Metso Top 5 Series Operating and maintenance manual

BALL VALVE

Series Top5®

Installation, Maintenance and

Operating Instructions

1 T5 71 en • 12/2008

21 T5 71 en

READ THESE INSTRUCTIONS FIRST!

These instructions provide information about safe handling and operation of the valve.

If you require additional assistance, please contact the manufacturer or manufacturer's representative.

Addresses and phone numbers are printed on the back cover.

SAVE THESE INSTRUCTIONS!

Subject to change without notice.

All trademarks are property of their respective owners.

Table of Contents

1 GENERAL........................................................ 3

1.1 Introduction ............................................3

1.2 Valve structure.......................................3

1.3 Markings.................................................3

1.4 Valve approvals......................................4

1.5 CE marking ............................................4

1.6 Recycling and disposal ..........................4

1.7 Safety precautions .................................4

2 TRANSPORTATION, RECEPTION AND

STORAGE........................................................ 5

3 INSTALLATION IN THE PIPELINE................. 5

4 COMMISSIONING ........................................... 5

5 SERVICING...................................................... 5

5.1 Gland packing........................................6

5.2 Dismantling the valve.............................6

5.3 Assembly................................................6

6 TESTING THE VALVE................................... 10

7 INSTALLING THE ACTUATOR .................... 10

7.1 Installing the BC/B1C-series actuator..10

7.2 Installing the BJ/B1J-series actuator....11

8 ORDERING SPARE PARTS ......................... 11

9 PARTS LIST .................................................. 13

10 DIMENSIONS AND WEIGHTS ...................... 14

11 TYPE CODING............................................... 20

1 T5 71 en 3

1 GENERAL

1.1 Introduction

These instructions describe the installation, operation

and main-tenance of Top 5®, a valve in the Metso Top-

Entry Rotary Control Valve series.

Top 5 is a generic name for a product series group

comprising the following valve series:

❑T5 — flanged, reduced bore, single seated

❑T4 — like T5, with weld ends

❑T25 — full bore, flanged, otherwise like T5

❑T35 — like T25, with weld ends.

When the valve is equipped with a control ball reducing

the flow rate and thus preventing noise and cavitation, it

is called Q-T5 etc.

Further information on the installation, operation and

maintenan-ce of actuators is given in the individual

manuals for each actuator model.

1.2 Valve structure

The Top 5 valve series is intended for either control or

special shut-off applications. It is tight in one direction.

The ball may be equipped with an attenuator element

(Q attenuator). The ball has been mounted on the body

and on the bonnet with bearings.

Thanks to its top entry structure, the valve is also appli-

cable for use as a butt weld end version, because the

valve can be serviced without removing it from the

pipeline.

1.3 Markings

In addition to the markings shown in Figure 2, the valve

may have directional arrows:

When standard seats are used, the arrow on the body

shows the tight direction.

Identification plate markings:

1. Body material

2. Stem material

3. Trim material

4. Seat material

5. Maximum and minimum operating temperatures

6. Maximum shut-off pressure differential / temperature

7. Pressure class

8. Type designation

9. Valve manufacturing parts list no.

10. Model

The type designation is explained in Metso standard

S389. An extract of the standard is shown on page 16.

NOTE:

Selection and use of the valve in a specific application

requires close consideration of detailed aspects. Due

to the nature of the product, this manual cannot cover

all the individual situations that may occur when the

valve is used. If you are uncertain about use of the

valve or its suitability for your intended purpose,

please contact Metso’s Automation business for more

information.

Fig. 1 The valve bonnet is bolted to the body

Fig. 2 Valve markings

Fig. 3 Identification plate markings

positioner id plate

Note. When the actuator

cover is removed, the ball

position can be checked at

the line stamped at the end

of the stem

actuator id plate

customer’s tag or position

number (if exists)

identification plate,

see fig. 3

manufacturing number

arrow showing the tight

direction, on both sides

of the body

FLOW DIRECTION

TIGHT DIRECTION

BODY

TRIM

SHAFT

SEAT

T max

T min

MAX. OPER. ps

RATING TYPE

No. MOD

ATTENTION : READ INSTRUCTIONS BEFORE INSTALLATION OR SERVICING. CONTACT METSO AUTOMATION FOR COPY. MADE BY METSO AUTOMATION

XXXX

(1) (2) (5) (7) (8)

(3) (4) (6) (9) (10)

41 T5 71 en

1.4 Technical specifications

The identification plate must be checked for the essen-

tial safety limits in the extreme range, such as pressure

and temperature resistance and the highest operable

pressure difference.

