daha kolaydr.

* The savings compund during installation due to ease of handling and only one set of flange studs

is required.Therefore, it is more cost effective to install, and also to maintain

Kullanm kolayl nedeniyle kurulum srasnda tasarruf salar ve sadece bir set flan saplama
gereklidir. Bu nedenle kurulum ve bakm iin daha az maliyet yaratr.

Eye Bolt (3f)

Body (1)

O-Ring (2c)

Disc (3)

Body Seatring (2)

Spring (3d)

Disc Pin (3b)

Seatring Bolt

Stopper Pin (3c)

Plug (3e)

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VA-IM-40D-3R0
1.6 OPERATION / LETME

The only moving parts in the valve are the discs and spring. The discs and spring are guided in the body
with a hinge pin and a full open disc stop pin. The pins are restrained in the body stabilization to
prevent vibration. The body also has a resilient seat for drop tight shut of
Valf iindeki hareketli paralar sadece disc (3) ve yaydr (3d). Disk ve yay, gvde iindeki bir mentee
pimi ve tam ak pozisyonda diski durdurma pimi ile yataklanmtr. Pimler gvde iindeki titreimi
nlemek iin sabitlenmitir.Gvde iinde szdrmaz kapama salamak iin bir seat (2) vardr.

1.7 INSTALLATION / KURULUM

The installation of the valve is important for its proper operation. The flow arrow on the valve body or
name plate must point in the direction of flow when the system is in operation. The valve is can be
installed in horizontal or vertical lines with the flow up.
Valfin dzgn almas iin kurulumu nemlidir. Valfin ak yn, etiket zerinde veya gvde zerinde
ak oku ile belirtilmitir. Valf hatta ak ynnde dikey yada yatay pozisyonda balanabilir.

Remove the valve from carton or packing box.

Valf karton kutusundan yada ambalajndan kartlr.

The protective rust proof coating on the internal parts of steel or cast iron valves should be
removed by brushing out with any standard petroleum solvent and air dry
elik veya demir dkm vanalarn i paralarndaki pas nleyici kaplama, herhangi bir petrol
zc ve kuru havayla dar doru fralanp temizlenmelidir.

Stainless Steel or Bronze valves need only to be wiped clean and installed.
Paslanmaz elik veya bronz valflerin sadece silinip temizlenmesi ve kurulmas yeterlidir.

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VA-IM-40D-3R0

ID

1.8 DIMENSIONS / LLER

DN

D
mm

ID
mm

150#

L
mm
300#

600#

mm

mm

mm

Cv

Kv

E
mm

2"

102

49

60

60

60

40

34

3"

133

74

73

73

73

130

110

15

4"

171

100

73

73

79

270

130

35

6"

219

150

98

98

137

670

570

40

8"

276

201

127

127

165

1450

1200

40

10"

336

252

146

146

213

2700

1300

60

12"

406

303

181

181

229

3900

3300

65

14"

447

334

184

222

273

5000

4200

85

16"

511

385

191

232

305

7000

5900

100

18"

546

436

203

264

362

10000

8500

115

20"

603

487

219

292

368

14000

11900

155

24"

714

589

222

318

438

27000

23000

210

30"

878

735

303

368

505

40000

34000

275

36"

938

779

368

478

635

45000

37000

300

42"

1215

1020

432

568

701

72000

61000

400

48"

1380

1166

524

630

787

152000

130000

425

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VA-IM-E40D.3R0

FIGURE A
Dual Disc Check
Valve

 In horizontal flow installation, the hinge pin

must be vertical.
Yatay ak kurulumunda, mentee pimi aka
dik olmaldr.

Pipeline


FIGURE B

Hook

Lifting
Eye

Lower valve between mating flange using

slings or chains around the valve
body.(Figure A-B)
Valf, zincir veya sapan kullanlarak kar
flanlar arasna indirilir. .(Figure A-B)
Lifting eye is used if the valves are over 30
kg or 10".
10" veya 30kg st valflerde mapa
kullanlr.

