ATTACHMENT B Sample Lesson Plan Outline Contents - Wm Lyles

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with, valve, union, ASAHI, VALVES, Ball, Caution, TRAINING, O-ring, Page, Type, Valve, connector, handle, from, Manual, wrench, ball, Maintenance, Installation,Operation, valve., body, ACTUATOR, strap, side, Nominal, excessive, pressure, size, Replace

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TRAINING OF OCSD PERSONNEL Solids Thickening and Processing Upgrade
Job No. P2-89
01820-10 CONFORMED
ATTACHMENT B
Sample Lesson Plan Outline Contents
Class Title: P2-89
Concept / Topic To Teach: OP RATION OF THE VALVES
Standards Addressed: MANUFACTURERS STANDARDS
Target audience (e.g.: operators, mechanical maintainers, electrical maintainers, instrument
techs, collections personnel) OPERATORS- ELECTRICAL/MECHANICAL
General Goal(s): IDENTIFY THE PRODUCTS
Specific Objectives: OPERATION AND MAINTENANCE
Required Materials: IOM MANUAL
Schedule (with times) HOURS
Lead-In (start time): TBT
Step-By-Step Outline of Presentation (with start times/durations): MANUAL
Plan For Hands-on Training/Exercises (with start times/durations): PRODUCT SAMPLE
Wrap-up (Reflect Lead-in) (start time): HOUR
Connections To Other Training Sessions/Topics:
Assessment Form (Based On Specific Objectives): Q & A AND REVIEW BY
* * * * * *
TRAINING #3 ASAHI VALVES
Page 1 of 21
SSI #19 2/20/2013 SPECIFICATION SUBMITTAL INFORMATION
THE FOLLOWING INFORMATION IS CORRECT AS NOTED BY THE FOLLOWING
INFORMATION FROM THE LISTED DATA SOURCES.
SUBMITTED BY MISCO SOUTHWEST
27101 BURBANK STE B
FOOTHILL RANCH, CA 92610
PHONE 949-458-5555
RICK BARTON
REFERENCE ORANGE COUNTY SANITATION DISTRICT
SOLIDS AND THICKENING UPGRADE
W. M. Lyles JOB T1098 MISCO JOB 0199VB
TONY MUELLER 951-757-4686
PROJECT P2-89
22212 BROOKHURST STREET
HUNTINGTON BEACH, CA
SCOPE SUPPLY OF ELECTRIC OPERATED BALL VALVES
TYPE ECCENTRIC
REFERENCE SPECIFICATION 15106 BALL VALVES
SPECIFICATION 15101ACTUATORS
VALVE MANUFACTURER ASAHI AMERICA
35 GREEN STREET
MALDEN. MASS
781-321-5409
MODEL 21-CPVC-VITON
SPEC COMPARISON
15106
15106.2.2.A.1 CONFORMS MATERIAL CPVC BODY TO MATCH PIPING
15106.2.2.A.2 ENDS ENDS TRU-UNION ENDS
15106.2.2.B.1 CONFORMS ENDS TRU-UNION ENDS
15106.2.2.B.2 CONFORMS RATING 150 PSI @ 73 F
15106.2.2.B.3 CONFORMS PORT FULL PORT TEFLON SEATS
15106.2.2.B.4 CONFORMS SEALS VITON
15106.2.2.B.5 NA NA MOV
15106.2.2.C.1 CONFORMS MFR ASAHI
SIZE VALVE TAG # PID LOCATION DESCRIPTION AND OPERATOR
3" 22I-NP-FV 339 22I-NP-181 TRU-UNION Valve with O/C Motor Operator with DISCONNECT
3" 22I-NP-FV-344 22I-NP-182 TRU-UNION Valve with O/C Motor Operator with DISCONNECT
3" 22I-NP-FV-369 22I-NP-191 TRU-UNION Valve with O/C Motor Operator with DISCONNECT
3" 22I-NP-FV-374 22I-NP-192 TRU-UNION Valve with O/C Motor Operator with DISCONNECT
ACTUATOR MANUFACTURER FLOWSERVE FLOW CONTROL
LIMITORQUE CORPORATION
