Coreline 150 Gebrauchsanweisung
English
www.coreline.dk
Installation-Operation-Maintenance Manual
Fig.150
2pc Flanged Ball Valve
ATEX, CE, SIL and EU1935/2004 (European food approval) for Coreline ball valves.
EU1935/2004
SIL
Installation-Operation-Maintenance Manual
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Pipe cleaning
Foreign matters in the pipeline may damage the sealing surface of the valve or prevent the movement of the valve ball,
resulting in the valve not closing properly. In order to reduce the possibility of dangerous situations, all pipes need to be
cleaned before installing the valve. Check that pipe dirt, metal chips, welding slag and other foreign objects have been
removed. In addition, check the flange surface of the pipe to ensure that there is a smooth surface (If any cleaning
proces after the valve is installed in pipeline, the ball valve has to be in open position and must not be activated before
rinsing completed, to avoid damage of seat).
Valve installation
There shall be flange gasket on the flange surface when the valve is installed. It is recommended that the flange
installed with the valve meet the relevant standards.
□ Check that the pipes are in a straight line and the flanges are clean and parallel. Do not install the valve between two
non-parallel flange faces.
□ The distance between the flanges must correspond to the face to face dimension of the ball valve.
□ Carefully place the valve between the flanges. After the valve is aligned with the pipeline, then gently tighten the bolts,
and finally tighten them in a staggered order. Correct tightening can avoid uneven valve pressing force, prevent
leakage, and also help to avoid flange damage.
Fasteners used during the installation should comply with the laws, regulations and standards of the relevant countries.
Those which do not meet the requirements of the relevant regulations are strictly prohibited to use for the installation.
When tightening the flange bolts and nuts, a reasonable torque should be used according to the relevant regulations.
The following table lists the torque values for reference.
Operation instructions
□ The opening and closing of the valve is done by turning the handle a quarter turn (90° turn).
The valve handle is marked showing proper rotation direction for “ON” and “OFF” positions. Rotation is clockwise for
“OFF” (closed) and counterclockwise for “ON” (open).
- Valve in OPEN position: The handle is in line with the valve or pipeline.
- Valve in CLOSED position: The handle is across the pipeline.
Use and maintenance
The use of the valve shall be carried out in accordance with the instruction manual, and shall not exceed the design
parameters. The operator must go through on-the-job training to understand the basic operationprinciple of the valve.
Prevent incorrect opening and closing of valves. The operator should clearly understand the role of each valve and its
position in the process pipeline to prevent misuse. It should be ensured that the valve can be opened and closed at
least twice within a week to prevent the valve from being stuck due to long-term inactivity.
Valves should be inspected regularly, at least every three months, or in accordance with the corresponding laws and
regulations, or on-site process conditions to set the frequency of maintenance. Regularly check the valve connections
for looseness and tighten in time. Check whether the valve leaks or malfunctions. If leaks or malfunctions occur, the
valves and pipelines should be repaired in time on the premise of ensuring safety.
If there is an actuator, attention should be paid to the actuator and its connecting mechanism during valve maintenance.
Maintenance should be carried out according to the instruction manual of the actuator.
Replace the seat and packing
Note: Stem seal leakage may be corrected by tightening the packing nut to flatten the belleville washers. If leakage
continues or the valve torque becomes excessive, then the seal/packing must be replaced.
Before replacing the thrust washer and the packing, the pipeline must be de-pressurized.
□ Rremove flange nuts and bolts and carefully lift the valve from the pipeline to avoid scratching or damaging serrated
gasket. The big diameter valves are heavy and should be adequately supported before removing them from the line.
□ Loosen the stem nut and remove the handle or actuators. Then remove lock cap, packing nuts, belleville washers and
gland.
□ Use proper wrench to remove body bolt nuts, then lift the body end. The valve seat will come out with the body end
and then remove the body seat and gasket.
□ Rotate stem so the valve is in fully closed position. Carefully take out the ball to make sure there is no damage to the
ball surface, use a strap and lift device if necessary.
□ Take out the other seat.
□ The stem must be removed from inside of the body. Slightly push the stem head to loose the stem. The stem washer
and the O-ring should come out together with the stem.
□ Remove the stem packing from the body.
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Visual inspection
Clean and inspect all the metal parts. It is not necessary to replace neither ball nor stem unless there are visual signs of
abrasion or corrosion on the surfaces.