Chain

 The valves have a tapped hole

for insetion of a lifting eye if need.(Figure B)

Eer gerekliyse mapa iin bir delik almaldr.
(Figure B)

Gasket

 Place gaskets on flange faces.(Figure C)

Contalar flan yzeylerine yerletirilir.
(Figure C)
Gasket

Plug

FIGURE C

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b


VA-IM-40D-3R0

Lubricate the flange bolts or studs and

insert them around the flange (Figure D)
Flan civatalarn yada saplamalar yalayn
ve flan etrafna takn(Figr D)

FIGURE D

Lightly turn bolts or nuts

until gaps are eliminated. (Figure E)
Saplama yada somunlar hafife evirin
ve boluunu aln. (Figr E)

FIGURE E

The tightening of the bolts should then be done in graduated steps

using the cross-over tightening method.(Figure F)
Civatalarn sklmas, karlkl skma metodu kullanlarak
kademeli olarak yaplmaldr. (Figr F)

FIGURE F


Recommended lubricated torques for use with flange bolt are given in table 1
Esnek conta ile kullanmda tavsiye edilen civatalarn tork deerleri tablo 1 de verilmitir.

1.9 Table 1 FLANGE BOLT TORQUES / Tablo 1. FLAN CVATA TORKLARI

Size (inch)

Torque (Nm)

Size (inch)

Torque (Nm)

1/2
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
1 5/8
1 3/4

61
117
203
324
489
708
984
1323
1731
2217
2785

2
2 1/4
2 1/2
2 5/8
2 3/4
3
3 1/4
3 3/4
3 7/8
4
4 1/2

4193
6013
8292
9622
11085
14443
18419
28427
30157
34565
49367

1 7/8

3441

4 3/4

58135

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VA-IM-40D-3R0

If leakage occurs, allow gaskets to absorb fluid and check torque and leakage after 24 hours
Eer kaak oluursa, contalarn akkan emmesine izin verin ve 24 saat sonra tork ve kaa
kontrol edin.

Do not exceed bolt rating or crush gasket more than 50 percent of its thickness
Civatalar gereinden fazla skmayn yada contay kalnlnn %50 sinden fazla ezmeyin.

1.10 MAINTENANCE / BAKIM

CAUTION: Make sure the valve is not under pressure before starting any maintenance
UYARI: Herhangi bir bakma balamadan nce vanann basn altnda olmadndan emin
olun.

Periodic inspection for leakage can be performed by listening for leakage noise from the valve
while the pump is shut down or is used ultrasonic detector.
Periyodik sznt kontrol, pompa kapal iken vanadaki sznt sesinin dinlenmesi ile yaplabilir veya
ultrasonik dedektrler kullanlr.

If leakage is heard, drain the pipeline, remove the valve, and inspect the seating, surfaces for wear
or damage. If the resilient seat is damaged, replace the valve (seat and disc) or return the valve to
the factory for service.
Eer kaak sesi duyulursa, hat boaltlr, valf sklr ve anma yada hasar iin seatler ve yzeyler
muayene edilir. Eer esnek seat yzeyleri hasar grm ise valf (seat ve disc) deitirilir veya
servis iin fabrikaya gtrlr.

1.11 TROUBLESHOOTING GUIDE / SORUN GDERME REHBER

Several problems and solutions are presented below to asist you in trouble shooting the valve
assembly in an efficient manner.
Verimli ekilde vana arzalarn gidermede size yardmc olmas iin baz sorunlar ve zmleri
aada verilmitir.

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b
1.

VA-IM-40D-3R0

Valve Leakage:
Valf Kaa:
Check gaskets and flange bolt torque for flange leakage. Drain line, remove valve, and inspect
seating surfaces.
Flan kaa iin contalar ve flan cvata torklarn kontrol edin.Hatt boaltn ve seat yzeylerini
kontrol edin.

2.

Valve Does Not Pass Flow:

Vanadan Ak Gemiyor:
Check flow arrow direction on valve body. Verify that downstream isolation valve is open and
there is no line blockage downstream.
Vana zerindeki ak ok ynn kontrol ediniz. zolasyon valfinin ak olduunu ve hatta blokaj
olmadn dorulayn.

