IMO - 207 Issue Date: 11/01

INSTALLATION, MAINTENANCE, AND

OPERATING INSTRUCTIONS

SERIES 3 VALUE-LINE™
3-PIECE BALL VALVES

Read entire instructions carefully before installation or servicing

1 GENERAL 2 INSTALLATION
This instruction manual contains important information 1. Screwed End Style - Screwed end valves have NPT
regarding the installation, operation and troubleshooting threads. To insure a leaktight joint, liberal use of a com-
of the Jamesbury Series 3 VALUE-LINE 3-Piece Ball Valves. patible pipe joint compound is necessary. Use standard
Please read these instructions carefully and save them for piping practices to install valves with threaded end
future reference. caps. When tightening the valve to the pipe, apply
wrench to end cap nearest the pipe being worked.
1.1 WARNING
FOR YOUR SAFETY, IT IS IMPORTANT THAT THE FOLLOWING PRECAU- 2. Weld End Style -
TIONS BE TAKEN PRIOR TO INSTALLATION, ANY SERVICING OR
REMOVAL OF THE VALVE FROM THE LINE OR BEFORE ANY DISASSEMBLY: A. Only a qualified person should weld pressure
retaining parts, as outlined in Section IX of the
1. WEAR ANY PROTECTIVE CLOTHING OR EQUIPMENT NORMALLY
REQUIRED WHEN WORKING WITH THE FLUID INVOLVED.
ASME Boiler and Pressure Vessel Code.
2. AT ALL TIMES DURING THIS ENTIRE PROCEDURE, KEEP HANDS B. Use the appropriate filler material and qualified
OUT OF THE VALVE. A REMOTELY ACTUATED VALVE COULD CLOSE procedure, in accordance with applicable piping
AT ANY TIME AND RESULT IN SERIOUS INJURY. codes and standards.
3. BEFORE REMOVING THE VALVE FROM THE LINE, DEPRESSURIZE THE C. Turn the valve to the full open position.
LINE AND PERFORM THE FOLLOWING:
A. PLACE THE VALVE IN THE OPEN POSITION AND DRAIN THE
D. Remove or protect the handle, actuator, and any
LINE. other part that might be damaged by heat, weld
B. CYCLE THE VALVE TO RELIEVE RESIDUAL PRESSURE IN THE BODY
splatter, or incidental arc strikes.
CAVITY BEFORE REMOVAL FROM THE LINE. E. Wrap a wet cloth or the like around the center
C. AFTER REMOVAL, AND BEFORE ANY DISASSEMBLY, CYCLE THE section of the valve body to minimize heat transfer
VALVE AGAIN SEVERAL TIMES. to the seats and seals.
4. IT IS IMPORTANT TO REFER TO THE INFORMATION ON EACH F. CAUTION: Multiple weld passes are required.
VALVE FOR THE PRESSURE RATING AND MATERIAL DESCRIPTION.
Maximum weld bead size should be less than
CONTACT METSO AUTOMATION IF ADDITIONAL INFORMATION IS
REQUIRED. 1/8” (3 mm). DO NOT heat the center section above
400˚F (204˚C). Use a temperature stick or other
5. THESE VALVES ARE SUITABLE FOR A WIDE VARIETY OF FLUIDS
AND GASES. BE CERTAIN THAT THE MATERIALS SELECTED ARE
means to monitor the valve body temperature.
SUITABLE FOR THE APPLICATION. For welds that require multiple passes to achieve
size,stop after each 360˚ pass and carefully monitor
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the inter-pass temperature to prevent over-heating 10. Carefully pry out and discard the old stem seals (7),
the center body. Between passes, ensure the wet and the stem bearing (8). Be careful not to damage any
cloth is still damp. of the sealing or bearing surfaces.
G. After cooling to a temperature where the valve can 3.2 Assembly
be safely touched, replace the handle or actuator
per the applicable instructions and procedures. The following instructions are for in-line assembly. For
bench assembly, which may be more convenient, follow a
3 MAINTENANCE similar procedure by holding the valve in a vise by one end
Periodically observe the valve to be sure of proper per- cap. Use care not to cut or scratch the seats (5) or seals (7).
formance. More frequent observation is recommended 1. With the valve body (1) swung to the out-of-line posi-
under extreme operating conditions. tion, insert the stem bearing (8), into the stem bore.
Routine maintenance consists of tightening the stem nut
1/4 turn periodically to compensate for the wear caused by 2. Insert the threaded end of the stem (4) into the stem
the stem’s turning against the resilient PTFE seal. bore and up out the top of the valve. Be careful not to
damage the stem bearing (8).
3.1 Disassembly
3. Holding the stem bearing in place from inside the
This ball valve is designed to be serviced in or out of the pipe valve, install two stem seals (7), the compression ring
line. The following instructions are for in-line disassembly: (18), and thread on one of the stem nuts (16) until the
stem starts to turn.
1. Comply fully with the instructions in the WARNING
Section at the beginning of this document. 4. Place a wrench through the body on the bottom of the
stem blade to hold the stem stationary. Place another
2. Be sure to cycle the valve. Leave the valve in the open wrench on the stem nut (16) and turn the nut down
position. The center body section will not swing out if until the seals bottom and the stem comes snugly into
the valve is in the closed position. place. Tighten the stem nut (16) until snug, plus an
3. Remove the top stem nut (16), lockwasher (9) and the additional 1/4 –1/2 turn.
handle (15).
5. Align the stem blade inside the valve body (1) with the
4. Loosen all four body bolts (20). Remove three of the ball (3). Insert the ball (3) and rotate the stem (4) to the
four bolts from the valve. Leave the remaining bolt in fully closed position.
place with the nut backed off at least 1/4" (6 mm)
6. Working at either end of the body (1), place a seat (5)
5. For positive alignment and ease of in-line assembly, each into the body valve (1). Push the seat (5) snugly against
end cap is interlocked approximately 1/16" (1.5 mm) the closed ball (3).
into the valve body. To overcome this feature during
in-line disassembly, it is necessary to separate each 7. Place a body seal (6) into the machined sealing groove
end cap at least 1/16" (1.5 mm) from the valve body. of the end cap (2). Be certain the groove and seal are
Sharply rap the valve body and the end cap with a clean.
block of wood or a rubber mallet to break loose the
body seal. Spread the end caps and swing the valve 8. Repeat steps 6 and 7 for assembly of the opposite end
body (1) out of the pipe line. Be careful not to damage of the valve.
the sealing surface at each end of the valve. 9. Turn the stem to the full open position.
6. Turn the stem (4) so that the valve is in the fully closed
10. Swing the entire body assembly back into the properly
position. Remove the body seals (6) from the end caps
aligned and interlocked position between the end
(2) and the seats (5) from the valve body (1). Body seals
caps (2), being careful not to scratch the body seals.
may be tightly compressed in their grooves. Use
The end caps (2) may have to be spread slightly to
extreme care when prying them out. Damage such as
accept the valve body (1).
scratches to the bottom of the groove will cause leaks.
If the seats are not easily removed, gently tap the ball 11. Close the valve.
(3) with a piece of wood or other soft material.
12. Bolt the valve together with body bolts (20) lockwash-
7. Remove the lower stem nut (16) and the compression ers (21) and nuts (19). Tighten the nuts evenly, alternat-
ring (18). ing between them to the torque listed in (Table 1).
8. Remove the ball (3) from the valve body (1).
13. Place the handle (15), lockwasher (9) and stem nut (16)
9. Press the stem (4) from the top into the valve body (1), over the stem (4). Tighten the stem nut (16) until it is
and remove it through one end of the body. snug.
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4 SERVICE KITS 5 REPAIR KITS/SPARE PARTS

