M70i/M80i Hygienic Ball Valve Installation and Maintenance Guide | Spirax Sarco

Installation and Maintenance Instructions

1. Safety Information
2. General Product Information
3. Installation
4. Commissioning
5. Operation
6. Maintenance and Spare Parts

1. Safety Information

Safe operation of this product can only be guaranteed if it is properly installed, commissioned, and maintained by qualified personnel (see Section 1.11) in accordance with the operating instructions. General installation and safety instructions for pipeline and plant construction must also be followed, and tools and safety equipment must be used correctly.

1.1 Intended Use

Refer to the Installation and Maintenance Instructions, nameplate, and technical literature to verify that the product is suitable for its intended application. This product complies with the requirements of the European Pressure Equipment Directive (PED) and can bear the CE marking where required.

The product complies with the following Pressure Equipment Directive classifications:

i) This product is specifically designed for clean/pure steam and other high-purity systems classified as Group 2 under the Pressure Equipment Directive. It is also suitable for liquid systems classified as Group 1 under the Pressure Equipment Directive. The product may also be used with other fluids. Contact Spirax Sarco to confirm its suitability for the intended application.
ii) Check material suitability and the pressure and temperature limits. If the upper operating limit of the product is lower than the requirements of the system in which it is installed, or if product failure could result in hazardous overpressure or overtemperature, ensure that the system is fitted with suitable safety devices to prevent these limits from being exceeded.
iii) Ensure correct installation and fluid flow direction.
iv) Spirax Sarco products are not designed to withstand external stresses imposed by the system. The installer is responsible for considering potential stresses and taking adequate precautions to minimize them.
v) Before installation in steam or other high-temperature applications, remove all protective covers from the connections and the protective film from the nameplate.

1.2 Access

Before working on the equipment, ensure safe access and, if necessary, provide suitable lifting equipment.

1.3 Lighting

Ensure adequate lighting, particularly where detailed or complex work is required.

1.4 Hazardous Liquids or Gases in the Pipeline

Consider the medium in the pipeline and its condition. Take account of flammable substances, substances hazardous to health, and substances at extreme temperatures.

1.5 Hazardous Environment Around the Product

Consider explosion hazards, lack of oxygen (for example, in tanks or pits), extreme temperatures, hot surfaces, fire hazards (for example, during welding), excessive noise, and moving machinery.

1.6 The System

Consider the effect of the intended work on the complete system. Determine whether any action, such as closing an isolation valve or performing electrical isolation, could place other parts of the system or personnel at risk.

Hazards may include isolation of vents or protective devices and failure of controls or alarms. Ensure that valves are opened and closed gradually to avoid system vibration.

1.7 Pressure Systems

Ensure that system pressure is isolated and safely vented. Consider double isolation (double block and bleed) and the locking or labeling of closed valves. Do not assume that the system is depressurized merely because the pressure gauge indicates zero.

1.8 Temperature

After isolating the valve, allow sufficient time for it to cool to ambient temperature to prevent burns.

When operated above 260 °C (500 °F), PTFE components release toxic fumes that can cause discomfort if inhaled. Smoking is prohibited in areas where PTFE is stored, handled, or processed. If tobacco contaminated with PTFE particles is smoked, inhalation of the fumes can cause a condition known as polymer fume fever.

1.9 Tools and Spare Parts

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

1.10 Protective Clothing

Consider whether operators or nearby personnel require protective clothing to guard against hazards such as chemicals, high or low temperatures, radiation, noise, falling objects, and injury to the eyes or face.

1.11 Permit to Work

All work must be carried out or supervised by qualified personnel.

Installation and operating personnel must be trained in the correct use of the product in accordance with its Installation and Maintenance Instructions.

A formal permit-to-work system must be followed. Where no such system exists, the person responsible should understand the work to be performed and determine where a person with specific responsibility for safety is required.

Post warning notices where necessary.