5114 Woodall Road
Lynchburg, VA 24506-1318
Phone: 434-528-4400
SPECIFICATION MATERIALS OF CONSTRUCTION CONFORMATION
TRAINING #3 ASAHI VALVES
Page 2 of 21
ACTUATOR MODEL LIMITORQUE QX2-WP-FA10-210000-10000 120 4S OC 120 VOLT CONTROL
WITH HANDWHEEL OVERRIDE
AND INTEGRAL LOCAL CONTROL STATION
AND DISCONNECT
CONTROL AT THE ACTUATOR - LOCAL CONTROL PANEL ON THE ACTUATOR IN "LOCAL"
AT THE REMOTE HAND STATION IN "LOCAL"
AT THE ACTUATOR - MANUAL OVERRIDE WITH THE ACTUATOR IN "OFF"
OR NO POWER
DISCRETE CONTROL FROM THE PLC IN "REMOTE"
VALVE TORQUE REQUIRED 29.5 FTLBS AT 150 PSI
ACTUATOR RATED TORQUE 250 FTLBS
SAFETY FACTOR >1.5
SPEED RANGE 8-30 SECONDS SET AT 8 SECONDS
TURNS FOR FULL CYCLE 90 DEGREES
VOLTAGE 480/3/60
FAIL ON LOSS OF POWER LAST POSITION
WIRING DIAGRAMS LIMITORQUE QX2-210000-10000 120 4S OC 120 VOLT CONTROL
ENCLOSURE RATING WP NEMA 4X
DISCONNECT NONE
REMOTE HAND STAION NONE
DOCUMENENT SUPPLIED VALVE CATALOG
ACTUATOR CATALOG
VALVE SHOP DRAWINGS
ACTUATOR SHOP DRAWING
INSTRUCTION MANUAL ACTUATOR
INSTRUCTION MANUAL VALVE
VALVE PARTS LIST
ACTUATOR (NO PARTS LIST INCLUDED)
MAINTENANCE INSTRUCTIONS
WARRANTY TWO YEARS FROM DATE OF DATE OF THE FINAL ACCEPTANCE BY THE AGENCY
ASSEMBLY: FACTORY INSTALLED
CYCLE TESTING: MISCOWATER, 27101 BURBANK STE B, FOOTHILL RANCH, CA 92610
FIELD START-UP PERFORMED BY MISCO AS REQUIRED
VALVE IDENTIFICATION STAINLESS STEEL NAMEPLATES ATTACHED TO THE VALVE PER
17075 316 SS TWO HOLE NAMEPLATE WITH SS WIRE
TAG NUMBER
SIZE
TYPE OF VALVE
PID DRAWING
TRAINING #3 ASAHI VALVES
Page 3 of 21
ASAHI/AMERICA
Rev. D 06-06
6
• Pressure rated up to 230 psi (PVC, CPVC, PVDF)
• Double O-ring seals on stem for an added
protection.
• Full bore, sizes 1/2" – 2"
• Full vacuum rated, all sizes
• Blocks in two directions, upstream and
downstream, leaving full pressure on the
opposite end of the valve
• Integrally molded ISO mounting pad for both
manual and actuated operations
• Integrally molded base pad to mount valves
Securely or panel mounting
• PTFE seats with elastomeric backing cushions
ensure bubble-tight shut-off and a low fixed
torque, while at the same time compensating
for wear
• True Union design for easier installation or
repairs without expanding the pipe system
• Built-in spanner wrench on the handle for valve
disassembly and assembly
• Two sets of end connectors (socket and
threaded) included with all PVC and CPVC valves
in sizes 1/2"– 2"
• CPVC threaded end connectors on sizes
1/2" – 1" come with stainless steel reinforcing
rings
Specifications
Sizes: 1/2" – 6"
Models: PVC & CPVC: Socket, Threaded
and Flanged (ANSI)
PP & PVDF: IPS and Metric (DIN)
Socket, Threaded, Butt and
Flanged (ANSI)
Bodies: PVC, CPVC, PP and PVDF
Seats: PTFE backed with EPDM or FKM
Seals: EPDM or FKM or AFLAS®‡
Sizes 1/2" - 4" PVC/EPDM/FKM Models
available with NSF-61 Certification
‡ Trademark of Asahi Glass Co., Ltd.
