SC Fepa Sa Bârlad: Installation, Operation&Maintenance Ball Valve Type RSD-BB

SC FEPA SA
BRLAD
CE 2295-PED-H-FEP-001-09-ROM
FIRE SAFE !
API 607
API 6FA
INSTALLATION, OPERATION&MAINTENANCE
BALL VALVE TYPE RSD-BB
SC FEPA SA
Str.REPUBLICII nr.316,
Cod postal 731120,
Tel.+40 0235 411812
Fax +40 0235 421 618/0235 413729
e-mail: fepa@fepa.ro / marketing@fepa.ro
Brlad-Romnia
Rev 0B
09.03.2015
Page 1 of 1
1. INTRODUCTION
The manual is designed to give the user complete information regarding installation, operation, adjustment,
perform periodic inspections and maintenance of valves type RSD-BB producer is FEPA Barlad.
READ THE INSTRUCTIONS CAREFULLY BEFORE INSTALLING AND USING THE PRODUCT!
For any further information it is recommended to contact the manufacturer.
User's responsibility to know all the information presented in this manual and the specific application for which it was
purchased valve.
It is also the responsibility of the user to use for installation, operation and maintenance only qualified and trained
On request the valve manufacturer can provide training to its headquarters or beneficiary.
The user is obliged to ensure all measures for safe operation, the health of staff, environment and function of the
equipment.
Before delivery valves are tested by the manufacturer.
If the instructions are not clear, please contact us address
S.C.FEPA SA str.Republicii nr.316cod 731120BARLAD, or fepa@fepa.ro.
At www.fepa.ro can find other information about the products FEPA.
1.1Application
Ball valves distributor RSD-BB type fall into the category of valves for pipes (may be used in piping systems
underground or over ground) in oil and gas industry.
The products fall into the category of accessories for pressure regulation and essential requirements related to
ensuring the safety of users of pressure equipment covered by Government 584/2004 amended (Directive97 / 23 / EC
PED)
1.2Technical characteristic
The valves can be classified:
Construction:
-monoblock type(wlded body)
-demontable type(split body)
Installation :
-overground
-underground
Type of connection to the process:

-with welding ends
-with flanges
-with threaded
Nominal diameter or NPS 50-1400 or 2-56

Nominal pressure: 6;10;16;25;40;60;100;150 bar; 600bar ANSI 150, ANSI 300; ANSI 600;
ANSI 900
Standard temperature ranges : -30C +110C and 0C +200C
Dimensions according to API 6D or SR EN558-1
Standard working environment: neutral or potential corrosive gases and liquids, filtrated, without any solid
particles bigger than 0,1 mm.
Special orders: fluids with suspensions; the nature of suspensions and the size of particles has to be mentioned.
Sealing area
-The primary sealing is assured by the metal gasket. After the primary gasket is wear the sealing is provided by the
Viton gasket.
Basically the force that assures the pressing of the gaskets is provided only by springs, the gaskets sealing diameter is
lower, in fact equal with the sealing diameter of the metal and the O-ring gaskets.
The metal gasket assures the sealing if the O-ring gasket is damaged, at least till the injection of the emergency
moulded gaskets.
The force produced by (pressure x valve section) is taken by the bearing system of the ball
Page 2 of 2
1.3Features
Antistatic construction
Constant contact between
metal parts.
Anti blow-aut proof stem

construction
The stem cannot be
extracted or expelled
pressure
SEAT SEALAT INJECTION
Emergensy tertiary
sealing injection
Full bore
] design
Fire seif
Matal/metal sealing
After fire exposure
Trunnion mounted ball

Ball with bearing
Double block and bleed

Both gasket are sealing the bal land
the valves chamber can be
depressurized
Page 3 of 3
2 FUNCTIONAL DESCRIPTION
Shut valve both sides of the
ball are under the pressure,
the valves chamber may
become depressurized
Open valve the valves chamber may become

depressurized to verify the tightness degree
3. CORROSION PROTECTION
-primer coat- Zinc-rich primer
-with special paint which corresponds to a voltage of 25kV verification for valves installed underground
-with high strength epoxy for valves mounted above ground
4.ACTUATION
-manually with a lever up tp DN100 /over DN 100with reducer or, or electrically, pneumatically, hidropneumatically,electro-hidraulically actuator.
5.TESTS
- Products are tested by the manufacturer
- Test pressure and loss rates are allowable according to SR EN12266 (without losses) / API598/API6D
6. CODIFICATION
-Coding RSD-BB top entry type is presented in the general product specification 839/2008
Rev.2
7.IDENTIFICATION
Each valve is equipped with label (identification card) that includes:
Page 4 of 4
-*Depending on the requirements of the technical specification of the beneficiary may appear on the nameplate - no
marking API 6D. License / no marking CE/fire marking test API607 or API 6FA.
8. PACKING, TRANSPORT, STORAGE,

