Page 33 - Apollo - Industrial Applications Guide

Most Soft-Seated Ball valves are placed in services for the single purpose of stopping or allowing flow … commonly referred to
as ON–OFF service. Frequently, valves are installed in the most common service position (Open or Closed), and remain in that
position through commissioning (start-up). It is not until the plant (system) is taken off-line (shut-down) that the valve position
is changed. Typically this would not be an application suitable or justifiable for a Preventative Maintenance Program (PMP).
However, when a Soft-Seated Ball valve is installed in a service where it will be cycled (Closed-Open-Closed) numerous times
during normal plant operation a PMP is warranted.

A Preventative Maintenance Program (PMP) should only be considered for those Soft-Seated Ball valves that are capable of
being serviced and/or repaired during an outage, or short turn-around. In the case of Apollo, we are only considering; the
Three-Piece valves, Flanged End valves and the Top-Entry valves to be suitable for a Preventative Maintenance (PM) program.

FOUR CHECK POINTS FOR PREVENTATIVE MAINTENANCE ON APOLLO BALL VALVES

1. Body Joint Leakage – Detectible leakage at a Body/Bonnet joint indicates insufficient Bolting Torque and/or a Gasket (Seal)
not sealing properly. Body Joint leakage should be addressed immediately. Torque values are provided in Apollo literature
and online.

2. Leakage by the Seat – Detectable leakage by the Seats indicates debris on the Seat and/or damage to the Seat/Ball from
debris in the system or wire draw. Damaged Seats and/or Balls should be replaced immediately to mitigate further damage
and leakage. The system should be checked for the source of the debris, and corrective actions should be taken.

3. Packing Leakage – Detectible leakage in the Packing Gland area indicates insufficient compression of the Packing … the
Gland Adjustment Screws (bolts) should be torqued per the recommended Packing Torque value published by Apollo, or
it may be necessary to add an extra Packing Ring to the Gland Stuffing Box. Attempt to torque the Packing Gland
Adjustment Screws, if a Packing Ring needs to be added, verify there is no pressure in the system and attempt to add the
ring if possible; however, Apollo does not recommend that practice, and further recommends that the entire Packing Set be
replaced in accordance with the Apollo Installation and Operation Manual (IOM can be found on our website at
www.apollovalves.com). Minor leakage by the Packing typically will not cause severe damage; however, if ignored for a
prolonged period of time, the Stem and Stuffing Box can be damaged beyond repair.

4. Operational Torque – Prior to placing a Soft-Seated valve in service, the Operating Torque should be verified with the Apollo
published Torque values. During this verification, the valve should be cycled four or five times to over-come any “set” the
Ball and Seat may have taken since leaving our manufacturing facilities. Once in service, periodically compare the original
Installed Torque Value to the actual Operating Torque during the valve service life. Typically, increases in operating torque
during in-service operations indicate;

a. Debris build-up in the valve and/or on the Seats and/or Ball. Check the system for the cause (source) for corrective action.
b. Thermal swings can cause changes in operational torque. Check again when the system is in the “normal” condition.
c. Changes in the flow media may not be compatible with the Seat material causing it to swell or “popcorn”. Seats should
be changed-out for a proper Seating material that is suitable for the service.
d. A packing adjustment has been made and was overtightened.

Preventative Maintenance is a tool used to optimize operating costs efficiency. A comprehensive PM program may seem
expensive on the outside, but on the inside it can result in considerable operational costs savings. When Body Joints, Packing
and Seats are not leaking, and when the Operating Torque is in a normal range, system operating costs go down and production
capacity goes up.

The next generation of Preventative Maintenance is Predictive Analysis Maintenance. Accumulated history does lead to
Predictive Maintenance over time, and time is the operative word because time is money. Already today we have the so called

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