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

1.1Preparation 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.

1.2Handling 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.

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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.

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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			Adjustment Screws
the open or closed position of the KTM ball
valve. For gear operated valves, the position is
indicated by the arrow-indicator (see picture).	Open position
Excessive over travel during handle operation				Indicator
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.	Closed position
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	LOCK PIN DIMENSIONS (OPTIONS) mm
manufacturer.
4. Never change the setting of the mechanical	Valve nominal diameter	Pin dimensions		Nominal pad lock
stops of the gearbox.	(full bore)	L	d	diameter alpha number
Locking device (option)	15 - 25	25	4.9	1.000 - 25 m/m
	40 - 50	31	6.5	1.000 - 25 m/m
A locking device can be provided to prevent	65 - 100	39	8.0	1.000 - 25 m/m
unauthorized operation.	150 - 200	-	-	1.000 - 25 m/m

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 Lock 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.

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					Standard tightening torque* (Nm)
mm (inch)				Bolt size					Bolt size
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

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