3.

Valve Slams:
Valfin arparak Kapanmas:
Remove valve and inspect spring. Heavier springs can be furnished for severe high-head
applications. Consult to VASTAS if the valve is installed in a vertical pipe with the flow downward.
Valfi skn ve yaylar kontrol edin. Kuvvetli uygulamalar iin daha ar yaylar kullanlabilir. Eer
valf aaya akl dikey bir boruya monte edilmise VASTA'a bavurunuz.

1.12 DISASSEMBLY/SKME

Remove the valve from the pipeline. 10" and larger valves have threaded holes for insertion of
and eye bolt (3f). Lay valve on flat surface or bench with the flow arrow facing upwards
Valfi hattan skn. 10" ve daha byk valflerde kaldrma ve tama mapasn kullann (3f). iin
dili delik almaldr. Vanay dz yzeyinin zerine yada ak yn yukarya gelecek ekilde
tezgaha yatrn.

Remove the plugs (3e) from the valve. 36" and larger valves have a thrust collar which must be
the removed prior to driving out the pins.
Tapalar (3e) skn. 36" ve daha byk vanalarda ncelikle skma bilezii sklp pin dar
kartlmaldr.

Drive out the pins (3b) with a round bar or punch while pressing down on the spring (3d) to
prevent it from unwinding. Valve 18" and larger have 2 springs and require extreme care to
prevent rapid uncoiling of the spring during disassembly.
Yaylarn gevemesini nlemek iin yayn (3d) zerine bastrrken, yuvarlak bir ubuk veya el ile
pini (3b) darya doru kartn. 18" ve daha byk valflerde 2 adet yay vardr ve skm ilemi
srasnda yayn zlmesini nlemek iin ok dikkatli davranmak gerekir.

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VA-IM-40D-3R0

Lift disc from body. Inspect pins and seating surfaces for wear. The shaft diameter is normally about 1/16"
smaller in diameter than the hole in the disc lugs. Some minor dents and discoloration are normal. Wear
areas in the resilient seat will cause leakage and require valve replacement or service at the VASTAS.
Diskleri gvdeden kaldrn.Pin ve seat yzeylerindeki anmay kontrol edin. Mil ap normalde, disk
kulaklarndaki delik aplarndan 1/16" daha kktr. Baz kk ezikler ve solmalar normaldir. Seat
yzeylerdeki anan ksmlar kaaa neden olur ve valfin deitirilmesi yada VASTA' a onarma getirilmesi
gerekebilir.

Remove spring and check for wear or cracks.

Yaylarn zerindeki anma yada atlaklar kontrol edin.

Remove bearings and inspect for wear.

Tayclar kartn ve anmalar kontrol edin.

Remove pins of the body ring.Drive out the pins from body. Inspect for wear on the ring surfaces. Remove
slowly o-ring on the body. Inspect for wear and cracks in the o-ring hole and o-ring.
Gvde ringinin pimlerini kartn.Ringi gvdenin dna aln. Ring yzeyindeki anmalar kontrol edin. Gvde
zerindeki oringi yavaca kartn. Oring yuvasndaki ve oringde ki anmay ve atlamalar muayene edin.

1.13 REASSEMBLY/ TEKRAR MONTAJ

All parts must be clean and the gasket surfaces should be cleaned with a stiff wire brush in the direction of
the serrations or machine marks. Worn parts, gaskets, and seals should be replaced during reassembly.
Btn paralar temiz olmal ve conta yzeyleri sert bir fra ile trtklar yada ileme izleri ynnde
fralanmaldr. Anm paralar, contalar ve szdrmazlk elemanlar tekrar montaj srasnda
deitirilmelidir.

Firstly put o-rings to o-rings hole on the body seatring.Place seatring into the body.Later lay body on flat
surface with arrow facing upwards. Carefully place the two discs with the machined sealing surfaces down
on the body sealing surface. Align the disc lugs with the pin holes in the body
lk nce o-ringleri gvde seatring zerindeki o-ring yuvalarna takn. Seatringi gvdenin iine yerletirin. Daha
sonra gvdeyi ak yn yukar bakacak ekilde dz yzeyinin zerine koyun Gvdede ki szdrmazlk
yzeylerine, ilenmi szdrmazlk elemanlarn 2 adet disk ile dikkatlice yerletirin. Gvdedeki pim
delikleriyle disk kulakklarn hizalayn.