The selected actuator size or the available instrument

air pressure may place restrictions on the highest ope-

rable pressure so that it becomes lower than the limits

determined by the mechanical strength of the valve.

Face-to-face length:

series T5 ANSI/ISA S75.03,

IEC 534-3-3

series T25, T4, T35 API Class 600

Body pressure and

temperature rating: ANSI B16.34*), see Table 1

Ball bearings:

bearings, code E Metal-reinforced PTFE

easy, low Δp use:

max. +230 °C

demanding, high Δp use:

max +200 °C

bearings, code B Cobalt based alloy

+450 °C

max. pressure difference

according to a separate

specification

Dimensions: See pages 14 and 15

Weights: See pages 14 and 15

*) Unless the selected ball bearings or flange stan-

dards impose a lower pressure and temperature rest-

riction.

1.5 Valve approvals

The valve is fire safe for hydrocarbon applications

according to API 607 and BS 6755.

1.6 CE marking

The valve meets the requirements of the European

Directive 97/23/EC relating to pressure equipment, and

has been marked according to the Directive.

1.7 Recycling and disposal

Most valve parts can be recycled if sorted according to

material. Most parts have material marking. A material

list is supplied with the valve. In addition, separate

recycling and disposal instructions are available from

the manufacturer. A valve can also be returned to the

manufacturer for recycling and disposal against a fee.

1.8 Safety precautions

1) Flange codes according to PN standards, see Chapter 13. Max resistance to pressure and temperature

depending to the flange and its material. Resistance in the middle part of the valve up to size DN 400 (16") accord-

ing to table A600.

CAUTION:

Do not exceed the valve performance limitations!

Exceeding the limitations marked on the valve may

cause damage and lead to uncontrolled pressure

release. Damage or personal injury may result.

CAUTION:

Do not dismantle the valve or remove it from the

pipeline while the valve is pressurized!

Dismantling or removing a pressurized valve will result in

uncontrolled pressure release. Always isolate the rele-

vant part of the pipeline, release the pressure from the

valve and remove the medium before dismantling the

valve. Be aware of the type of medium involved. Protect

yourself and the environment from any harmful or poi-

sonous substances. If the valve is equipped with an

actuator, do not forget to close and detach the actuator

pressure supply pipeline. Failure to do this may result in

damage or personal injury.

CAUTION:

Beware of the cutting movement of the ball!

Keep hands, other parts of the body, tools and other

objects out of the open flow port. Leave no foreign

objects inside the pipeline. When the valve is actuated,

the ball functions as a cutting device. Close and detach

the actuator pressure supply pipeline for valve mainte-

nance. Failure to do this may result in damage or per-

sonal injury.

CAUTION:

Protect yourself from noise!

The valve may produce noise in the pipeline. The

noise level depends on the application. It can be

measured or calculated using the Metso Nelprof soft-

ware. Observe the relevant work environment regula-

tions on noise emission.

CAUTION:

Beware of a very cold or hot valve!

The valve body may be very cold or very hot during

use. Protect yourself against cold injuries or burns.

Table 1 Body materials commonly used by Metso and their resistance to pressure and temperature according

ANSI 16.34,

Pressur

e class

Flange

code 1) Body material Material

code °C

38 50 100 150 200 250 300 350 400

ANSI

300 D A216 gr WCB

Carbon steel

A351 gr CF8M

Stainless steel

A 51,1

49,6 50,1

48,1 46,4

42,2 45,2

38,5 43,8

35,7 41,7

33,4 38,7

31,6 37,0

30,4 34,5

29,1

ANSI

600 F A216 gr WCB

Carbon steel

A351 gr CF8M

Stainless steel

A 102,1

99,3 100,2

96,3 92,8

84,4 90,5

77,0 87,6

71,3 83,4

66,8 77,5

63,3 73,9

60,8 69,0

58,2

1 T5 71 en 5

2 TRANSPORTATION, RECEPTION

AND STORAGE

Check the valve and the accompanying devices for any

damage that may have occurred during transport.

Store the valve carefully before installation, preferably

indoors in a dry place. Do not take the valve to the

intended location and do not remove the flow port pro-

tectors until the valve is installed. The valve is delivered

in the open position, with the exception of valve pack-

ages where the actuator spring closes the valve.

3 INSTALLATION IN THE PIPELINE

Remove the protecting plates around the valve and

check that the valve is clean. Flush and blow the pipe-

line carefully before installing the valve. Foreign parti-

cles, such as sand or pieces of welding electrode, will

damage the valve.

Check that the pipeline is supported properly. Do not

attempt to correct any pipeline misalignment by means

of the flange bolting or welding of the valve. Do not sup-

port the pipeline using the valve as help.

