Page 1: Table Of Contents
INSTALLATION, OPERATION AND MAINTENANCE MANUAL AOP SERIES D TRUNNION BALL VALVE, 2”FP – 6”RP CONTENTS 1. Parts list……………………... 2. Description……..…………… 3. Safety information’s…….……… 4. Installation and storing… 5. Operation …….……… 6. Maintenance…………………. 7. D valve Reconditioning……… 7.1 D valve disassembly……….
Page 2 Figure 1 – D Series-Standard Seat (class 150-900) – BARE STEM (see parts list below) IOM-BLV-D-006 REV.01 PAGE 2 of 21...
Page 3: Parts List
Parts list – D Series Standard Seat 150-900 class– BARE STEM (reference Figure 1): Item Description BODY ADAPTER- CLOSURE BALL STEM LOWER TRUNNION SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT) BONNET (GLAND PLATE) ADAPTER PLATE- GEAR ADAPTER STUDS ADAPTER NUTS...
Page 4 Figure 2 – D Series-Standard Seat (class 150-900) – LEVER OPERATED (see parts list below) IOM-BLV-D-006 REV.01 PAGE 4 of 21...
Page 5 Parts list – D Series Standard Seat 150-900 class– LEVER OPERATED (reference Figure 2): Item Description BODY ADAPTER- CLOSURE BALL STEM LOWER TRUNNION SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT) BONNET (GLAND PLATE) LOCKING BEARING HOUSING FOR 2FP UP 4RP VALVES —OR...
Page 6 Figure 3:D Series Bare Stem Valve – Lubricated Seat - 1500 Class IOM-BLV-D-006 REV.01 PAGE 6 of 21...
Page 7 Parts list: D Series Lubricated Seat 1500 class– BARE STEM (reference Figure 3): Item Description BODY ADAPTER- CLOSURE BALL STEM TRUNNION SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT) BONNET (GLAND PLATE) TRUNNION COVER GEAR PLATE ADAPTER STUDS ADAPTER NUTS CAP SCREW SOCKET HEAD- BONNET...
Page 8 Figure 4 – D Series Lever Operated Valve – Lubricated Seats – 1500 Class IOM-BLV-D-006 REV.01 PAGE 8 of 21...
Page 9 Parts list – D Series Lubricated Seat 1500 class– LEVER OPERATED (reference Figure 4): Item Description BODY ADAPTER- CLOSURE BALL STEM TRUNNION SEAT SUBASSEMBLY (SEAT RING + SEAT INSERT) BONNET (GLAND PLATE) TRUNNION COVER LOCKING BEARING HOUSING FOR 2FP UP 4RP VALVES —OR...
Page 10: Description
2. Description D series ball valves 2” FP to 6” RP are full bore, through conduit, bi-directional, anti-blowout stem, double block and bleed with trunnion mounted ball for easy operation. These valves are equipped with seats with plastic insert; self relieve type seats to eliminate cavity pressure lock.
Page 11 After welding, clean and check the weld bead and repair as required. AOP D valves may be installed in any position with either end facing upstream. The valve should be installed in such a way as to facilitate maintenance and actuating operations.
Page 12: Operation
5. Operation D series ball valves only work in the fully closed or fully open position; these valves work for on/off service only. WARNING: These valves shall never be operated partially open or partially closed. Throttling (partial opening) or “pinching” flow may cause non-uniform wear on seats and ball over the sealing surfaces where it is exposed to the flow line, preventing tight shut-off.
Page 13 If necessary use a backup wrench to prevent the fitting body from unscrewing. 6.2. Lubrication- Grease injection The D series valves have been designed and tested in such a way that they do not require the use of lubricating or sealing grease during their normal service operation.
Page 14: D Valve Reconditioning
LUBCHEM INC: P.O. BOX 2626, Spring, TX 77383; 281/350-9600 7. D series valve Reconditioning The D series valves can be rebuilt if it is necessary. The disassembly and reassembly of the valve require proper lifting equipment and normal maintenance tools.
Page 15 10. Remove the trunnion O-ring from the trunnion groove and the lower trunnion fire safe seal from its housing in the body. 11. Remove the body stud nuts or, for the studded ends valve, the body capscrews. 12. Lift the closure off the body paying attention not to damage the soft seals. 13.
Page 16: Lever Valve Assembly
7.2. Assembly the D series valve 7.2.a. Assembling a Lever Operated Valve After inspecting the parts and getting the new replacement parts as required, follow the next steps: Place the body on the flange on a clean, solid surface so it will hold the weight of the assembled valve securely.
Page 17 Wrap all the external fittings thread with Teflon tape. Note: The hole in the drain fitting should not be covered with tape. Place the spring washers into the body and closure, so that the outside of the washer is facing down and away from the assembler. Note: Lubricated seat valves use a wave spring which is not directional.
Page 18 Fig.6 Fig.7 Insert the gland plate (bonnet) cap screws into their threads on the body and tighten them evenly. The cap screws will need to be torqued, please refer to the table 2 for the correct torque. The gland plate and trunnion vent/drain and the body grease fitting should be installed at this time.
Page 19: Gear Valve Assembly
Before sliding the operator completely against the plate adapter check the position of the hand wheel shaft, on all D series valves the shaft will be to the top right (right handed gear) when the valve is in horizontal position. The shaft will always be at 90 degrees from the centerline of the valve toward the fitting side of the body.
Page 20 Fig.8 After setting the closed stop, a quick check should be made to ensure that it has been correctly set. This is accomplished by turning the hand wheel shaft several turns towards the open position, and then returning it until the closed stop is contacted. The keyway will be at a 90 degree angle to the flow bore.
Page 21: Troubleshooting
Trash into the fitting trash Tighten safety cap or replace fitting Damaged fitting WARNING: never remove the entire fitting with the valve under pressure *Contact AOP representative for proper trim selection for the required application IOM-BLV-D-006 REV.01 PAGE 21 of 21...