8.1 Packing
Each valve must be drained of fluid test.
The ends of the body must be covered to prevent foreign bodies and moisture-protective covers are removed only
when installing.
The valves are delivered with the obturator in the open position!
The packing is designed,made and marked according to the transport and storage conditions contractually agreed,
and provide good protection for equipment.
8.2. Transportation
During transportation, environmental conditions that have influence on the valves are described, according to SR EN
60721-3-2, the next series of classes of environmental conditions:2K4/2B2/2C2/2M2(IE23).
8.3. Storage conditions

The valves should be stored in a clean dry environment and should be left on shipping pallets or in original packing
prior to installation.
All flange protectors should remain in place until installation of RSD-BB Valve.
The Valves should be stored in the FULLY OPEN position (prevents damage to ball and seats).
For the storage of products applies IE12 from Table 7 and described in Annex B of SR.EN 60721-3-1
9. INSTALLATION-OPERATION
9.1 Unpacking
All valves should be inspected on receipt for lost or damaged components.
9.2 Handling
Because of physical dimensions and heavy equipment will be used properly and lifting methods for transport, storage
and installation.
-valves are furnished in open position, in order to minimize the effect of mechanical loads and impurities on seats,
gaskets, and other pressure parts.
Page 5 of 5
Before handling the valve, verify it is open position. Lift valve with sling suitable for its weight. Never use lever, actuator
or gear operator to lift the valve
9.3Installation.
Inspect the piping system prior to valve installation whenever possible, to insure that it has been properly
flushed and cleared of construction and fabrication debris. The seating surfaces in soft seated valves are particularly
susceptible to weld slag and sand blasting grit. Pipe scale, metal chips and other foreign materials should be removed.
Verify that Actuator, and mounting hardware as appropriate were included with the valve and are in good
shape, that proper tagging is in place and any warning labels are eligible and observed .
Just prior to installation, remove each valve from its packing and remove any end covers.
Examine the flow bore for debris. All FEPA ball valves are shipped in the open position to prevent damage to
the ball surface. Any grit or foreign matter must be removed. Scratched or damage balls must be replaced. Do not
install a damaged valve.
It is also important to check for valve operation clearances. Valves may be installed in any position using standard pipe
fitting practices. If possible, mount the valve in such a position that the actuator can, if necessary, be detached without
removing the valve from the pipeline. The actuator must not touch the pipeline, as pipeline vibrations may damage it or
cause disturbance.
Flanged End Valve Installation

After determining that the valve is in good condition, extra attention should be given to the raised face surface. Dents
and heavy scratches should be repaired. At installation make sure that the conditions of:
a. Lateral alignment-misalignment: max 2mm flange for.NPS 4(DN100) including
- 3mm misalignment flange max. for. higher NPS 4 (DN100)
b. Alignment angle-difference max. Measured between flanges max 2.5mm
Page 6 of 6
c. Max total misalignment. for allowable holes. org. assembly

-2mm flange misalignment: max for NPS 4(DN100) including
- 3mm misalignment flange: max. for higherNPS4( DN100),are respected.
- grease the bolt and nuts to get a correct bolt load.
- Tighten the screws criss-cross (to avoid uneven loading gaskets and flanges)
Weld-End Valve Installation

Both butt-weld and socket -weld valves require special consideration for installation. In addition to the general cautions
already discussed, the heat of welding may damage seats and seals. The valves are mounted in the pipeline by using
standard welding methods and must be supported during the welding. When welding or annealing the joint, assure that
the temperature of the body in PTFE or rubber sealing material,e.g.120C.The increase of temperature can be prevent
by wet protection cloth around the body during the welding.
After welding, binding clean compressed air network so as to be removed rust, welding, metal debris
and any foreign body.
Foreign bodies of any kind, depreciation overheating welding seen through the paint may compromise the
sealing group valves and get product warranty.
Threaded-End Valve Installation