Options
• Pneumatic and electric actuators & accessories
• Stem extensions
• 2" square operating nut or “T” nut
• Locking and/or spring return handles
• Limit switches
• Vented Ball
Parts List (Sizes 1/2" – 2")
* Used for flanged end
**Used for CPVC body, threaded end, 1/2”–1”
Standard Features (Sizes 1/2" – 6")
Type 21 Ball Valve
STRAP
.ON NOITPIRCSED .SCP LAIRETAM
1 ydoB 1 FDVP,PP,CVPC,CVP
2 llaB 1 FDVP,PP,CVPC,CVP
3 reirraC 1 FDVP,PP,CVPC,CVP
4 rotcennoCdnE 2 FDVP,PP,CVPC,CVP
5 tuNnoinU 2 FDVP,PP,CVPC,CVP
6 metS 1 FDVP,PP,CVPC,CVP
7 taeS 2 EFTP
8 )A(gniR-O 2 srehtO,MKF,MDPE
9 )B(gniR-O 1 srehtO,MKF,MDPE
01 )C(gniR-O 2 srehtO,MKF,MDPE
11 )D(gniR-O 1 srehtO,MKF,MDPE
21 )E(gniR-O 1 srehtO,MKF,MDPE
31 *gniRpotS 2 FDVP
41 eldnaH 1 SBA
a4 **gniR 2 leetSsselniatS403
TRAINING #3 ASAHI VALVES
Page 4 of 21
ASAHI/AMERICA
Rev. D 06-06
8
14
15
e 10
L
2 1 7 9 53 8 13 4
n-øht
e 1
ø
d 3
1
H
P
.C
.D

d C
ø
D
2
11
H
12
6
A
1
S
L
4
L
4
SOCKET END
ø
d 2
ø
D
ø
d 1 1
THREADED END
1
ø
d ø
D
1
4
L
ø
d ø
D
1 1
SPIGOT END
t l l l FLANGED END
Dimensions (Sizes 2 1/2" – 4") FOR 6" SIZE CONSULT FACTORY
LANIMON
EZIS
DEDAERHT
d3 1D H H1 A
)DNETTUB(TOGIPS
e1 e2 S1d1 l L
FDVP,PP
2443NID PP FDVP
LSEHCNI mm d1 l t t
2 2/1 56 2 2/1 TPN8- 62.1 64.8 82.2 42.5 69.4 38.2 78.7 359.2 694.1 272.0 241.0 27.9 53.0 42.0 98.1
3 08 TPN8-3 ....... 83.1 93.01 07.2 89.5 15.5 53.3 54.9 345.3 694.1 323.0 961.0 16.11 34.0 82.0 71.2
4 001 TPN8-4 ....... 77.1 71.41 45.3 72.8 10.7 33.4 18.11 133.4 257.1 493.0 902.0 27.21 34.0 13.0 65.2
Type 21 Ball Valves
LANIMON
EZIS
d DEGNALF TEKCOS
051SSALCISNA
L t
CVPC,CVP )NID(FDVP,PP )SPI(FDVP,PP
08HCSMTSA
L
26961NID
L d1 l LSEHCNI mm D C n h d1 d2 l d1 d2 l
2 2/1 56 65.2 7 5.5 4 57.0 2.01 17.0 988.2 868.2 57.1 54.9 329.2 119.2 22.1 51.8 88.2 257.1 54.9
3 08 70.3 5.7 6 4 57.0 79.11 17.0 615.3 294.3 578.1 1.11 215.3 894.3 4.1 88.9 84.3 478.1 1.11
4 001 49.3 9 5.7 8 57.0 56.41 17.0 815.4 194.4 2 9.31 392.4 872.4 36.1 2.21 84.4 252.2 73.41
NOTE: Quantity on Nos. 3 and 9 (see p. 6) is 2.
)"2–"2/1MORFSREBMUNTNEREFFID(STRAP
.ON NOITPIRCSED .SCP LAIRETAM
01 noihsuC 2 srehtO,MKF,MDPE
51 wercS 1 leetSsselniatS403
TRAINING #3 ASAHI VALVES
Page 5 of 21
35 Green Street, P.O. Box 653, Malden, MA 02148 • Tel: 800-343-3618 • 781-321-5409 • Fax: 800-426-7058 • E-mail: asahi@asahi-america.com
Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.com
9
Sample Specification
Pressure vs. Temperature (PSI, WATER, NON-SHOCK)
• Do not use ball valves where media has
suspended particles. Use the following valves:
Butterfly Valves – PVDF disc is most abrasion
resistant and make sure of chemical compatibility.
Diaphragm Valves – Elastomeric diaphragm is
designed for handling suspended particles.
• Volatile fluids such as sodium hypochlorite (NaClO)
and hydrogen peroxide (H
2
O
2
) could be trapped
and gasified within the valve. We can provide you
with a Type 21 ball valve with a vented ball to
relieve pressure build-up inside the valve.
