INSTALLATION & MAINTENANCE MANUAL

CONCENTRIC BUTTERFLY VALVE

AV - C Series

ACE VALVE CO., LTD.

1-12, Somang-gil, Juchon, Gimhae, GyeongNam, Korea
Tel : +82-55-310-8000, Fax : +82-55-329-0657
E-mail : [email protected]

PAGE 22
 INDEX
1. FORWARD

2. STORAGE

3. LIFTING AND TRANSPORTATION

4. INSTALLATION INSTRUCTIONS

5. CORRECT INSTALLATION

6. THE DISASSEMBLY PROCEDURE OF CONCENTRIC BUTTERFLY VALVE

7. THE ASSEMBLY PROCEDURE OF CONCENTRIC BUTTERFLY VALVE

8. TROUBLE SHOOTING

9. CONCENTRIC BUTTERFLY VALVE CONSTRUCTION

PAGE 23
1. FORWARD
Design philosophies of ACE VALVE have concentrated in reliability and safety being of principle

importance to all modern process industries.

ACE VALVE type 'AV-C Series' concentric butterfly valve shall be capable of bi-directional flow and

provide bubble tight shut-off at full rated pressure.

Long life durability is achieved with the ball shape seat and flat edge disc which minimizes seat

compression, wear, unexpected movement of the disc at closed position.

In addition, the valve is designed with following technical features

1. The face to face dimensions are provided in accordance with ISO5752, KS V7490, JIS B2032

JIS F7480 and API 609 standard.

2. Provisions to connect with actuator are provided in accordance with ISO standard.

3. Spherical shape of seat ring is adopted to avoid unexpected movement of disc when closed

4. Three point grooves are provided in the seat ring design for good fastening to the body.

5. Sealings in way of shaft are provided in three positions.

6. Taper pin is adopted to fix the disc at the shaft.

7. The through shaft in way of the disc is provided to reinforce strengthening of disc.

8. The parts are interchangeable for easy maintenance.

These excellent design features are complemented by ACE VALVE established quality assurance

system duly approved by major end users.

Although it is possible to carry out on-site maintenance of this type of valve, it is recommended

that the valves are serviced at : -

ACE VALVE COMPANY LIMITED.

1-12, Somang-gil, Juchon, Gimhae, GyeongNam, Korea

Tel : +82-55-310-8000

Fax. : +82-55-329-0657

E-mail : [email protected]

PAGE 24
2. STORAGE
■ Be careful not to get a scratch on Disc edge and Seat ring.

The openings must be protected by plywood or other things

when carrying valve.

■ Valve must not be shocked and shaken too much.

(It may cause the crack of neck, lever, handle and body)

■ Valve must be protected from sunlight.

■ Valve to be kept and transported under partially opened.

■ The suitable temperature from -10℃ to 70℃ and humidity between

10%~60% to be maintained.

■ During valve storage, check the smooth operation once per month.

3. LIFTING & TRANSPORTATION

■ The Valves shall not be lifted by operator or handwheel.

■ When the valves shall be installed with horizontal shaft ;

- A flexible strap around the neck of the valve and if possible also around the bottom of the valve.

If not possible to fasten around the bottom, a flexible strap is used in one of the free hole for

flange drilling.

■ When the valves shall be installed with vertical shaft and operator shall be upwards ;

- A flexible strap is used around the neck of the valve.

■ When the valves shall be installed with vertical shaft and operator shall be downwards ;

- The Valve to be lifted by flexible strap in the free holes for flange drilling.

4. INSTALLATION INSTRUCTIONS
General
■ Valves can be installed in the pipeline in any position.

■ Before installation, the valve and pipeline interior must be sufficiently cleaned from dirt

and foreign particles like a welding residues etc., otherwise seat may be damaged.

■ To ensure no interference between the disc and pipings against thick pipe wall, Lined or coated

pipe, derect connection with strainer or equipment etc.,

■ The pipeline must be free from tension and electric current.

■ When handling valves, be careful to avoid touch or impact by other equipments, construction

walls.

PAGE 25
■ To ensure valve seat/disc surface as well as mating flange are all clean.

■ Tighten again, if any, all bolts loosened during transport and/or handling.

■ Open and close valves to check for smooth operation.

■ Do not use valve as a fulcrum of jack for piping alignment.

■ The length of connecting pipe with valve should be free from such excessive load which may cause

serious bending damage of the valve.

■ Do not carry out welding work around the valve under valve installed condition.