After removing the valve from its packing inspect the NPT threads for damage. Occasionally threads may require
chasing prior to installation to remove burrs or other minor imperfections.
Apply a good grade of pipe sealant compound to the male pipeline threads only. Do not use sealant on the female
threads because excess compound would be forced into the valve body. This could cause sticking of the ball or
encourage the accumulation of dirt and debris that could prevent good valve shutoff.
FEPA valves are shipped with a securely fastened nameplate. Information included on each is documented in next fig.
Although each valve is thoroughly tested and inspected before it leaves the factory, nameplate could be lost or
destroyed during shipment or while in storage. If either is missing or not legible, contact your distributor or the factory
for assistance before operating valve.
9.4Operation
Ball valves are intended to be on-off devices operating through 90 rotation of the stem.
Gear operated ball valves have an indicator showing the open and closed position of ball. The hand wheel rotates
clockwise to close the valve.
Do not leave the ball in a partially opened position, as it will cause severe damage to the ball and seat resulting in
leakage.
The most common service failures not related to the installation and start-up processes are:
-exceeding the operating temperature or pressure limits of the valve due to a process upset condition.
-a chemical attack on valve components due to either misapplication, or changes in the service.
-violating temperature and pressure limits can result in immediate valve failure where chemical attack or corrosion
generally occurs overtime.
Always utilize factory authorized replacement parts.
Good operating procedure requires periodic inspection of valves and replacement of necessary parts to ensure proper
valve function.
NOTE: Valves showing through leakage or high operating torque may be damaged. DO NOT use excessive force or
bars to operate valve. Disassemble valve, inspect components, and replace damaged parts.
CAUTION: before attempting removal/repair, always cycle valve with system pressure isolated to relieve excess
pressure which may be trapped in body cavity.
10 .INSTRUCTIONS FOR USE AND MAINTENANCE

Working fluid temperature must not exceed the minimum / maximum inscribed on the valve body or on its label.
Working with valves does not require specially qualified personnel.
Where it is installed must meet environmental conditions imposed by the materials in valve
Will open-close maneuver once a year to avoid blocking valve.
Condensate drain is recommended after each actuation (when the valve is equipped with purge)
Venting the body cavity is made in the body until the pressure reached atmospheric pressure
(when the valve is equipped with ventilation)
Page 7 of 7
During venting flammable gases can be released! -Make sure that it removes any source of
fire. Make sure that the exhaust valve does not affect the operator.
Never attempt to open the valve PURGE AND / OR AIR WHILE valve is in the partially open!
Valves are equipped with injection system paste the shaft seal and ball-it provide additional sealing in emergency
cases with damaged sealing surfaces.
The use of a suitable injection device and only in emergencies!
Position valve works / off operation allowed a position partially open / closed.
The manually operated valves:
-Closing the valve is rotated clockwise to 90.
-Do not use bars, pipes, keys or other devices for amplifying lever or handwheel torque -can cause injury and
damage to the valve.
We will check the operation of the valve.
The manufacturer is not responsible if the valve is not used and maintained properly!
Never attempt to interfere with the valve under pressure!

Revision should be done in appropriate workshops and requires no special tools.
Any violation of instructions will void the warranty!

On stream maintenance
This section covers maintenance and repair which can be performed without removing valve from the line.
When performing any work on this valve, use normal safety precautions to protect yourself against any residual fluid or
trapped pressure in the line.
With the line under pressure the valve body cavity can be vented to the atmosphere and completely drained down with
the ball in closed position only. Stem seal replacement can be made see Annex A
10Spare parts
Each valve shall be accompanied by a safety related parts, the method of
replacement and specific instructions for assembly and use-Annex A.
11. HEALTH, SAFETY, ENVIRONMENT

- products are designed, manufactured, tested and equipped in the system if necessary, so as to guarantee safety of
the user and the environment.
- the installation shall comply with all applicable law labor protection
- will wear all required personal protective equipment
- do not use the valve than the designed parameters
-beneficiary will not make changes without consulting the manufacturer / or if the manufacturer recommends
- please check before installation if the environmental regulations , safety or other restricting use of the product.
- Please firstly return to repair products that have circulated hazardous fluids decontaminated them.
Also any faucet returned must be accompanied by minimal information regarding the conditions of use, changes in the
product, operations decontamination and / or cleaning fluid and safety data sheet
- used packaging and waste from the retirement harness the special without regulatory requirements.
However please consider conditions of use of the product and to indicate the applicable legislation and packaging
equipment.
Page 8 of 8
12. RISK ANALYSIS

Causes
Category risk
Consequences
Elimination
handling
Improper lifting and trasportation
Damage valve
storage
Storage in an area
inappropriate
Damage valve
Improper
installation
- Failure to follow the installation