Caution
What if the fluid still flows when valve is closed?
1. Carrier is not properly tightened. Tighten it.
2. PTFE seat is damaged or worn. Replace
seat.
3. Foreign material is caught between ball and
PTFE seat. Remove material and clean.
4. Ball is damaged or worn. Change ball.
What if fluid leaks outside of valve?
1. Union nut not properly tightened. Retighten.
2. Carrier is not properly tightened. Thread it in
firmly.
3. Carrier or face O-ring is damaged, worn, or
missing. Replace O-ring.
What if handle does not rotate smoothly?
1. Foreign material has formed on the ball or
seat. Clean both.
2. Internal part(s) chemically attacked or
swollen. Refer to Asahi/America Chemical
Resistance Chart for compatibility. Replace
part(s) as required.
3. Carrier over-tightened. Retighten properly.
What if handle rotates too freely?
1. Stem is damaged. Replace stem.
2. Handle is not engaged with stem.
Disassemble and reengage. Inspect.
3. Engaging part of stem and/or ball is
damaged. Change stem and/or ball.
Troubleshooting
Weight (POUNDS)Cv Values
• Never remove valve from pipeline under pressure.
• Always wear protective gloves and goggles.
• Watch out for trapped fluid in valve. It is safe to
close valve before removing it from the pipeline.
Caution
LANIMON
EZIS
CVP CVPC PP FDVP
F0̊3
F0̊7
F1̊7
F5̊01
F6̊01
F0̊21
F1̊21
F0̊41
F0̊3
F0̊7
F1̊7
F5̊01
F6̊01
F0̊21
F1̊21
F0̊41
F1̊41
F5̊71
F6̊71
F5̊91
F5̊-
F5̊8
F6̊8
F0̊21
F1̊21
F0̊41
F1̊41
F5̊71
F5̊-
F0̊7
F1̊7
F5̊01
F6̊01
F0̊41
F1̊41
F5̊71
F6̊71
F0̊12SEHCNI mm
2/1 2- 05-51 032 071 051 03 032 071 051 021 57 55 051 011 09 55 032 581 051 511 58
2 2/1 56 032 071 051 AN 032 071 051 021 57 55 051 59 07 04 032 581 051 511 58
3 08 032 071 051 AN 032 071 051 58 55 04 051 59 07 04 032 581 051 001 07
6-4 051-001 051 051 051 AN 051 051 051 58 55 04 051 59 07 04 051 051 051 001 07
Type 21 Ball Valves
All TYPE 21 Ball Valves, sizes 1/2” to 4”, shall be of
true union design with two-way blocking capability.
All O-rings shall be EPDM or FKM with PTFE seats.
PTFE seats shall have elastomeric backing cushion
of the same material as the valve seals. Stem shall
have double O-rings and be of blowout-proof design.
The valve handle shall double as carrier removal
and/or tightening tool. ISO mounting pad shall be
integrally molded to valve body for actuation. PVC
conforming to ASTM D1784 Cell Classification
12454-A, CPVC conforming to ASTM D1784 Cell
Classification 23567-A, PP Conforming to ASTM
D4101 Cell Classification PP0210B67272 and
PVDF conforming to ASTM D3222 Cell Classification
Type II. The ball valves, except PP, shall have a
pressure rating of 230 psi for sizes”1/2” to 3” and
150 psi for 4” (150 psi for PP, all sizes) at 70 º F.
Type 21 Ball Valves must carry a two-year
guarantee, as manufactured by Asahi/America, Inc.
LANIMON
EZIS TEKCOS
DEDAERHT
DEGNALF
SEHCNI mm
2/1 51 44.0 01.1
4/3 02 66.0 45.1
1 52 01.1 07.2
1 4/1 23 45.1 03.3
1 2/1 04 46.2 04.4
2 05 04.4 51.8
2 2/1 56 71.6 08.8
3 08 07.9 00.31
4 001 00.42 76.62
LANIMON
EZIS CV
SEHCNI mm
2/1 51 41
4/3 02 92
1 52 74
1 4/1 23 27
1 2/1 04 551
2 05 091
2 2/1 56 563
3 08 014
4 001 086
TRAINING #3 ASAHI VALVES
Page 6 of 21
TRAINING #3 ASAHI VALVES
Page 7 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 0
Serial No. H – V027 E – 4
Contents
(1) General operating instructions
(2) General instructions for transportation,
unpacking and storage
(3) Name of parts
(4) Comparison between working
temperature and pressure
(5) Installation procedure
(6) Operating procedure
(7) Method of Adjusting face pressure
           between ball and seat
(8) Disassembling method
for parts replacement
(9) Mounting actuator, metal Ensert and base(panel)
(10) Inspection items
(11) Troubleshooting
(12) Handling of residual and waste materials
(13) Inquiries
Ball Valve Type 21
User’s Manual
13
14
13
13
11
4
3
2
1
1
9
9
10
ASAHI AV VALVES
TRAINING #3 ASAHI VALVES
Page 8 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 1
(1) General operating instructions
○ Operate the valve within the pressure Vs temperature range.
