M10S Ball Valve Installation, Operation, Safety and Maintenance Guide | Spirax Sarco

1. Safety Information

Compliance with the operating instructions, and correct installation, commissioning and maintenance by qualified personnel, are the only guarantees of safe operation of this valve (see Section 1.11). During installation, follow the applicable pipeline and plant installation and safety guidelines. Use tools correctly and ensure that the necessary safety equipment is available.

1.1 Intended Use

Refer to the Installation and Maintenance Instructions, the nameplate and the technical documentation to confirm that the product is suitable for the intended application. This product complies with the requirements of the European Pressure Equipment Directive 97/23/EC and is classified as “SEP”. Products in this category are not required to bear the CE mark.

i) The product is designed for use with Group 2 fluids under the Pressure Equipment Directive, including steam, air and water/condensate. Consult Spirax Sarco if it is to be used with other fluids.
ii) Ensure that the product materials are suitable for the operating conditions, and that the maximum and minimum system pressures and temperatures are within the product’s design limits. If the product’s maximum operating limits are below the system operating conditions, or if product failure could cause an overpressure or overtemperature condition, install suitable protective devices.
iii) Ensure that the product is installed correctly and that the inlet and outlet are not reversed.
iv) Spirax Sarco products are not designed to withstand external loads. The installer must ensure that external forces in the system are not imposed on the product.
v) Before installing the product in a steam or other high-temperature system, remove the protective covers from all connections and the protective film from the nameplate.

1.2 Accessibility

After installation, ensure that there is adequate access for operation. If necessary, provide a safe working platform before operating the product. Provide lifting equipment where required.

1.3 Lighting

Ensure adequate lighting, particularly when carrying out detailed or complex work.

1.4 Hazardous Fluids or Gases in the Pipeline

Consider in advance the fluid in the pipeline and any fluids that may be present. Take care with flammable, hazardous-to-health, and hot or cold substances.

1.5 Hazardous Environments

Consider the risks of explosion, oxygen deficiency (for example, in tanks or low-lying areas), hazardous gases, hot or cold conditions, hot surfaces, fire (for example, during welding), excessive noise and moving machinery.

1.6 The System

Understand how the entire system operates. Before carrying out any work, such as closing an isolation valve or operating an electrical switch, consider whether this could put another part of the system or other personnel at risk.

Hazards may include the isolation of vents or protective devices, or the disabling of controls or alarms. Open and close isolation valves slowly to avoid system shock.

1.7 Pressure Systems

Ensure that the system is isolated from the pressure source or fully depressurized. Consider double isolation and locking or tagging closed valves. Do not assume that a zero reading on a pressure gauge means the system is fully depressurized.

1.8 Temperature

After isolating the product, allow it to cool to room temperature to prevent burns. If PTFE components are heated to or above 260°C (500°F), toxic fumes will be produced. Inhalation of these fumes may cause temporary discomfort. Smoking is prohibited in areas where PTFE is stored, handled or processed. If tobacco contaminated with PTFE particles is smoked, the resulting fumes may cause a temporary fever known as “polymer fume fever”.

1.9 Tools and Spares

Before starting work, ensure that suitable tools and spare parts are available. Use only genuine Spirax Sarco spare parts.

1.10 Protective Clothing

Consider whether operators or nearby personnel need protective clothing to guard against hazards such as chemicals, hot or cold conditions, radiation, noise, falling objects, and eye or facial injuries.

1.11 Permits to Work

All work must be carried out by competent personnel or under their supervision. Installation and operating personnel must be trained in accordance with the product’s Installation and Maintenance Instructions so that they can use the product correctly.

Where a permit-to-work system is in force, personnel must comply with it. If no such system is in force, the person responsible must be fully aware of the nature of the work and, where necessary, appoint a safety assistant.

Where necessary, post warning notices.

1.12 Handling

Manual handling of large or heavy products can cause injury. Lifting, pushing, pulling, carrying or supporting heavy loads by bodily force can cause injury, particularly to the back. Assess the task, the individual, the load and the working environment, and use appropriate handling methods for the conditions on site.

1.13 Residual Heat

During normal use, the external surface of this product may become very hot. At the maximum permissible operating temperature, the product surface may reach 260°C (500°F).

This product is not self-draining. Take care when removing or moving it from its installed position (refer to the Maintenance Instructions).

1.14 Freezing

For non-self-draining products used in ambient temperatures below freezing, provide frost protection where necessary.

1.15 Safety Information - Product-Specific

Hydraulic Locking

When a ball valve is used in hot or cold applications involving both steam and water in the flowing medium, it may become hydraulically locked. This can occur because, as the valve closes, water trapped in the ball is heated, generating high pressure inside the ball. To prevent locking, a small hole is drilled in the ball during manufacture to relieve the pressure that builds up after the valve closes. Spirax Sarco ball valves with this feature are marked with the correct installation orientation, with the hole facing the steam side when the valve is closed.

Bonnet Gasket

If the temperature of the O-ring reaches or exceeds 260°C (500°F), it will decompose and produce hydrogen fluoride gas (hydrofluoric acid). Avoid skin contact with and inhalation of hydrofluoric acid fumes, which can cause skin burns and respiratory injury.

