INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR INSTRUMENT ISOLATION VALVE

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1 PAGE : 01 OF 07 INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR INSTRUMENT ISOLATION VALVE PREPARED BY CHECKED BY APPROVED BY NAME M.Bhuvaneswari Y.Nesabalan M.Selvam DATE 22-Mar Nov Nov-2013

2 PAGE : 02 OF 07 TABLE OF CONTENTS Sl.No. DESCRIPTION PAGE NO. 1. GENERAL DESCRIPTION 3 2. VALVE PART NAMES 3. INSTALLATION 3.1 Installing the Valve 3.2 Connecting the Purge Ports. OPERATION.1 Operating the Valve. MAINTENANCE.1 Precautions.2 Replacing the Packing.3 Replacing the Seat Rings. Replacing the Ball. Replacement Parts. TRANSPORTATION AND STORAGE.1 Handling.2 Unpacking.3 Storage 7. TROUBLESHOOTING 8. RETURN REQUIREMENTS

3 PAGE : 03 OF GENERAL DESCRIPTION: The Instrument Isolation valve (IV) is a 1 ball valve that mounts to a 3 10# tapped flange on a tank, and a 3 10# flange attached to a pressure transmitter. This valve is a wafer type ball valve with two purge ports that can be used for purging the body cavity and fluid volume between the valve and the pressure transmitter. They assist in preventing product from hardening and interfering with operation of the valve or a transmitter. These purge ports are sealed with pressure tight pipe plugs at shipment. VALVE SHOWN IN OPEN POSITION VALVE SHOWN IN CLOSED POSITION

4 PAGE : 0 OF VALVE PARTS NAME : 1. BODY 2. BALL 3. RETAINER GASKET. SEAT RING. RETAINER RING. PACKING 7. GLAND NUT 8. STEM 9. NPT PLUG 10. LOCKOUT PIN 11. NAME PLATE 3. INSTALLATION: 3.1 INSTALLING THE VALVE : Install four /8 studs in the tapped holes in the tank flange While installing a gasket between the IV and the tank flange, push the IV assembly up against the gasket to trap the gasket between IV and the tank flange Tank flange thickness depends on Vessel diameter or wall thickness Allow the protruding 2 7/8 diameter pilot of the IV to enter the bore of the tank flange and allow the four /8 studs to pass through the mating 3/ holes in the IV Install /8 nuts on the four studs and tighten in a staggered sequence to compress the gasket trapped between the tank flange and the IV Install four /8 studs in the tapped holes in the IV Install the pressure transmitter and gasket on the open end of the IV and secure with four /8 nuts The nuts should be tightened in a staggered sequence /8 studs & nuts to be supplied by contractor installing the equipment /1 gaskets to be supplied by the contractor. 3.2 CONNECTING THE PURGE PORTS: Two purge ports are located in the IV. They are plugged and sealed at shipment with NPT pipe plugs. The two ports are Body purge connection and face purge connection.. OPERATION:.1 OPERATING THE VALVE:.1.1 To open the valve, turn the handle 90 degrees counter-clockwise..1.2 A lock nut is provided to limit the rotational travel of the handle..1.3 To close the valve, turn the handle 90 degrees clockwise..1. If it is desired to lock the valve in either the open or closed position, use the provided lockout pin.. MAINTENANCE:.1 PRECAUTIONS:.1.1 All procedures must be performed by qualified personnel..1.2 When the process fluid is hazardous, thermal (hot or cold), or corrosive, take extra Precautions..1.3 Employ the appropriate safety devices and be prepared to control a process media Link..1. Always wear protective clothing and equipment to safeguard the eyes, face, hands and skin from the particular fluid in the line.

5 PAGE : 0 OF 07.2 REPLACING THE PACKING:.2.1 Drain the tank..2.2 Loosen and remove the set screw (dog point) to remove the stem from the body..2.3 Loosen and remove the gland nut from the body to remove the packing (Teflon)..2. Remove the upper and lower packing (Teflon)..2. Clean all the metal parts using a suitable solvent and a non-abrasive cloth..2. Install the new packing (Teflon) by sliding it over the top of the body and allowing it to rest on the counter bore of the body..2.7 Install the Gland nut over the packing and allow it to rest on the upper packing..2.8 Install the Stem thru the gland nut..2.9 Install the set screw (dog point) to fix the stem in the body The stem may have to be turned for the tang to enter the slot..3 REPLACEING THE SEATS:.3.1 Drain the tank..3.2 Loosen and remove the four nuts connecting the transmitter to the IV and remove the transmitter and gasket..3.3 Using a spanner wrench, loosen and remove the retainer ring from the body..3. Remove the retainer ring gasket, Seat and Ball from the body..3. Clean all the metal parts using a suitable solvent and a non-abrasive cloth..3. Set the body on a horizontal surface with transmitter side resting down..3.7 Install the new Seats in the body then install the ball allowing the stem to engage the slot in the ball..3.8 Install the retainer gasket in the body..3.9 Using a spanner wrench, Thread the retainer into the body until it bottoms Tighten the retainer until it firmly seats on the body The valve is now assembled. Complete assembly to the tank using the installation instructions provided above.. REPLACING THE BALL:..1 Place the valve in partially open position...2 Clean the valve exterior and interior...3 Disassemble the valve... Disassemble the Retainer ring... Remove the Retainer gasket... Remove the Ball and Seat Rings...7 Replace the Ball and reassemble the valve.. REPLACEMENT PARTS: PARTS MATERIAL QUANTITY RETAINER GASKET TEFLON 1 SEAT RTFE 2 PACKING TEFLON 2

6 PAGE : 0 OF 07. TRANSPORTATION AND STORAGE:.1 HANDLING:.1.1 Use care when handling the product..1.2 Leave protective caps and covers on the product still installation..2 UNPACKING:.2.1 Inspect the package for damaged or missing items upon delivery..2.2 Note any damaged or missing items on the receipt and freight bill.3 STORAGE:.3.1 Check the valve is in open position..3.2 If you are not immediately installing the product, store it in a dry place with constant room temperature..3.3 Make sure the products are not stacked on one another..3. The protective caps provided during shipment should not be removed until installation. 7. TROUBLESHOOTING: SYMPTOM The Ball is locked or seat ring or the ball and stem are damaged. The connection between the Tank flange and valve is leaking. Packing is leaking. Valve dose not operate Ball is not closing fully. CAUSE Media Crystallization. Connection is too loose. Packing is too loose. Foreign matters in the ball valve. The ball and stem may deformed. SOLUTION Heat trace the valve. Tighten the nuts connection and again it continues to leak, then disassemble and inspect the valve. Tighten the Gland nut. Remove the foreign matter from the valve. Replace the ball and seat rings. 8. RETURN REQUIREMENTS: Ensure these requirements are met before you return the product to FLS: 8.1 Contact FLS for specific instruction on how to return the product. 8.2 Clean the valve of all hazardous material. 8.3 Obtain a return material authorization from the factory.

7 PAGE : 07 OF 07 In case of any clarification on product manual, contact us. M/s. FLOW LINK SYSTEMS (P) LTD #189, Uthupalayam, Avinashi Road, Arasur, Coimbatore , Tamil Nadu, India. Phone : Fax : sales@flowlink.net, marketing@flowlink.net Web : This Document is the soul property of Flow link systems (P) ltd. This document may not be reproduced or distributed without prior written permission from Flow Link Systems (P) Ltd. We reserve all rights.

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