Installation of wafer type butterfly valve in the existing pipe

■ Verify the distance permitting installation of valve freely between two flanges by using

flange spreader, if any.

■ Insert at least two flange-bolts in the lower part of flanges.

■ Close valve disc but partially open so that disc edge is positioned at least 10mm inside

the body.

■ Put the valve in the designated position between flanges. Valve will be held by the two

flange-bolts previously fitted in the lower part of flanges.

■ Insert the flange-bolt through centering lugs of valve.

■ Insert the remaining flange-bolts and tighten bolts partially.

■ Ensure the valve is correctly aligned, remove flange spreaders carefully and tighten

bolts partially.

■ Check open and close of valve for easy and smooth operation.

■ Open the valve completely and tighten the bolts diagonally with adequate torque.

Installation procedure of lug type butterfly valves is the same that of wafer type except

using studs instead of flange bolts and nuts.

Installation of butterfly valve in the new pipeline

■ Align the connecting pipe with the valve in the designated position.

■ And then, Install the valve as per the installation instruction in the existing pipeline.

PAGE 26
5. CORRECT INSTALLATION
Correct Installation Incorrect Installation

1.1.Spread
Spreadflange enough
flange to allow
enough to allow
the
thevalve installation
valves with discwithindisc
semi-
in partly position.
closed opened position.
This
Thisprevents
preventsthe the
damage
damageof discofand
seat
discduring installation
and seat duringand reduces
installation
initial torque. initial torque.
and reduces

2. It is not recommended to apply

2.gaskets
It is recommended
because the seat flange
act
gaskets
gaskets are not be provided.
as well.

3. Insert two bolts at the low

part of bottom pipe flange to rest
3.valve
Insert bolts
during through the two bottom
installation.
pipe
Disc flange
should holes
not be in to
fullrest
openvalves on
duringafter
position installation.
flange alignment
and before evenly tightening
flnage bolts.

4. Tighten the flange bolts

4.inTighten
the diagonal
the positions and evenly to
flange bolts
evenly to prevent
prevent the leakage
the leakage between
between flange
flange
and and valve.
valve.

5/8

PAGE 27
6. The disassembly procedure of concentric butterfly valve
Caution
Do not attempt to remove an actuator from the valve being serviced under pressure.

Ensure that the valves at just upstream and downstream are closed or isolated(in due turn)

and then, remove the actuator.

■ Turn the disc② to the nearly closed position. Loosen and remove all flange bolting.

Spread the flange if necessary and remove the valve from the pipeline.

■ Turn the disc② to the almost open position. Remove the actuator if still mounted.

■ Remove the disc pins⑤ from the disc②.

■ Remove the packing gland⑦.

■ Remove the stem④ by pulling it out through the valve top plate.

■ Remove the disc② from the valve body① by pulling or rolling out the disc from the body.

■ Remove the seat③ by stripping out from both seat edges at one point. Collapse the seat③ in

shape of a round bottom heart and pull the seat out from the body bore.

■ If needed, remove the o-ring⑥ and inspect for damage. Replace it if necessary.

7. The assembly procedure of concentric butterfly valve

■ Clean all reusable parts by using silicone base oil or lubricant.

■ Install bearing bush⑨ into the valve body. (2pc for upper part and 1pc for lower part respectively.)

■ Collapse the valve seat③ in shape with round bottom heart configuration. Firmly place

the "bottom" part of the seat③ into position carefully with attention to make an alignment

with the lower stem holes. Hear the snap of the seat into position within the body① and

check all stem holes for proper alignment.

■ Install disc② into the valve seat③ with taper disc pin holes toward the valve top plate and align

stem holes.

■ Install the stem④ by downward rotary motion carefully not to cut or tear the seat

due to misalignment of the stem holes.

■ Install packing o-ring⑥.

■ Install packing gland⑦ and tighten fixing screws.

■ Install bottom cover⑪ with o-ring⑩ (for ND 400A and over size only.)

■ Align taper disc pin holes in the disc② and the stem④ and install taper disc pin and tighten

securely.

PAGE 28
 8. TROUBLE SHOOTING
SYMPTOM PROBABLE CAUSE SOLUTION

Valve opens only a few

Improper installation. Loosen the flange bolts. Realign
degrees and stops
The valve is improperly the valve with flanges. And retighten
(It will not open to the
aligned. the flange bolts with correct torque.
full angle desired.)