(The valve can be damaged by operating beyond the allowable range.)
○ Select a valve material that is compatible with the media, refer to “CHEMICAL RESISTANCE ON ASAHI AV
VALVE”.
(Some chemicals may damage incompatible valve materials.)
○ Do not use the valve to fluid containing slurry. (The valve will not operate properly.)
○ Do not use the valve on condition that fluid has crystallized.
(The valve will not operate properly.)
○ Do not step on the valve or apply excessive weight on valve. (It can be damaged.)
○ Do not exert excessive force in closing the valve.
○ Make sure to consult a waste treatment dealer to dispose of the valves.
(Poisonous gas is generated when the valve is burned improperly.)
○ Allow sufficient space for maintenance and inspection.
○ Keep the valve away from excessive heat or fire. (It can be deformed, or destroyed.)
○ The valve is not designed to bear any kind of external load. Never stand on or place anything heavy on the valve
at anytime.
○ Certain liquid such as H2O2, NaClO, etc may be prone to vaporization which may cause irregular pressure
increases, which may destroy the valve.
(2) General instructions for transportation, unpacking and storage
○ Keep the valve packed in the carton or box as delivered until installation.
○ Keep the valve away from any coal tar, creosote (antiseptic for wood), termite insecticide, vermicides, and
paint.
(This could cause swelling damage the valve.)
○ Do not impact or drop the valve. (It can be damaged.)
○ Avoid scratching the valve with any sharp object.
TRAINING #3 ASAHI VALVES
Page 9 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 2
(3) Name of parts
No. DESCRIPTION No. DESCRIPTION
◯1 Body ◯7 Seat
◯2 Ball ◯8 O-ring (A)
◯3 Carrier ◯9 O-ring (B)
◯4b End connector (Flanged end type) ◯10 Cushion
◯4c End connector (Socket end type) ◯11 O-ring (C)
◯4d End connector (Threaded end type) ◯12 O-ring (D)
◯4e End connector(Spigot type) ◯13 Stop ring
◯5 Union nut ◯14 Handle
◯6 Stem ◯15 Screw
No. DESCRIPTION No. DESCRIPTION
◯1 Body ◯7 Seat
◯2 Ball ◯8 O-ring (A)
◯3 Carrier ◯9 O-ring (B)
◯4b End connector (Flanged end type) ◯10 O-ring (C)
◯4c End connector (Socket end type) ◯11 O-ring (D)
◯4d End connector (Threaded end type) ◯12 O-ring (E)
◯4e End connector(Spigot type) ◯13 Stop ring
◯5 Union nut ◯14 Handle
◯6 Stem
Nominal size 15-50mm (1/2”-2”)
Nominal size 65-100mm (2 1/2”-4”)
TRAINING #3 ASAHI VALVES
Page 10 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 3
(4) Comparison between working temperature and pressure
Do not operate the valve beyond the range of working temperature and pressure.
(The valve can be damaged.)
Caution
Nominal size: 15mm-50mm (1/2”-2”) Nominal size: 65mm (2 1/2”)
Nominal size: 80mm, 100mm (3”, 4”)
TRAINING #3 ASAHI VALVES
Page 11 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 4
(5) Installation procedure
Flanged type (Material: PVC,C-PVC,PP,PVDF)
   
● Torque wrench ● Spanner wrench
● AV gasket ● Bolt, Nut, Washer (For many flanges specification)
(When a non-AV gasket is used, a different tightening torque specification should be followed.)
    Procedure
1) When the union nut ◯5 flange assembly set was removed or loosen from body ◯1 , O-ring (A) ◯8
should be installed into carrier and body groove. (In either horizontal or vertical installation, if necessary
apply a small amount of lubricant to O-ring to hold in place.) Align union nut and end connector with
the body. Insure end connector mates with body and O-ring. Make certain union nut threads onto body
smoothly. Tighten union nuts on each side valve until hand tight. Then using a strap wrench tighten
union nuts uniformly on each side approx 90o -180o turns, 1/4 to 1/2 turns.
