Emerson KTM Installation Manual

KTM OM-2 SPLIT BODY FLOATING BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Before installation these instructions must be fully read and understood

SECTION 1 - STORAGE

1.1 Preparation and preservation for storage

All valves should be properly packed in
order to protect the parts that are subject to
deterioration during transportation and storage
on site. In particular, the following precautions
should be taken:

• The valves must be packed with the ball in the
open position.

• The flange sealing surface (raised face) shall
be protected with suitable protective oil.

• The end faces of the valve must be protected
with appropriate seal discs.

• The type of packing must be defined in
the Customer’s Order and be appropriate
to ensure safe transportation to the final
destination and eventual storage before
installation. Wrapping and/or covers should
be left in place until just prior to installation.

1.2 Handling requirements

1.2.1 Packed valves

Crates: Appropriate crate handling

equipment should be used to prevent
damage to crated valves.

Boxes: Handling of valves packed in carton

boxes should be done with extra
caution, taking specific note to lifting

points and the center of gravity.
The transportation of all packed valves and
components must be carried out safely and in
accordance with all local safety regulations.
Pay particular attention to the lifting limits
of handling equipment with reference to the
overall weight of packed and unpacked valves.

1.2.2 Unpacked valves

• The handling of valves unpacked from its
original packing needs to be carried out with
additional exterior protection in order to avoid
damages to machined surfaces. Use pallets
at all times, where appropriate.

• When handling large valves, appropriate tools
(brackets, hooks, fasteners, ropes) should
be used to secure valves firmly; and lifting
loads should be balanced in order to prevent
the valves from falling or moving during the
handling process.

CAUTION

• When handling valves, the correct equipment
and accessories (slings, fasteners, hooks,
etc.) must be sized and selected, taking into
consideration the individual and/or overall
valves weight indicated in the packing list and/or
delivery note.

• Lifting and handling must be made only by
qualified personnel. Improper hoisting can
cause valve deformation or damage from
dropping the valve.

• Do not lift valves by using lifting points or lugs
located on the actuator as these lifting points/
lugs are for the actuator only.

• Do not lift the valve by its hand-lever as these
levers are not designed to take the load of the
whole valve. Doing so may cause the lever to
break off or be disconnected from the valve,
resulting in possible valve damage or injury.

• Avoid lifting over a worker’s head or equipment,
or any other thing that can possibly be damaged
or cause of injury in the event that the lifted load
falls off the handling equipment.

• All local safety regulations must be observed
and complied with at all times.

1.3 Storage and preservation before installation

The storage of the valves should be in
accordance with the following criteria:

• Storage room should be clean and dry.

• The ball must be in the open position and the
end faces must be protected with appropriate
seal discs.

• Periodical checks have to be carried out
in the storage area to verify that the above
mentioned conditions are maintained.

CAUTION

The ball valves are delivered with the ball in the
full-open position and should be stored as they
are. Keeping the ball in other positions or half­open position for an extended period of time could
cause seat leakage.

NOTE

• Do not place consignment package directly on the
ground.

• Do not expose consignment packages to the rain/
wind or directly to the sun.

• Storage in an open area for a limited period can
be considered only if the valves have appropriate
packing (packed in cases covered with vinyl sheets
protecting from rain, wind, dust etc, and contents
well protected with barrier sacks).

• Store in a dry and well ventilated condition.

• If storage is anticipated for an extended period, the
desiccant bags (if supplied) should be changed every
6 months.

Emerson.com/FinalControl © 2017 Emerson. All Rights Reserved. VCIOM-01862-EN 17/09

KTM OM-2 SPLIT BODY FLOATING BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

2 INSTALLATION

2.1 Preparation before installation

• Remove the valve from the shipping package
(box or pallet) with care taken to avoid any
damage to the valve and actuator (plus
accessories where applicable).

• Before installation, remove the seal discs
from the flange. Clean the inside of the valve
using an air line that includes an appropriate
air-filter. Ensure that there are no solid
objects such as pieces of wood, plastic or
packing materials within the valve or on the
valve seat.

• Confirm that the materials of construction
listed on the valve nameplates are
appropriate for the service intended for and
are as specified. When in doubt contact KTM,
or your local Emerson facility.

• Define the preferred mounting orientation
with respect to the system pressure.
The arrow on the body helps to identify
the upstream side (high pressure) and
downstream side (low pressure).

• Ensure that all stud bolts and nuts of the body
joint are firmly fastened.

CAUTION

• Verify that the direction of the flow in the line
corresponds to the arrow indicated on the
valve body. Valves without the arrow are bi­directional.

• See the Actuator User Manual for the actuator
preparation.