- failure to align
flanges
- mounting additional
accessories
Damage valve
- additional charge bolts,
gaskets, flanges
- additional load risk of
rupture
Lose on the shaft
O-ringuri
Gas leaks in atmosphere
Lose to vent and

purge valves,
lubricators
-lose valves
Gas leaks in atmosphere
Category risk
Causes
Consequences
Elimination
-installation and operating error

- environmental or
characteristics differ from those
of technical sheet
improperly working fluid with
particles
-electromagnetic induction.
-leakage current
-electrostatics charge
Damage valve
-explosion hazard
- bodily injury in contact
with the valve
Damage valve
decrease the life of a slave.
- Damage valve
- electric sparks,
sources of ignition
- respect pressure/temperature
control
Clening periodically valve dust
using working fluid according to
data sheet
endowment valve antistatic device
used improper spare parts

damage pressure parts
used improper /operation failure
- malfunction
-loss
fire, explosions
design fire
use proper working conditions
Operation
-overcome working
pressure/overcome
working temperature
-external corrosion
-internal corrosion
-electrical charge
maintenance
improper
fugitive emissions
ignation source
SC FEPA SA
Str.REPUBLICII nr.316,
Cod postal 731120,
Tel.+40 0235 411812
Fax +40 0235 421 618/0235 413729
e-mail: fepa@fepa.ro / marketing@fepa.ro
-correct handling
-closely inspecting the download
and installation
-correct storage
-Inspect carefully before
installation
-Installation and preparation for
installing them in the correct
- check alignment flanges and
pipes
- do not modify without the
agreement manufacturer's
-replacement o-rings as spare
parts list
Check and replace the defective
valves
Brlad-Romnia
Page 9 of 9
ANNEX A 1
Ball valve RSD-BB 1.1.50.150.1.0.3.0.1.1.1.FB
A1.1 Speare parts list

O-ring 20x2.65 -shaft gasket

O-ring 23,47x2.62-gland gasket
O-ring88.57x2.62-body gasket
O-ring 53.34x5.33-seat gasket
4024.4350
-seat
3825.6811
-graphit paking
O-ring 12.37x2.62 -trunnion gasket
O-ring 23.81x2.65 -shaft gasket

O-ring 26.64x2.62-gland gasket
O-ring 53.34x5.33-seat gasket
4024.4256
-seat
3825.6786
-graphit paking
A1.2 On stream maintenance

Stem seal replacement can be made on stream (Refer to Assembly drawing fig.1)
FIG.1 ASSEMBLY DRAWING

Page 10 of 10
The RSD-BB has2 stem seals, one primary seal(poz.38 Graphit paking ) backed up by second
independent seal (poz19.shaft gasket)
1. Turn valve to fully open position.
2. Remove the action.
3. Remove Extension.(42)
4. Remove GLAND [17], and clean gland surfaces.
5.Clean and grease GLAND BEARING(poz18)
6. Check and replace if necessary GRAPHIT PAKING(poz38).
7. Check and grease if necessary Stem(poz.21)
To rebuild the valve, first make sure all seals are in good working condition. Have grease lubricant handy and use it on
all seals.
Caution: Make sure any lubricant is compatible with the Seals and the intended valve service conditions.
Reassemble in reverse order ;make sure that is correct alignment of actuation components after re-assembly.
A1.3OFF STREAM MAINTENANCE

Major repairs which necessitate removing the valve from the line equipment.
Handling equipment as required for the weight involved.
DISASSEMBLY PROCEDURE
(Refer to Assembly Drawing)
1. If the valve is in line, isolate the valve from the line pressure.
2. Release the pressure from the inlet and outlet ports.
3. Place the valve in the open position.
4. Remove the valve from the line.
6.Remove the Extension
6.To disassemble the gland [17], carefully remove theGLAND SEALS[40.38)SPACER [11] , SEGMENTS[10] ,STEM
sealing(9,19.20)Axial bearig(8)], then carefully remove STEM [13]
7. Position the valve so that it rests on one port/flange face.
8. Remove theSTUD and NUTS [6,7] from the CLOSURE FLANGED [5], lift up the upper end
9.remove from the body and place on a clean solid surface.
10. Hang the BALL [37] with a strap through the bore, so that the weight of the ball is supported by the strap. Do not lift
the whole valve. Remove the Trunnion [35]
11. Lift the BALL [37] carefully out from the BODY [12] and place it on a clean solid surface.
12. From the end CLOSURES FLANGED[5], disassemble SEAT SUBANSAMBLY [25], SEALS [26] , and SPRINGS
[24].
INSPECTION AND CLEANING