2) Set the AV gasket between the flanges.
3) Insert washers and bolts from the pipe side, insert washers and nuts from the valve side, then
temporarily tighten them by hand.
Unit : mm (inch)
Nom. Size AxialMisalignment
Parallelism
(a-b)
15-32mm
(1/2”-1 1/4”) 1.0mm (0.04”) 0.5mm (0.02”)
40-80mm
(1 1/2”-3”) 1.0mm (0.04”) 0.8mm (0.03”)
100mm
(4”) 1.0mm (0.04”) 1.0mm (0.04”)
4) Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal manner.
(Refer to fig.1.)
Recommended torque value Unit: N-m{kgf-cm}[lb-inch]
Nom. Size 15-20mm(1/2”-3/4”)
25-40mm
(1”-1 1/2”)
50, 65 mm
(2”, 2 1/2”)
80, 100 mm
(3”, 4”)
Torque value
17.5
{179}
[155]
20.0
{204}
[177]
22.5
{230}
[230]
30.0
{306}
[266]
Necessary items
(Axial misalignment) (Parallelism)
Fig. 1
Caution
The parallelism and axial misalignment of the flange surface should be under the values shown in the
following table to prevent damage the valve.
(A failure to observe them can cause destruction due to stress application to the pipe)
Avoid excessive tightening. (The valve can be damaged.)
Caution
TRAINING #3 ASAHI VALVES
Page 12 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 5
Threaded type (Material : PVC,C-PVC,PP,PVDF)
● Sealing tape(A non-sealing tape can cause leakage.)
● Strap wrench(Do not use Pipe wrench.)
● Spanner wrench
Procedure
1) Wind a sealing tape around the external thread of joint, leaving the end (about 3mm) free.
2) Loosen the union nut ◯5 with a strap wrench..
3) Remove the union nut ◯5 and the end connector ◯4d .
4) Lead the union nut ◯5 through the pipe.
5) Tighten the external thread of the joint and the end connector ◯4d hardly with hand.
6) Using a spanner wrench, screw in the end connector ◯4d by turning 180°-360°carefully without damaging it.
7) Make sure that the O-ring (A) ◯8 is mounted.
8) Set the end connector ◯4d and union nut ◯5 directly on the body without allowing the O-ring (A) ◯8 to come off.
9) Tighten union nuts ◯5 on each valve until hand tight.
10) Using a strap wrench tighten union nuts uniformly on each on each side approx 90°-180°turns, 1/4 to
1/2 turns.
Necessary items
Make sure that the threaded connections are plastic x plastic.
(Metallic thread can cause damage.)
Avoid excessive tightening. (The valve can be damaged.)
Avoid excessive tightening. (The valve can be damaged.)
Caution
Caution
Caution
TRAINING #3 ASAHI VALVES
Page 13 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 6
Socket type (Material : PVC, C-PVC)
● Adhesive for hard vinyl chloride pipes
● Strap wrench (Do not use the pipe wrench)
Procedure
1) Loosen the union nut ◯5 with a strap wrench.
2) Remove the union nut ◯5 and end connector ◯4c .
3) Lead the union nut through the pipe.
4) Clean the hub part of the end connector ◯4c by wiping the waste cloth.
5) Apply adhesive evenly to the hub part of the end connector ◯4c and the pipe spigot.
Adhesive quantity (guideline)
Nom. Size 15mm(1/2”)
20mm
(3/4”)
25mm
(1”)
32mm
(1 1/4”)
40mm
(1 1/2”)
50mm
(2”)
65mm
(2 1/2”)
80mm
(3”)
100mm
(4”)
Quantity(g) 1.0 1.3 2.0 2.4 3.5 4.8 6.9 9.0 13.0
6) After applying adhesive, insert the pipe quickly to the end connector ◯4c and leave it alone for at least 60
seconds.
7) Wipe away overflowing adhesive.
8) Make sure that O-ring(A) ◯8 is mounted
9) Set the end connector ◯4c and union nut ◯5 directly on the body without allowing the O-ring (A) ◯8 to come off.
10) Tighten union nut ◯5 hardly with hand.
11) Using a strap wrench tighten union nuts uniformly on each side approx 90°-180°turns, 1/4 to 1/2 turns.