An arrow pointing at the tight direction of a seat that is

tight in one direction (the most commonly used version)

is cast on both sides of the valve. This is usually the

flow direction. If the flow direction and the tight direc-

tion can be opposite to each other, the piping plan must

be checked for the correct position.

Check that the unbroken side of the ball faces the seat

when the valve is in the CLOSED position.

Install the valve in the position shown in the piping

installation drawing. The position code shows the instal-

lation position that should be used when the actuator

has been installed at the factory. The position code has

been given either on the specification sheet or in the

dimensional drawing of the valve.

There should be enough free space around the valve

so that the actuator can be removed and the valve dis-

mantled without detaching the valve from the pipeline.

Check that the indicator arrow on the actuator is paral-

lel to the ball flow opening.

The actuator must not touch the pipeline or any perma-

nent structures, because pipeline vibration may dam-

age it or interfere with its operation. If the pipeline

drawings show a support for the actuator, the support

must be installed.

Make sure that the valve is in the OPEN position when

welding a weld end valve into the pipeline.

Note! A valve equipped with a BJ actuator is in the

CLOSED position when it is not pressurized. Direct

compressed air into the cylinder to turn the valve open.

When welding a valve into a pipeline, protect the valve

from welding spatter, see Fig. 5. Always ground the

welding apparatus on the side of the pipeline.

4 COMMISSIONING

The gland packing may leak after long storage. If the

packing leaks, tighten it steadily until the leaking stops.

Do not tighten the packing unnecessarily as this will

increase the required torque and impair the control

properties. (More information about the gland packing

in section 5.1.).

Check that the valve has been installed correctly in

relation to the flow direction.

5 SERVICING

The valve can be serviced without removing it from the

pipeline. Servicing in a workshop is, however, recom-

mended whenever possible.

If the valve is removed from the pipeline, the body must

be supported for servicing with the stem standing

upright.

The numbers in parentheses refer to the exploded view

and the parts list on pages 12 and 13, unless otherwise

NOTE:

Valves with a carbon steel body may become badly

corroded on the inside if the inside is left damp during

storing.

CAUTION:

Never lift the valve or valve package by the actua-

tor, positioner, limit switch or their piping. Place

the lifting ropes securely around the valve body.

Fig. 4 Installation of the valve into the pipeline

Fig. 5 Protecting the valve during welding

CAUTION:

Observe the safety precautions listed in section

1.8 before starting work.

61 T5 71 en

indicated.

5.1 Gland packing

The gland packing of the valve may be made of graph-

ite with a PTFE finish or it may be a model where the

lowest graphite ring has been replaced with a metallic

O-ring sleeve, see Fig. 6. If the gland packing is tight-

ened too much, the control properties of the valve may

suffer. The need to tighten the packing may be reduced

by means of the O-rings.

Even if the O-rings were damaged, there will be enough

graphite rings to enable tightening of the packing and

to ensure reliable operation.

The standard is a graphite gland packing with a PTFE

finish.

5.1.1 Changing the gland packing

❑Remove the actuator.

❑Make sure the valve is not pressurized.

❑Detach the gland (9).

❑Remove the old packing rings (69), see Fig. 7.

❑Clean the packing ring counterbore.

❑Check that there are no burrs on the edges of the

key slot.

❑Install the new packing rings one by one using

the gland as a tool.

❑Tighten the gland packings uniformly.

If the packing has O-rings, lubricate them with silicone

grease before installation. Put the outer O-ring on the

bottom of the packing ring counterbore and the inner

O-ring on the gland.

Cover the stem key slot with tape, a plastic bag or other

similar material that protects the O-ring when you push

the gland over the key slot.

5.2 Dismantling the valve

❑Remove the actuator and the actuator mounting

shelf.

❑Remove the key (10). Check that there are no

burrs on

❑the edges of the key slot.

❑Loosen the gland packing by unscrewing the

nuts (18).

❑Remove the hexagon nuts (16) on the bonnet.

❑Lift the bonnet. You may use an extractor as help,

see Fig. 8.

❑Turn the valve ball 180 degrees from the

CLOSED position, see Fig. 9.

❑Lift the ball. Check that the unbroken side of the

ball does not rest on the seat, see Fig. 10.

❑Remove the seat (7). You may use a tool to pull

out a seat that has been installed by means of O-

rings, see Fig. 11.

5.3 Assembly

Check all sealing surfaces with care. If necessary, lap

the sealing

surfaces with diamond powder and thereafter with

water sanding

NOTE:

If you send the valve to the manufacturer for servicing,

do not dismantle it. Clean the valve. If the medium is

dangerous, inform the manufacturer when you send

the valve.