Insert the disc hinge pin into the hole on one side of the body, but not through the disc lugs. Install a thrust
bearing between the inside diameter of the body and the disc lug. Push the disc hinge pin further to engage
the first disc lug.
Gvdenin bir kenarndaki delie disk mentee pimini sokun fakat disk kulakklarndan geirmeyin. Gvde i
apyla disk kulakklar arasna tayc pimi yerletirin.lk disk kulakn tutana kadar disk mentee pimini
ileri ittirin.

Install the second thrust bearing between the first and second disc lugs and push the pin further to engage
the second disc lug.
Birinci ve ikinci disk kulakklar arasna ikinci tayc ringi takn ve ikinci disk kulakn geirmek iin pimi
ileri itin.

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VA-IM-40D-3R0

While holding the torsion spring with one of the ends facing you, wind the rear tab 180 degrees in a
clockwise direction and then press the spring between the two sets of disc lugs. Engage the pin further to
retain the spring and the third disc lug. The legs of the spring should apply a downward force on the disc .
Ular size bakacak ekilde torsiyon yayn tutarken arka ucunu saat ynnde 180 derece evirerek kurun
ve sonra iki set disk kulakklarnn arasna yay bastrn. 3. disk kulakn ve yay tutmak iin pimi ileri
ekin. Yay bacaklar disk zerinde aa ynl bir kuvvet uygulamaldr.

Note: 18" and larger valves have 2 springs and require extreme care to pervent rapid recoiling of the
springs. Restrain the spring during assmebly with boards and clamps.
Not: 18" ve daha byk vanalarda 2 adet yay kullanlmaktadr ve yaylarn birden sarmasn nlemek iin
ok dikkatli davranmak gerekir. Montaj srasnda yaylar pense ile skca tutun.

While pushing the pin further, install the third thrust bearing and the fourth disc lug, and the fourth thrust
bearing. The pin should now be centered in the body and disc should rotate without binding.
Pimi ileri iterken,nc bask taycy, drdnc disk kulakn ve drdnc bask taycy takn. Pim
gvde merkezinde olmal ve disk tutucu olmadan dnebilmelidir.

Insert the disc stop pin into the holes in the body.
Gvdede ki deliin iine disk durdurma pimini takn

Insert a graphite gasket into each of the six pin holes. 48" and larger valves have rubber washers instead
of graphite.
Alt deliinin herbirine grafit conta takn. 48" ve daha byk vanalarda grafit yerine kauuk pullar
kullanlabilir.

Stand the valve on its edge with the eye bolt vertical and verify smooth operation of the valve before
installation into the pipeline. Apply a light coat of silicone grease on the rubber seat for air sevice valves.
Mapa ile birlikte vanay hatta balayn boru hattna kurulumdan nce valfin dzgn altn
dorulayn.Gaz uygulamalar iin kauuk seatin zerine ince bir silikon ya kaplamas uygulayn.

1.14 SPARE PART and SERVICE / YEDEK PARA ve SERVS

SPARE & REPAIR

PARTS

Parts and service are available from your local representative or the factory. Make note of the valve size
and figure number located on the valve and contact with VASTAS
Paralar ve servis yerel temsilcimizde veya fabrikamzda mevcuttur. Valf zerindeki lsn ve model
numarasn not alp VASTAS ile iletiime geiniz.
Part No

Part Name

Spare Part

Repair Part

2
2c
3
3b
3c
3d
3e

Body Seatring
O-Ring
Disc
Disc Pin
Stoper Pin
Spring
Plug



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1.15 REVSON HSTORY/ REVZYON TARHES

Effective Date
Rev. No
2R0
3R0

06.08.2012
30.08.2013

Description
First Edition / lk Bask
New language added / Yeni dil eklendi
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