Necessary items
Do not install a socket type valve where the atmospheric temperature is 5℃ or lower.
(The valve can be damaged.)
Do not apply more adhesives than necessary.
(The valve can be damaged due to solvent cracking.)
Avoid excessive tightening. (The valve can be damaged.)
Caution
Caution
Caution
TRAINING #3 ASAHI VALVES
Page 14 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 7
Socket type (Material : PP, PVDF )
● Strap wrench (Do not use the pipe wrench.)
● Sleeve welder or automatic welding machine
● User’s manual for sleeve welder or automatic welding machine
Procedure
1) Loosen the union nut with a strap wrench.
2) Remove the union nut ◯5 and the end connector.
3) Lead the union nut ◯5 through the pipe.
4) For the next step, refer to the user’s manual for the sleeve welder or the automatic welding machine.
5) After welding, make sure that the O-ring (A) ◯8 is mounted.
6) Set the end connector ◯4c and the union nut ◯5 directly without allowing the O-ring (A) ◯8 to come off.
7) Tighten union nut ◯5 hardly with hand.
8) Using a strap wrench tighten union nuts uniformly on each side approx 90°-180°turns, 1/4 to 1/2 turns.
Spigot type (Material : PVDF )
● Strap wrench (Do not use the pipe wrench.)
● Automatic welding machine
● User’s manual for automatic welding machine
  Procedure
1) Loosen the union nut with a strap wrench.
2) Remove the union nut ◯5 and the end connector.
3) Lead the union nut ◯5 through the pipe.
4) For the next step, refer to the user’s manual for the sleeve welder or the automatic welding machine.
5) After welding, make sure that the O-ring (A) ◯8 is mounted.
6) Set the end connector ◯4e and the union nut ◯5 directly without allowing the O-ring (A) ◯8 to come off.
7) Tighten union nut ◯5 hardly with hand.
8) Using a strap wrench tighten union nuts uniformly on each side approx 90°-180°turns, 1/4 to 1/2 turns.
Necessary items
Avoid excessive tightening. (The valve can be damaged.)
Necessary items
Avoid excessive tightening. (The valve can be damaged.)
Caution
Caution
TRAINING #3 ASAHI VALVES
Page 15 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 8
Nominal size 15mm - 50mm (1/2” – 2”)
{15mm-50mm(1/2”-2”)}
It is recommended to install the valve with the threaded carrier to the upstream side of the system.
This allows for an increase safety factor and eliminating a threaded connection when used as a blocking valve.
This also allows the down stream union nut and end connector to be removed safely under pressure.
It increases the safety where there is no chance of thread leakage or accidentally removing the carrier.
The designation of the up stream side (non threaded carrier is marked as shown) on the body.
Caution
TRAINING #3 ASAHI VALVES
Page 16 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 9
(6) Operating Procedure
○ Turn the handle gently to open or close.
(Turn the handle clockwise to close and counter clockwise to open.)
Fully closed …… The position of the handle should be perpendicular to the pipe.
Fully opened …… The position of the handle should be parallel to the pipe.
(7) Method of Adjusting Face Pressure between Ball and Seat
● Strap wrench ●Safety goggles
● Protective gloves ●Screwdriver (+) (only with nominal size 65~100mm)
Procedure
1) Completely discharge fluid from pipes.
2) Turn the handle to full close.
3) Loosen the right union nut and the left one ◯5 with a strap wrench.
4) Remove the body part from piping system.
5) Pull the handle off the body part.
6) Engage the upper convex part of the handle with the concave part of
the union ◯3 .
7) Make an adjustment by turning the union clockwise (to tighten it)
or counter clockwise (to loosen it).
8) Make sure that the handle can be operated smoothly.
9) Assemble the valve by following the above procedure in the reverse
order, starting at 6)
Avoid excessive tightening. (The valve can be damaged.)
Fully opened Fully closed
Necessary items
Wear protective gloves and safety goggles as some fluid remains in
the valve. (You may be injured.)
As for nominal size 65-100mm (2 1/2”-4”), loosen the screw ◯15
properly with a screwdriver before pulling it off..
As for nominal size 15-50mm
Only the union ◯3 on the right side when viewed from the
trademark (AV mark) can be adjusted.
As for nominal size 65-100mm
adjust the unions on both sides.
Caution
Caution
Caution
Caution
TRAINING #3 ASAHI VALVES
Page 17 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 10
(8) Disassembling Method for Replacing Parts
● Strap wrench ●Safety goggles
● Protective gloves

Procedure
1) Completely discharge fluid from pipes.