Fig. 6 Gland packing

CAUTION:

Do not dismantle the valve or remove it from the

pipeline while the valve is pressurized!

graphite

O-ring

Fig. 7 Using a special tool to remove the gland

packing

CAUTION:

Do not dismantle the valve or remove it from the

pipeline while the valve is pressurized!

Fig. 8 Detaching the bonnet

1 T5 71 en 7

paper no. 1200. Clean all parts carefully.

Spray the sealing surfaces of the ball and the seat

thinly with e.g. Molykote 321R dry lubricant. Wipe the

surfaces with a soft cloth after the lubricant has dried.

Check the gland packing. If it shows any signs of dam-

age, remove it and clean the packing ring counterbore.

Do not install a new gland packing until you have put

the bonnet back.

5.3.1 Installing a seat

The same seat selection is available for all Top 5 series

valves. The dimensions of seat recesses have been

standardized to be of equal sizes since June, 1990.

Push the seat into the body by hand; the final installa-

tion is done using a tool (in the reverse order compared

5.3.1.1 A-seat, Figure 13

❑Check the sealing surfaces.

❑Install the back seal (130) on the seat (7).

❑Install the ring (129).

❑Install the spring (62) into the seat body.

❑Install the support ring (35).

❑Spread some anticorrosive agent, e.g. Cortec

VCI-369, in the seat recess of a carbon steel

body.

❑Push the seat into its place.

5.3.1.2 F-seat, Figure 14

❑Check the sealing surfaces.

❑Check the sealing surfaces at the ends of the

spring (62).

❑Check the spring countersurface in the body.

❑Spray both ends of the spring and their counter-

surfaces thinly with dry lubricant.

❑Install the spring on the seat (7).

❑Spread some anticorrosive agent, e.g. Cortec

VCI-369, on the countersurface of the spring in a

carbon steel body.

❑Push the seat into its place.

Fig. 9 Turning the ball

Fig. 10 Lifting the ball from the body

Fig. 11 Using a tool to pull out the seat

Fig. 12 Installing the seat

Fig. 13 A seat

81 T5 71 en

5.3.1.3 G-seat, Figure 15

❑Check the sealing surfaces.

❑Lubricate the O-rings (63, 75) with silicone

grease before installation.

❑Install the O-ring (63).

❑Install the support rings (64) into their groove.

Cut the ribbon ends diagonally to make a flexible

seam.

❑Install the back seal (130) and the ring (129).

❑Install the spring (62) into the seat body (7).

❑Install the O-ring (75).

❑Install the support ring (76) into its groove. Cut

the ribbon ends diagonally to make a flexible

seam. See Fig. 15.

❑Spread some anticorrosive agent, e.g. Cortec

VCI-369, on the seat recess of a carbon steel

body.

❑Push the seat into its place.

5.3.1.4 R-seat, Figures 16 and 17

❑Check the sealing surfaces.

❑Lubricate the O-ring (63) with silicone grease

before installation.

❑Install the O-ring (63).

❑Install the support ring (64) into its groove. Cut

the ribbon ends diagonally to make a flexible

seam.

❑Only in the Fire Safe version:

❑Install the back seal (130) and the ring (129). See

Fig. 17.

❑Install the spring (62) into the seat body (7).

❑Install the spring support ring (131).

5.3.1.5 E1-seat, Figure 18

❑Check the sealing surfaces.

❑Install the back seal (130) on the seat (7).

❑Install the ring (129).

❑Install the spring (62) into the seat body.

❑Install the ring (133).

❑Install the seal (135).

❑Install the support ring (35).

❑Spread some anticorrosive agent, e.g. Cortec

VCI-369, in the seat recess of a carbon steel

body.

❑Push the seat into its place.

Fig. 14 F seat

Fig. 15 G seat

The G-seat has been replaced with the A-seat

Deliveries of the G-seat ceased in 1990

Fig. 16 R-seat. Delivered after 4/95 only as a spare

part.

Fig. 17 R-seat (Fire Safe)

1 T5 71 en 9

5.3.2 Installation of bearings

Check the bearings and the bearing surfaces. If neces-

sary, grind the bearing surfaces with an abrasive cloth

and replace worn bearings. Spray the bearing surfaces

lightly with dry lubricant.

5.3.2.1 Standard bearings

The bearing material is PTFE reinforced with an acid-

resistant steel

net. If the bearings are so worn that the net is visible on

the wear

surface, you should replace the bearings (60, 61, 89,

94). See Fig. 19.