1.12 Handling

Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing, pulling, striking, or supporting a load using the body can cause injury, particularly to the back. It is recommended that the risks be assessed with consideration given to the task, personnel, load, and working environment, and that appropriate handling methods be used.

1.13 Residual Heat

During normal operation, the external surface of this product may become very hot. When operated at the maximum allowable conditions, the product surface temperature may reach 200 °C (392 °F).

These products are not self-draining. Exercise caution when dismantling or removing the product from the pipeline (refer to the “Maintenance Instructions”).

1.14 Freezing

Products that are not self-draining must be protected against freezing when used in applications where the ambient temperature may fall below the freezing point.

1.15 Disposal

Unless otherwise specified in the Installation and Maintenance Instructions, this product is recyclable, except for PTFE, and presents no ecological hazard provided it is disposed of correctly.

PTFE:

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

1.16 Returning Products

Customers and distributors returning products to Spirax Sarco must comply with UK and EC health, safety, and environmental regulations. Where contamination by hazardous residues or mechanical damage may present a health, safety, or environmental hazard, information must be provided regarding the hazards and the precautions to be taken. This information must include safety data for any substances identified as hazardous to health or safety.

2. General Product Information

2.1 Introduction

M70i and M80i 316L ISO and ASME BPE valves are intended for liquid, gas, and process-support applications, including clean steam.* These valves must be used as isolation valves, not as control valves.

ISO mounting

The integral ISO mounting allows the valve to be automated without dismantling the valve body, thereby maintaining sealing integrity. Fitting a Spirax Sarco BVA300 series pneumatic actuator enables straightforward conversion from manual to automatic operation. Contact Spirax Sarco for further information.

Standards:

The product fully complies with the European Pressure Equipment Directive (PED). The CE marking is available where required.

Certification:

The following certificates are available:

• EN 10204 3.1 material certificate
• FDA/USP elastomer compliance certificate
• Surface finish certificate

Note:

All certification and inspection requirements must be specified when placing the order.

Available Models

2.2 Sizes and Pipeline Connections

*Note: Steam service: Cavity fillers are not recommended for steam system applications.

Figure 1 M70i ISO - 1/2”, 3/4”, 1”, 1 1/2”, and 2”

Note: The 3” and 4” end connections have a different design and are fitted with six bolts.

Figure 2 M80i ISO - 2 1/2”, 3”, and 4”

2.3 Limiting Conditions

The product must not be used in this region.

A - B Virgin PTFE TFM 1600

A - C PTFE

*Note: Steam service: Cavity fillers are not recommended for steam system applications.

Note: Consult Spirax Sarco for operation at lower temperatures.
DPMX, the maximum differential pressure, is limited by PMO.

3. Installation

Note: Before installation, carefully read the “Safety Information” in Section 1.

Although the valve has a robust design, tensile stress caused by pipe misalignment or incorrect pipe length will adversely affect the valve and must be avoided. Take particular care to ensure that the pipework is correctly aligned and that the pipe and valve are on the same axis.

The valve is intended for on/off applications and is manually operated.

Allow sufficient clearance around the installed valve for operation and maintenance.

Before installing the valve, verify that its size, pressure rating, material, connection type, and other specifications are suitable for the application.

Before installation, remove any contaminants that may have accumulated in the ball valve during storage. Maintain cleanliness throughout installation, as contaminants may damage the valve seats and operating mechanism.

To reduce valve seat wear caused by abrasive particles, install a strainer upstream of the ball valve.

When installing the valve, ensure that the handle is in a suitable position. The ideal position is with the handle vertical. For gas service, the ball valve may be installed in any orientation (see Figure 4).

For steam service:

(Ball valves fitted with cavity fillers are not recommended for steam systems.)

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

For liquid systems, the valve must not be installed upside down (Figure 3).

Figure 3 Incorrect installation for liquid systems

The valve must be fully closed before installation in the pipeline.

Open the ball valve slowly to avoid system shock.

Figure 4 Correct installation for gas systems

4. Commissioning

After installation or maintenance, ensure that the system is fully operational. Test all alarm and protective devices.