2) Turn the handle to full close.
3) Loosen the right union nut and the left one ◯5 with a strap wrench.
4) Remove the body part from piping system.
5) Pull the handle off the body part.
6) Engage the upper convex part of the handle with the concave part
of the union.
7) In the engaged state, turn the handle ◯14 counter clockwise to loosen it
and remove the union ◯3 .
8) Remove the seat ◯7 carefully by hand without damaging it.
9) Push out the ball ◯2 by hand.
10) Push out the stem ◯6 from the top flange side to the body side.

Procedure
Carry out the assembly work in the reverse procedure from item 10)
Necessary items
Wear protective gloves and safety goggles as some fluid remains in the valve.
(You may be injured.)
With regard to item 8), before installing seat ◯7 on the valve, check the seat for its face and back.
As for nominal size 65-100mm (2 1/2”-4”), loosen the screw ◯15
properly with a screwdriver before pulling it off..
As for nominal size 15-50mm
Only the union ◯3 on the right side when viewed
from the trademark (AV mark) can be adjusted.
As for nominal size 65-100mm, adjust the unions on both sides.
Caution
Caution
Caution
Caution
TRAINING #3 ASAHI VALVES
Page 18 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 11
(9) Mounting actuator, Ensat and base (panel)
○ Attach actuator to the top flange
Procedure
1) Remove the handle ◯14 .
2) Fix the stand ◯24 to actuator ◯23 with bolt (A).
3) Fix the stem ◯6 to the joint ◯25 with screw (B) ◯28 .
4) Engage the joint ◯25 with actuator ◯23 .
5) Fix the stand ◯24 to the top flange
with bolt-nut (B) ◯27 .
6) Make sure that the valve works smoothly, by operating actuator ◯23 by hand.
○ Attach Inserted metal to the bottom stand.
Procedure
Refer to the user’s manual for the Inserted metal
(Commercially available.)

As for nominal 65mm-100mm, tighten the screw ◯15
properly before removing it.
Bottom stand dimension Unit; mm
Nom.Size S1 S2 S3
15mm (1/2”) 19 7.3 11
20mm (3/4”) 19 7.3 11
25mm (1”) 19 7.3 11
32mm (1 1/4”) 30 9 15
40mm (1 1/2”) 30 9 15
50mm (2”) 30 9 15
65mm (2 1/2”) 48 9 6
80mm (3”) 55 11 7
100mm (4”) 65 11 8
Nominal 15-50mm(1/2”-2”)
Bottom stand
Nominal 65-100mm (2 1/2”- 4”)
Bottom stand
Caution
TRAINING #3 ASAHI VALVES
Page 19 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 12
○Fixation of bottom stand with panel
Nominal size: 15mm-50mm (1/2”-2”)
Nominal size: 65mm-100mm (2 1/2”-4”)
Before the fixation After the fixation
Before the fixation After the fixation
TRAINING #3 ASAHI VALVES
Page 20 of 21
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Ball Valve Type 21 13
(10) Inspection items
○Inspect the following items.
(11) Troubleshooting
Problem Cause Treatment
The carrier is loosened.
Adjust the face pressure between the
ball and the seat.
(Refer to page 9)
The seat is scratched or worn. Replace the seat with a new one.
Foreign matter is in the valve. Clean up.
Fluid leaks from the valve
even when the valve is closed
fully.
The ball is scratched or worn. Replace the scratched ball with a newone.
The union nut is loosened. Tighten up the union nut.
The carrier is loosened.
Adjust the face pressure between the
ball and the seat.
(Refer to page 9)
Fluid leaks from the valve.
The O-ring is scratched or worn. Replace the O-ring with a new one.
Foreign matter is in the valve. Clean up.
The handle can not be turned
smoothly.
Deformation. (By heat etc.) Replace the parts.
The stem is broken. Replace the stem with a new one.
The handle fails to engage.
The engagement between the stem and the ball
is broken.
Replace the stem and ball with new
ones.
(12) Handling of residual and waste materials
In discarding remaining or waste materials, be sure to ask waste service company.
(Poisonous gas is generated.)
(1) Existence of scratches, cracks, deformation, and discoloring.
(2) Existence of leakage from the valve to the outside.
(3) Existence of leakage when the valve is opened fully at right or left.
Caution
TRAINING #3 ASAHI VALVES
Page 21 of 21

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