1. Wipe off metal parts with a soft cloth, using petroleum solvent.
2. Inspect metal parts for damage or burrs on all moving surfaces.
3. Replace defective parts.
NOTE: O-rings are made to stretch with a certain tension around metal shoulder. Any stretching or swelling of o-ring
may cause cutting on re-assembly. Do not re-use orings unless their dimensions are carefully checked against new
parts.
LUBRICATION
Lubricate all moving surfaces
RE-ASSEMBLY
all seals. Reassemble in revers order ,make sure that is correct alignment of action components after re-assembly
Test the valve
Page 11 of 11
ANNEX A 2
O-ring 31.34x3.53-gland gasket
O-ring 75,79x3.53-seat gasket
4024.4352
-seat
3825.4520-1
-graphit paking
4024.3776-1
-CHEVRON paking

Page 12 of 12
The RSD-BB has 3 stem seals, one primary seal(poz.22.CHEVRON paking) backed up by second
independent seal(poz.21.Graphit paking)and third sealing (poz18.shaft gasket)
2. Remove the action
3. Remove Extension(42)
4. Remove GLAND [17], and clean gland surfaces.Check the GLAND SEALS (poz18.and 20)clean and replace them if
are damaged
6. Check and replace if necessary GRAPHIT PAKING (poz21)and CHEVRON PAKING (poz22)
7. Check and grease if necessary STEM (poz.24)
all seals.
A2.3 OFF STREAM MAINTENANCE

6.To disassemble the gland [17], carefully remove theGLAND SEALS[18,20)SPACER [11] , SEGMENTS[10] , ,STEM
THRUST WASHER[23], then carefully remove STEM [24]
9.remove from the body and place on a clean solid surface.
the whole valve. Remove the plate[37]
[29].

parts.
LUBRICATION
RE-ASSEMBLY
Test the valve
Page 13 of 13
ANNEX A 3
O-ring 23,47x2.62-gland gasket
-95x 90.5 h=3.6 body gaskets(spring energized PTFE seal)
-65x 58.8 h=4.8 -seat gasket(spring energized PTFE seal)
4024.4353
-seat
3825.6811
-graphit paking


Page 14 of 14
The RSD-BB has2 stem seals, one primary seal(poz.38 Graphit paking ) backed up by second
independent seal (poz19.shaft gasket)
3. Remove Extension.(44)
4. Remove GLAND [17], and clean gland surfaces.
6. Check and replace if necessary GRAPHIT PAKING(poz38).
7. Check and grease if necessary Stem(poz.21)
all seals.
A3.3 OFF STREAM MAINTENANCE

6.To disassemble the gland [17], carefully remove theGLAND SEALS[40.38)SPACER [11] , SEGMENTS[10] ,STEM
sealing(9,19.20)Axial bearig(8)], then carefully remove STEM [21]
9 .Remove from the body and place on a clean solid surface.
the whole valve. Remove the Trunnion [35]
[24].

parts.
LUBRICATION
RE-ASSEMBLY
Test the valve
Page 15 of 15

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Available Formats

SC FEPA SA

Type of connection to the process:

Nominal diameter or NPS 50-1400 or 2-56

Anti blow-aut proof stem

SEAT SEALAT INJECTION

Trunnion mounted ball

Double block and bleed

Open valve the valves chamber may become

8. PACKING, TRANSPORT, STORAGE,

8.3. Storage conditions

Flanged End Valve Installation

c. Max total misalignment. for allowable holes. org. assembly

Weld-End Valve Installation

Threaded-End Valve Installation

10 .INSTRUCTIONS FOR USE AND MAINTENANCE

Never attempt to interfere with the valve under pressure!

Any violation of instructions will void the warranty!

11. HEALTH, SAFETY, ENVIRONMENT

12. RISK ANALYSIS

Improper lifting and trasportation

- Failure to follow the installation

Lose on the shaft

Gas leaks in atmosphere

Lose to vent and

Gas leaks in atmosphere

-installation and operating error

used improper spare parts

Ball valve RSD-BB 1.1.50.300.1.0.3.0.1.1.1.FB

O-ring 20x2.65 -shaft gasket

O-ring 23.81x2.65 -shaft gasket

A1.2 On stream maintenance

FIG.1 ASSEMBLY DRAWING

A1.3OFF STREAM MAINTENANCE

INSPECTION AND CLEANING

A2.2 On stream maintenance

FIG.1 ASSEMBLY DRAWING

A2.3 OFF STREAM MAINTENANCE

INSPECTION AND CLEANING

A3.2 On stream maintenance

FIG.1 ASSEMBLY DRAWING

A3.3 OFF STREAM MAINTENANCE

INSPECTION AND CLEANING

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