5. Operation

The ball valve is manually operated using the handle. During operation, take particular care to move the handle in the correct direction.

The valve is intended for on/off service and may be placed in either the fully open or fully closed position.

6. Maintenance and Spare Parts

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

6.1 Introduction

As with all mechanical equipment, regular maintenance is the most effective way to ensure continuous and efficient operation.

Inspect all valves regularly, particularly those that are used infrequently.

6.2 Routine Maintenance

The complete valve does not need to be removed from the pipeline for maintenance. Remove the two upper bolts and nuts (see item 1 in the parts table) and loosen the two lower bolts. Remove the complete body assembly and install the new parts. See Sections 6.3 and 6.4 for M70i ISO and M80i ISO spare parts and maintenance instructions.

6.3 M70i ISO Spare Parts and Maintenance Instructions

6.3.1 Available Spare Parts

Parts shown with solid lines are available as spares. Parts shown with dashed lines are not available as spares.

Ordering Spare Parts

Order spare parts using the description given above, and specify the ball valve model and size.

Example: 1 - ½” M70i CF ISO forged stainless steel ball valve, virgin PTFE TFM 1600, seat and stem seal kit with cavity fillers

Figure 5 M70i ISO spare parts exploded view

6.3.2 Replacing the Seats and Body Gaskets (and Cavity Fillers, If Fitted)

• Remove the valve body as described in Section 6.2.
• Remove the valve body, seats (5), and body gaskets (16).
• Install the new seats (5) and body gaskets (16), pressing them into the valve body recesses.

6.3.3 Replacing the Stem Seals

• Remove the valve body as described in Section 6.2.
• Ensure that the valve is in the closed position.
• Remove the stem nut (10).
• Remove the handle (12) and locking washer (9).
• Remove the gland nut (8).
• Remove the Belleville washer (17) and washer (7).
• Remove the seats (5), body gaskets (16), and cavity fillers (15), if fitted.
• Push the ball to either side and remove it (3).
• Push the stem (4) down through the valve body cavity (1) and remove it.
• Replace the stem seals (6 and 18).

Figure 6 M70i ISO with cavity fillers

6.3.4 Reassembly

Reassemble by following the instructions above in reverse order. Ensure that the bolts and nuts (14) are tightened to the recommended torque specified in Table 1.

Retighten the body bolts after 24 hours of operation.

6.4 M80i ISO Spare Parts and Maintenance Instructions

6.4.1 Available Spare Parts

Parts shown with solid lines are available as spares. Parts shown with dashed lines are not available as spares.

Ordering Spare Parts

Order spare parts using the description given above, and specify the ball valve model and size.

Example: 1 - 4” M80iV ISO cast stainless steel ball valve, integral seats and cavity fillers, stem seals, stem O-ring, body seal kit, seal compression ring, and thrust washer

Figure 7 M80i ISO spare parts exploded view

6.4.2 Replacing the Seats and Body Gaskets

• Remove the valve body as described in Section 6.2.
• Remove the valve body, seats (5), and body gaskets (16).
• Install the new seats (5) and body gaskets (16), pressing them into the valve body recesses.

6.4.3 Replacing the Stem Assembly

• Remove the valve body as described in Section 6.2.

• Ensure that the valve is in the closed position.

• Remove the stem nut (10).

• Remove the handle (12) and locking washer (9).

• Remove the gland nut (8).

• Remove the Belleville washer (17) and washer (7).

• Remove the seats (5/5a) and body gaskets (16).

• Push the ball to either side and remove it (3).

• Push the stem (4) down through the valve body cavity (1) and remove it.

• Replace the stem seals (6), stem O-ring (11), seal compression ring (18), and thrust washer (19).

6.4.4 Reassembly

Reassemble by following the instructions above in reverse order. Ensure that the bolts and nuts (14) are tightened to the recommended torque specified in Table 1.

Retighten the body bolts after 24 hours of operation.

Figure 8