We strongly recommend replacement of all soft parts whenever the valve is disassembled for reconditioning. Contact
Coreline for replacement kits that contain all the replaceable parts.
Note: The valve can be assembled and operated dry witouth any lubricant. However, a light lubrication will help in
assembly and reduce initial operating torque. Lubricant used must be acceptable with the pipeline media.
Assembly
□ Install one seat in the body cavity with the spherical curvature facing the ball. A split drawing is found on page 9 in
this manual.
□ Install the stem seal and O-ring on the stem and slide the stem up through the body.
Install packing, gland, belleville washers, and then screw the packing nut onto the stem. Lock the cap on the packing
nut afterwards.
□ Install stem washer and handle. Screw the stem nut onto the stem until the handle is secure.
□ Turn the handle to the fully closed position. Line up the ball slot with the stem end and slide the ball into the right
position. Turn the handle to open position to keep the ball in the right place.
□ Install the remaining seat into the body side.
□ Put the body seal gasket into the body and lineup the end flange. Because the body flange bolt pattern is different
from the line flange bolt pattern, it is possible to assemble the valve in a way that the line flanges bolt pattern does not
lineup. Be certain to align the end flanges bolt holes to the straddle valve center lines. Be careful not to damage the
body seal when putting the cap end into body.
□ Install the cap end nuts and tighten them in a staggered order to the proper torque (See Table 1). Make sure that the
ball is in an open position. There should be at least one stud thread exposed on the side of the body bolt.
□ Gradually open and close the valve until a full 90° turn is obtained. The seat sealing surface will form a permanent
seal shape against the ball by this process.
Valve tests
Make pressure test of the valve prior to place it back into pipeline.
□ Fix the valve on the pressure test machine between a mating flanges with full bolting and suitable gaskets. Orient
valve so seat to be tested is facing upwards.
Pressure test
□ Introduce 6bar air. Carefully operate the valve under the given air pressure, and then slowly close to make sure the
cavity is pressurized. Put water into the upper port to cover the ball and then visually check if there are bubbles. If
bubbles appear, pour water out and then operate the valve several times and recheck. Reverse the valve and put air
pressure to the port just checked to check for leakage in the other port.
□ Check stem seal by covering the stem top area with water/soap solution. Tighten stem seal if leakage occurs until
leakage just stops.
□ Apply a water pressure test according to API598 if
Valve torque test
Coreline Fig.150 ball valves are applied with below torques (See Table 1) when the valves are delivered.
Valve torque *)
Body bolt Stem nut
INCH DN
1/2" 15 8
20-23 14.3
3/4" 20 8
23-26 14.3
1" 25 16
31-34 14.3
1 1/4" 32 26
34-36 19.4
1 1/2" 40 50
41-46 22.4
2" 50 55
41-46 22.4
2 1/2" 65 95
41-46 22.4
3" 80 104
56-61 32.7
4" 100 200
56-61 32.7
Size
[Nm]
*) Torque values include 30% safty factor (Test: 0bar differential pressure, ambient temperature, non-lubricating).
Table 1
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Installation-Operation-Maintenance Manual
No. Part name Material No. Part name Material
A351 CF8M 9 Handle sleeve Vinyl
A351 CF8 10 Nut SS304
A216 WCB 11 Anti-static device SS316
A351 CF8M 12 Lock cap SS304
A351 CF8 13 Nut SS304
A216 WCB 14 Belleville washer SS301
SS316 15 Gland SS304
SS304 16 V-ring packing *) PTFE+25% carbon
4 Seat *) PTFE+25% carbon
*) PTFE+25% carbon
17 O-ring FPM
5 Gasket 18 Stem sealing PTFE
SS316 19 Stop bolt SS304
SS304 20 Nut SS304
7 Handle SS304 21 Body bolt SS304
8 Locking device SS304
6 Stem
1 Body
2 Body cap
3 Ball
Material part list
*) Other material available on request.
CORELINE VALVE CO., LTD.
Add: No.210 Xinyuan Road, Ehu Industrial Park, 214116 Wuxi, China
Phone: +86 510 8852 5336
The contents of this catalogue are confidential
and proprietary to Coreline, we reserve the right
to change the specifications without any notice.
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www.coreline.dk2020-12-01 Coreline Valve Co., Ltd.
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