1.16 Disposal

Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable and can be disposed of without ecological hazard, except for PTFE:

PTFE:

• Dispose of PTFE only by an approved method. Do not incinerate it.
• Store PTFE waste in a separate container and send it to a waste disposal site. Do not mix it with other waste.

1.17 Returning Products

In accordance with EC health, safety and environmental laws, customers and resellers must provide hazard information when returning products and take care to handle any residual contamination or mechanical damage that could pose a health, safety or environmental risk. Hazard information must be provided in writing and include health and safety data sheets identifying any known or potential hazards.

2. Product Information

2.1 Introduction

The M10S three-piece ball valve is an isolation valve and must not be used as a control valve. It is suitable for steam and other industrial fluids, from vacuum conditions to high temperatures and pressures.

The M10S can be serviced in-line without removing it from the pipeline (threaded and welded versions only).

Available models

Standards

This product fully complies with the European Pressure Equipment Directive 97/23/EC. CE marking is available as required.

Certificates

An EN 10204 3.1 certificate is available for this product.

Note: Please specify when ordering if an inspection certificate is required.

Note: For further information, refer to TI-P133-06.

2.2 Sizes and Pipe Connections

Figure 1. M10S flanged connection illustration

2.3 Pressure/Temperature Limits

Pressure (psi g)

This product must not be used in this region.

A - B Threaded, butt-weld and socket-weld connections, 1/4” - 1 1/2” FB, RB and 2” RB.

A - C Threaded, butt-weld and socket-weld connections, 2” FB and 2 1/2” RB only.

A - D ASME (ANSI) 300 flanged

A - E EN 1092 PN40 flanged

A - F ASME (ANSI) 150 flanged

Note 1: For M10S2 and M10S3 in 2” FB and 2½” RB sizes, a PTFE gasket is fitted between the body and bonnet.
Note 2: The maximum operating pressure may be limited by the flange standard. Please consult Spirax Sarco for details.

3. Installation

Note: Before installation, read Section 1, “Safety information”.

Although the valve is of robust construction, stress caused by poor pipe alignment and/or incorrect pipe length can adversely affect the valve and must be avoided. Take particular care to align the pipework correctly, ensuring that the pipework and valve are on the same axis.

The valve is intended for on/off service and can be operated manually.

Allow sufficient clearance when installing the valve to facilitate operation and maintenance.

Before installation, ensure that the size, pressure rating, material and connection type are suitable for the application.

Before installation, remove any contaminants that may have accumulated in the ball valve during storage. Keep the valve clean during installation, as contaminants can damage the valve seals and operating mechanism.

Install a strainer upstream of the ball valve to reduce seat wear caused by coarse particles.

Ensure that the handle is correctly positioned during installation. The ideal position is with the stem vertical. For gas service, the ball valve can be installed in any position (see Figure 3 below).

For steam service:

1. Install a drain point upstream of the ball valve.
2. Open the ball valve slowly to prevent water hammer.

For liquid service, do not install the valve upside down (Figure 2).

Figure 2. Incorrect installation for liquid service

The valve should be fully closed before installation in the pipeline. Before socket-welding or butt-welding the valve to the pipeline, you must:

1. Remove the end caps from the body.
2. Remove the seats and body gasket.
3. Weld each end cap to the pipeline.
4. Refit the seats and body gasket.
5. Reassemble the ball valve.

Open the ball valve slowly to avoid system surges.

Figure 3. Correct installation for gas service

4. Commissioning

After installation or maintenance, ensure that the system can operate safely. Test the alarm or protective devices.

5. Operation

The ball valve is operated manually by a handle or by an actuator. Take special measures to ensure the correct direction of operation. The valve is for on/off service and must be either fully open or fully closed.

6. Maintenance

Note: Before carrying out any maintenance work, read Section 1, “Safety information”.

6.1 General

As with all mechanical equipment, regular maintenance is the most effective way to ensure long-term operating efficiency.

Regular maintenance of all equipment is essential, particularly for valves that are used infrequently.

6.2 Introduction

The valve does not need to be removed from the pipeline for maintenance. Remove the two upper bolts and nuts (15, 16), and loosen the two lower ones. The complete body assembly can then be removed so that new parts can be fitted.

Flanged version - The complete valve must be removed from the pipeline for maintenance. Remove the four nuts (16), then remove the complete body assembly and fit new parts.

6.3 Replacing the seat (5):

• Remove the body as described above.
• Remove the seat (5).
• Fit the new seat (5) into the recess in the body.

6.4 Replacing the stem seal (6):

• Remove the body as described above.
• Remove the nuts (9 and 11) and washer (8).
• Replace the stem seal (6).

6.5 Assembly

Reassemble by reversing the steps described above. Tighten the bolts and nuts (15, 16) to the recommended torque; see Table 1.

Retighten the body bolts and nuts 24 hours after maintenance.

Figure 4

7. Spare Parts

Spare parts are shown in solid lines. Parts shown in dashed lines are not available as spares.

Available spare parts

Seats and stem seals

5,6

Ordering spare parts

When ordering spare parts, use the descriptions in the “Available spare parts” section above and specify the ball valve size and model.

Example: One set of seats and stem seals for a 1/2” M10S2FB ball valve.

Figure 5. M10S threaded connection illustration