NOTE: Service kits include two seats (5), one stem bearing For further information on spare parts and service or
(8), two stem seals (7), and two body seals (6). assistance visit our web-site at www.jamesbury.com.

TABLE 1 TABLE 2
BOLT TORQUE SERVICE KITS
Valve Size Bolt Torque Valve Size T Seats M Seats
1/2” (DN 15) 4 lb. - ft. (5.4 Nm) 1/2” (DN 15) RKN-107-TT RKN-107-MT
3/4” (DN 20) 9 lb. - ft. (12 Nm) 3/4” (DN 20) RKN-108-TT RKN-108-MT
1” (DN 25) 16 lb. - ft. (22 Nm) 1” (DN 25) RKN-109-TT RKN-109-MT
1-1/4” (DN 30) 16 lb. - ft. (22 Nm) 1-1/4” (DN 30) RKN-110-TT RKN-110-MT
1-1/2” (DN 40) 16 lb. - ft. (22 Nm) 1-1/2” (DN 40) RKN-111-TT RKN-111-MT
2” (DN 50) 25 lb. - ft. (34 Nm) 2” (DN 50) RKN-112-TT RKN-112-MT

PARTS LIST
ITEM PART NAME QTY
1 Body 1
2 Body Cap 2
3 Ball 1
4 Stem 1
5 Seat 2
6 Body Seal 2
7 Stem Seal 2
15
8 Stem Bearing 1
9 Lockwasher 1
9 16 4 15 Handle 1
16 Stem Nut 2
18 Compression Ring 1
19 Hex Nut 4
20 Body Bolt 4
8 18 7
21 Lockwasher 4

20 2 6 1 3 5 21 19
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www.jamesbury.com

IMO-207-11/01 © 2001 Metso Automation Printed in U.S.A.-M-J