1. Flange bolts are not 1. Loosen the flange bolts and

evenly tightened. tighten the flange bolts with correct
Leakage from the flange
torque.
face
2. Improper flanges. 2. Replace flange.

The disc is not closed fully

1. Refer to actuator adjustment
1. Actuator is not properly
procedures.
set.
2. Replace seat.
Leakage in way of disc 2. Damaged seat.
(Passing in the pipeline)
3. Reduce line pressure to valve
3. Line pressure exceeds
working pressure.
valve's working pressure
4. Replace disc.
4. Damaged valve disc.

Leakage at the valve stem Packing/bushing failure Refer to valve disassembly procedure

Improper operation time of

Water hammer Adjust the valve operation time.
the valve

1. Remove valve from pipeline and

remove obstruction.
1. Obstruction in the
pipeline
2. Return valve to factory for
disc / stem replacement.
(Check for water hammer or
Excessively high torque 2. Valve stem or disc bent.
freezing of line material)

3. Open and close the valve several

3. Foreign Particle Stuck
times. Operate the valve at least
on stem or seat.
once a month. Check the valve
seat for deterioration.

PAGE 29
9. CONCENTRIC BUTTERFLY VALVE CONSTRUCTION

P.NO. PART NAME REMARK

1 BODY

2 DISC

3 SEAT

4 STEM

5 DISC PIN

6 O-RING

7 PACKING GLAND

8 GLAND BOLT

9 BEARING BUSH

10 O-RING 400A & OVER

11 BOTTOM COVER 400A & OVER

12 BOLT & WASHER 400A & OVER

PAGE 30
 INSTALLATION & MAINTENANCE MANUAL

Double Eccentric High Performance type Butterfly Valve

AV - H & F Series

ACE VALVE CO., LTD.

1-12, Somang-gil, Juchon, Gimhae, GyeongNam, Korea
Tel : +82-55-310-8000, Fax : +82-55-329-0657
E-mail : [email protected]

PAGE 31
 INDEX

1. FORWARD

2. STORAGE

3. LIFTING AND TRANSPORTATION

4. INSTALLATION INSTRUCTIONS

5. CORRECT INSTALLATION

6. MAINTENANCE

7. TROUBLE SHOOTING

8. HIGH PERFORMANCE BUTTERFLY VALVE CONSTRUCTION

PAGE 32
1. FORWARD
Design philosophies of ACE VALVE have concentrated in reliability and safety being of principle

importance to all modern process industries.

ACE VALVE type 'AV-H & F Series' high performance butterfly valve shall be capable of

bi-directional flow and provide bubble tight shut-off at full rated pressure.

Long life durability is achieved with the double offset operating principle which minimizes seat

wear.

● The high-performance valve is designed with following technical features

1. The face to face dimensions are provided in accordance with API 609.

2. Provisions to connect with actuator are provided in accordance with ISO standard.

3. It is designed to adopt a specially self energized spring supported teflon seat.

4. The retainer and seat is positioned without any other interruption from mating flange etc.,

5. The continuous single stem is adopted.

6. The shaft seal packing is fixed with Gland bush independently.

7. The stem packing can be adjusted without removal of actuator.

8. The parts are interchangeable for easy maintenance.

These excellent design features are complemented by ACE VALVE established quality assurance

system duly approved by major end users.

Although it is possible to carry out on-site maintenance of this type of valve, it is recommended

that the valves are serviced at : -

ACE VALVE COMPANY LIMITED.

1-12, Somang-gil, Juchon, Gimhae, GyeongNam, Korea

Tel : +82-55-310-8000

Fax. : +82-55-329-0657

E-mail : [email protected]

PAGE 33
2. STORAGE
■ Be careful not to get a scratch on Disc edge and Seat ring.

The openings must be protected by plywood or other things

when carrying valve.

■ Valve must not be shocked and shaken too much.

(It may cause the crack of neck, lever, handle and body)

■ Valve to be kept and transported under partially opened.

■ The suitable temperature from -10℃ to 70℃ and humidity between

10%~60% to be maintained.

■ During valve storage, check the smooth operation once per month.

3. LIFTING & TRANSPORTATION

■ The Valves shall not be lifted by operator or handwheel.

■ When the valves shall be installed with horizontal shaft ;

- A flexible strap around the neck of the valve and if possible also around the bottom of the valve.

If not possible to fasten around the bottom, a flexible strap is used in one of the free hole for

flange drilling.