2.2 Installation Instructions

• Ball valves are normally installed in
horizontal pipes with the stem facing up.
However, there are no limitations regarding
the pipe or stem orientation.

• Unless otherwise recommended by KTM, the
valve should be installed with the ball in the
open position, to ensure that the seat rings
are not damaged during installation.

• Particular care should be taken for valves
equipped with “fail-close” actuators.

• For operating temperatures above 200°C
(392°F), thermal insulation of the valve
body is recommended to protect the
actuator/accessories from heat beyond the
recommended temperature range.

• Handling and lifting of the valves during
installation MUST be performed following the
same criteria and instructions described in
points 1.2. and 1.3.

IMPORTANT

• It is recommended to perform pipe flushing
before installation of the valve. If this is not
possible, the installed valve must be in its open
position before flushing takes place.

• When conducting pressure test of the pipe
system, the valve should be in a full or half
open position. Check for any leakage from
the joint flange and gland portion during the
pressure test.

• If the piping system is pressurized with water
for testing, and if the piping system has been
shut down for a long time after testing, the
following recommendation should be adopted:

1. Use corrosion inhibitor with water to

pressurize the piping system.

2. After testing, the piping system should be

depressurized and the test water completely
drained.

3. Ensure that the corrosion inhibitor does not

leave a residue within the system as the
particulates may damage the valve sealing
surfaces.

CAUTION

During the pipe system pressure test, care must
be taken not to set the valve in the closed position
to avoid overload pressure which may cause seat
deformation or seat leakage.

2.3 Valve verification before start-up

• Tighten the gland nut just enough to prevent
stem leakage. Over-tightening will decrease
packing life and increase operating torque.
There is no need to over-tighten the stud
bolts/nuts to assure gasket tightness.

• Check the operation of the valve by stroking it
to “full open” and “full close”. The valve ball
travels clockwise to close.

2

KTM OM-2 SPLIT BODY FLOATING BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

3 OPERATION INSTRUCTIONS

Either the hand lever or the direction of the
parallel flats on the top of the stem indicate
the open or closed position of the KTM ball
valve. For gear operated valves, the position is
indicated by the arrow-indicator (see picture).

Excessive over travel during handle operation
may break the lever, injure the operator, and/
or deform the stopper or the stem, which may
lead to seat leakage.

The following instructions will help provide a
satisfactory and long life service.

1. Perform periodic valve verification.

2. In the case of actuated valves, always
follow the specific instructions given by the
actuator’s manufacturer.

3. Never change the setting of torque and/or
limit switches set during the final test by the
manufacturer.

4. Never change the setting of the mechanical
stops of the gearbox.

Locking device (option)

A locking device can be provided to prevent
unauthorized operation.

LOCK PIN DIMENSIONS (OPTIONS) mm

Valve nominal diameter
(full bore)

15 - 25 25 4.9 1.000 - 25 m/m
40 - 50 31 6.5 1.000 - 25 m/m
65 - 100 39 8.0 1.000 - 25 m/m
150 - 200 - - 1.000 - 25 m/m

Open position

Closed position

Adjustment Screws

Indicator

Pin dimensions Nominal pad lock

diameter alpha numberL d

4 MAINTENANCE

No routine maintenance is required other
than periodic inspection to ensure satisfactory
operation.

4.1 Gland packing maintenance

If leakage is observed through the gland
packing, tighten the gland nuts slowly and
evenly until the leakage stops. Do not over­tighten the packing gland nuts. Over-tightening
will increase the torque required to operate the
valve. Follow the torque table to ensure correct
torque used when tightening the gland nut.

Lock

TIGHTENING TORQUE FOR BODY JOINT AND GLAND

Body joint Gland
Class 150 300 150 and 300
Packing material RTFE or Soft carbon PTFE Soft carbon
Valve size
mm (inch)

15 (½) 13 - 18 M8 18 - 23 M8 2 4
20 (¾) 13 - 18 M8 18 - 23 M8 2 4
25 (1) 27 - 35 M10 36 - 46 M10 3 6
40 (1½) 13 - 18 M8 36 - 46 M10 7 15
50 (2) 27 - 35 M10 61 - 77 M12 7 15
65 (2½) 49 - 54 M12 93 - 123 M14 16 30
80 (3) 49 - 54 M12 93 - 123 M14 16 30
100 (4) 75 - 86 M14 148 - 187 M16 19 40
150 (6) 118 - 131 M16 385 - 488 M22 19 40
200(8) 220 - 270 M20 492 - 625 M24 32 65

* Standard for Soft (E) seat, Gratite seat and Metal seat

Bolt size Bolt size

Standard tightening torque* (Nm)

3