5.3.2.2 Heat-resistant bearings

The position of the ball in the direction of the stem is

determined by means of the bearings (4, 60). Pipeline

pressure causes a pressure force towards the cross

section of the ball stem; this force removes the clear-

ances against the bearings (4, 60) supported on the

bonnet.

The bearings (4, 5) are precision-machined cobalt

based alloy sleeves.

The bearing countersurface is a sleeve (60, 61) of spe-

cial steel, which has been installed against the ball

using a press-on fit. See Fig. 20.

If the surfaces are badly damaged and cannot be

‘restored’ using an abrasive cloth, the bearings and the

ball must be replaced.

When installing new bearings (4, 5), lock them securely

to the bonnet and the body using a nail punch.

5.3.3 Installing the ball

If the ball surface has deep scratches that cannot be

removed using an abrasive cloth or if it is not com-

pletely round, you should send the ball to the manufac-

turer for repair.

Adjust the seat to the ball by lapping them together with

diamond powder before you install the ball (and the

seat) into the body.

Install the ball into the body with the ‘cut’ side against

the seat. Take care not to damage the bearing and the

seat with the ball. In valves that have PTFE bearings

and have a size of 6" or more, the bearings (94, 61, 5)

are ready-fitted on the ball and locked using a lock ring

(27).

When the ball is in its place, turn the ball against the

seat and check visually that the ball has enough room

to complete the operating circle and that it turns easily

against the seat.

5.3.4 Installing the bonnet

The bonnet is installed in the reverse order compared

to the disassembly, see section 5.2. Spray the bolts

lightly with Molykote 321R dry lubricant.

Twist the bonnet gasket (graphite ribbon) around two

times so that the ends overlap for about 25 mm, see

Fig. 21.

Fig. 18 E1-seat

Fig. 19 Standard bearings

bearing (60)

thrust bearing (89)

(61, 94)

Fig. 20 Heat-resistant bearings

thrust bearing (4)

bearing (60)

(5, 61)

sleeves made of

special steel have been

installed in the ball

using a press-on fit

10 1 T5 71 en

Pull at the stem to make the ball perpendicular. The

bonnet settles in the correct position, and the neces-

sary pre-compression between the ball and the seat is

achieved, see Fig. 22.

Tighten the bonnet nuts crosswise as shown in Table 2.

Stages 1 to 4: all bolts are tightened crosswise.

Stage 5: the bolts are tightened in succession along the

circumference.

Install the gland packing as explained in section 5.1.

6 TESTING THE VALVE

We recommend that the valve body be pressure tested

after the valve has been assembled.

The pressure test should be carried out in accordance

with an applicable standard using the pressure rating

required by the pressure class or flange bore of the

valve. The valve must be in an open position during the

test.

If you also want to test the tightness of the closure

member, contact the manufacturer.

7 INSTALLING THE ACTUATOR

Installation of the actuator must not cause bearing

loads on the valve. The valve has two bearings, and the

actuator serves as the third bearing. They must all be

aligned.

If the actuator causes extra torsion on the stem, it is

seen as increased need for torque and impaired con-

trol properties.

More detailed information on actuators can be obtained

from the installation, operation and maintenance

instructions for each actuator type.

7.1 Installing the BC/B1C-series

actuator

❑Drive the actuator piston to the extreme outward

end and turn the valve into the closed position.

❑Clean the stem bore and file off any burrs.

❑If a coupling is needed between the actuator and

the valve stem, install it into the stem bore. Lubri-

cate the coupling and stem bore. Note the cor-

rect position. The line at the end of the stem

indicates the direction of the ball flow bore.

❑Fasten the bracket loosely to the valve.

❑Push the actuator carefully onto the valve stem.

Avoid forcing it, since this may damage the ball

and seats. We recommend mounting the actua-

tor so that the cylinder is pointing upwards.

❑Align the actuator as accurately as possible

using the valve as help. Lubricate the mounting

Fig. 21 Installing a gasket for the bonnet Fig. 22 Adjusting the bonnet by pulling at the ball stem

Table 2 Torques for the bonnet nuts

Valve size

Screws Stage 1

0,2xMfinal

(Nm)

Stage 2

0,5xMfinal

(Nm)

Stage 3

0,8xMfinal

(Nm)

Stage 4

1xMfinal

(Nm)

Stage 5

1xMfinal

(Nm)

Size

UNC

Pcs. Wrench

opening

015

3/8

5/8

3/4

1 1/4

1 1/16

1 1/4

1 5/8

165

200

415

145

320

665

100

180

400

830

100

180

400

830

CAUTION:

Pressure testing should be carried out using

equipment conforming to the correct pressure

class!

CAUTION:

Beware of the cutting movement of the ball!

This manual suits for next models

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