■ When the valves shall be installed with vertical shaft and operator shall be upwards ;

- A flexible strap is used around the neck of the valve.

■ When the valves shall be installed with vertical shaft and operator shall be downwards ;

- The Valve is lifted by flexible strap in the free holes flange drilling.

4. INSTALLATION INSTRUCTIONS
General
■ Valves can be installed in the pipeline in any position.

■ Before installation, the valve and pipeline interior must be sufficiently cleaned from dirt

and foreign particles like a welding residues etc., otherwise seat may be damaged.

■ To ensure no interference between the disc and pipings against thick pipe wall, Lined or coated

pipe, derect connection with strainer or equipment etc.,

■ The pipeline must be free from tension and electric current.

■ When handling valves, be careful to avoid touch or impact by other equipments, construction

walls.

PAGE 34
■ To ensure valve seat/disc surface as well as mating flange are all clean.

■ Tighten again, if any, all bolts loosened during transport and/or handling.

■ Open and close valves to check for smooth operation.

■ Do not use valve as a fulcrum of jack for piping alignment.

■ The length of connecting pipe with valve should be free from such excessive load which may cause

serious bending damage of the valve.

■ Do not carry out welding work around the valve under valve installed condition.

Installation of wafer type butterfly valve in the existing pipe

■ Verify the distance permitting installation of valve freely between two flanges by using

flange spreader, if any.

■ Insert at least two flange-bolts in the lower part of flanges.

■ Close valve disc but partially open so that disc edge is positioned at least 10mm inside

the body.

■ Put the valve in the designated position between flanges. Valve will be held by the two

flange-bolts previously fitted in the lower part of flanges.

■ Insert the flange-bolt through centering lugs of valve.

■ Insert the remaining flange-bolts and tighten bolts partially.

■ Ensure the valve is correctly aligned, remove flange spreaders carefully and tighten

bolts partially.

■ Check open and close of valve for easy and smooth operation.

■ Open the valve completely and tighten the bolts diagonally with adequate torque.

Installation procedure of lug type butterfly valves is the same that of wafer type except

using studs instead of flange bolts and nuts.

Installation of butterfly valve in the new pipeline

■ Align the connecting pipe with the valve in the designated position.

■ And then, Install the valve as per the installation instruction in the existing pipeline.

PAGE 35
5. CORRECT INSTALLATION

Correct Installation Incorrect Installation

1.
1. Spread flangeenough
Spread flange enough to allow
to allow
the
the valves with discwith
valve installation in semi-
disc
closed position.
in partly opened position.
This prevents the damage of
This prevents the damage of
disc and seat during installation.
disc and seat during installation.

2. Flange gaskets should be

positioned aligned with valve bore.
2. Flange gaskets should may
Pipe misalignment be cause
positioned
interference betweenvalve
aligned with disc bore.
edge
Pipe
and misalignment
flange face, may cause
creating
leakage and
interference excessive
between torque
disc edge
to open
and flangevalve.
face, creating leakage
and excessive torque to open valve.

3. Inserttwo
3. Insert bolts through
bolts the two
at the low
part of bottom pipe flange to rest
bottom pipe flange holes
valves on during installation.
to rest valves during installation.
Disc should not be in full open
Disc should not be in full open
position after flange alignment
position after evenly
and before flange alignment
tightening
and before
flange evenly tightening
bolts.
flnage bolts.

1 6

8 4
4. Tightenthe
4. Tighten the flange
flange bolts evenly to
bolts
prevent the leakage
in the diagonal positionsbetween
and flange
3 7 and valve.
evenly to prevent the leakage
2
between flange and valve.
5

5/8

PAGE 36
6. MAINTENANCE
Caution
Before attempting any maintenance, ensure that the system has been depressurized and,

if necessary, drained of any dangerous fluid.

Replacement of Packing
If further adjustment of the packing⑫ is required, adopt the following procedure for

its removal and replacement.

■ Remove the operator (Lever, Gearbox or Actuator)

■ Remove actuator stand⑩.

■ Remove packing gland bolts / nuts㊷.

■ Remove packing gland⑦.

■ Remove gland ring⑧.

■ Remove packing⑫

■ Fit new packing⑫.

■ Refit gland ring⑧.

■ Refit packing gland⑦.

■ Refit gland bolts/nuts㊷ and tighten evenly until heavy resistance is felt.

Then, ensure smooth operation by turning the stem that the packing is not over tightened.

■ Refit actuator stand⑩.

■ Refit the operator.

Replacement of Seat
PTFE or RUBBER seated valves

■ Remove retainer bolt㊶.

■ Remove retainer⑥.

■ Remove PTFE or RUBBER seat③.

■ Ensure inside parts including seat ring sealing surfaces are clean.

■ Position the disc② in the closed position.

■ Refit new seat and components in reverse order shown in above. Then ensure smooth

operation by turning the operator.

PAGE 37
Fire Safe seated valves

■ Remove retainer bolt㊶.

■ Remove retainer⑥.

■ Remove Metal seat gasket(71).

■ Remove Metal seat(3.1).

■ Remove Metal seat gasket(71).

■ Remove seat③.

■ Ensure inside parts including seat ring sealing surfaces are clean.

■ Position the disc② in the closed position.

■ Refit new seat assembly(3,3-1,71) and components in reverse order shown in above.

Replacement of Shaft bearing

Removal

■ Remove the operator (Lever, Gearbox or Actuator)

■ Remove the packing⑫ according to replacement of packing procedure.

■ Remove seat assembly(3,3.1,71) according to replacement of seat procedure or

seat assembly may retained is situ to prevent accidental damage of seat assembly.

■ Remove bottom bolt㊸.

■ Remove bottom cover⑨.

■ Remove bottom gasket⑮.

■ Remove thrust plate⑬.

■ With the disc② in the fully open position and support the stem and disc not to fall or twist.

■ Remove the disc pins⑤ using a punch.

■ Remove the stem④ from the body①.

■ Remove the disc② toward opposite direction of the retainer position from the valve body①.

■ The stem bearings⑪ are now exposed and can be removed.

Refitting

■ Clean out bearing cavities and fit new stem bearings⑪.

■ Insert the disc② into the body① with the fully open position toward opposite direction of

the retainer position and the stem and disc not to fall or twist.

■ Refit the stem④.

■ Refit the disc pins⑤.

■ Refit thrust plate⑬.

■ Refit bottom gasket⑮.

PAGE 38
■ Refit bottom cover⑨.

■ Refit bottom bolt㊸.

■ Refit packing⑫ according to replacement of packing procedure.

■ Refit seat ring according to replacement of seat ring procedure.

■ Ensure smooth operation by turning the stem.

■ Refit the operator.

7. TROUBLE SHOOTING
SYMPTOM PROBABLE CAUSE SOLUTION

Valve opens only a few

Improper installation. Loosen the flange bolts. Realign
degrees and stops
The valve is improperly the valve with flanges. And retighten
(It will not open to the
aligned. the flange bolts with correct torque.
full angle desired.)

1. Flange bolts are not 1. Loosen the flange bolts and

evenly tightened. tighten the flange bolts with correct
Leakage from the flange
torque.
face
2. Improper flanges. 2. Replace flange.

The disc is not closed fully

1. Refer to actuator adjustment
1. Actuator is not properly
procedures.
set.
2. Replace seat.
Leakage in way of disc 2. Damaged seat.
(Passing in the pipeline)
3. Reduce line pressure to valve
3. Line pressure exceeds
working pressure.
valve's working pressure
4. Replace disc.
4. Damaged valve disc.

Refer to replacement of
Leakage in way of stem Packing/bushing failure
packing procedure.

Improper operation time

Water hammer Adjust the valve operation time.
of the valve.

1. Remove valve from pipeline and

1. Obstruction in the remove obstruction.
pipeline
2. Return valve to factory for
disc / stem replacement.
2. Valve stem or disc bent. (Check for water hammer or
Excessively high torque
freezing of line material)

3. Foreign particle stuck 3. Open and close the valve several

on stem or seat. times. Operate the valve at least
once a month. Check the valve
seat for deterioration.

PAGE 39
8. HIGH PERFORMANCE BUTTERFLY VALVE CONSTRUCTION

P.NO. PART NAME P.NO PART NAME

1 BODY 11 STEM BEARING

2 DISC 12 PACKING

3 SEAT 13 THRUST PALTE

3.1 METAL SEAT 15 BOTTOM GASKET

4 STEM 41 RETAINER BOLT

5 DISC PIN 42 PACKING GLAND BOLT

6 RETAINER 43 BOTTOM COVER BOLT

7 PACKING GLAND 71 METAL SEAT GASKET

8 GLAND RING

9 BOTTOM COVER

10 ACTUATOR STAND

PAGE 40