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.

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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
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)

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KTM OM-2 SPLIT BODY FLOATING BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Replace the gland packing as and when
necessary.

• Remove the lever or gear operator, snap ring
and stopper.

• Remove the gland bolts and flange.

• Replace the gland packing.

Reverse the procedure.

4.2 Body seal maintenance

Any sign of leakage through the body joint seal
should be addressed immediately by tightening
the stud nuts until the leakage stops. Follow
the torque table to ensure the correct torque is
used when tightening the gland nut.

CAUTION

Before removing the valve from the piping, ensure
that the system has been fully depressurized
and any dangerous fluids have been drained off.
Failure to do so may cause serious personal injury
and/or damage to the valve.

4.3 Valve disassembly

Refer to the respective construction drawing(s)
on the following page(s) of the valve(s) when
disassembling. Numbers of parts vary slightly
depending on the valve size, but the basic
structures are identical.
The valve shall be in the half open position.

• Before disassembling the valve, ensure
that it has been decontaminated from any
harmful gasses or fluids and is within a safe
temperature range for maintenance.

• Rotate the ball to a closed position.

• Loosen the hexagon nuts and remove the
body cap from the body. The seat and gasket
can then be easily removed.

• Remove the ball and seat with care so as to
prevent damage to the seal face of the ball.

• Remove the snap ring of the stem with a pair
of pincers and remove the gland bolts. Tap
the stem head with a plastic hammer and
withdraw it towards the interior of the body.

Stopper

Gland

bolt

Gland bolt

Stopper

Snap ring

Gasket

Bolt
Nut

Stopper

Gland cover

EB11 - 15mm - 100mm
EB12 - 15mm - 100mm

EB11 - 150mm - 200mm
EB12 - 150mm - 200mm
EB21 - 150mm - 250mm
EB22 - 150mm - 250mm

Gland bolt
Gland flange
Gland packing

Stem

Gland
bolt

Gland
flange

Gland
packing

Stem

NOTE

The stem has been designed as “anti-blow out” to
improve safety during system operation. This means
that the stem cannot be removed from the valve body
through the top of the body. It must be removed from
within the valve body.

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KTM OM-2 SPLIT BODY FLOATING BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

4.4. Valve re-assembly

This work shall be carried out by reversing
the aforementioned disassembling procedure.
Further, the following points should be noted:

• As shown in the diagram, slip a stem bearing
over the stem; set in such a way so that it
does not detach from the stem. Then insert it
into the gland from the interior of the body.

• Insert the gland packing (see 4.1.) and tighten
the gland bolts lightly.

• Since old gaskets occasionally adhere to
the body and body cap when the valve is
disassembled, the wastes of old gaskets
should be completely scraped off and the
sealing surfaces should be cleaned before
fitting new gaskets.

• When inserting the ball into the valve body,
hold the stem in the “SHUT” position as in the
case of disassembling and perform insertion
in the reversed manner for disassembling.

• Tighten the body cap with the ball in the
“SHUT” position. Nuts which face each other
are diagonally and uniformly tightened with
equal strength, taking care to avoid one-sided
tightening.

• Exercise care in re-assembling the valve
because its opening and closing vary
depending upon whether the correct facing of
the stopper (indicating OPEN and CLOSE) is
well-set upwards.

• Check the valve operation torque under
no load in a dry form before pressure test.
Ensure that the measured torque is within
range of the standard torque table. In the
event the torque is more than the standard
torque for Metal and Gratite seated ball
valves, reduce the torque by adding an extra
gasket for the body joint.

VALVE TORQUE AFTER ASSEMBLY

Class 150 and 300
Seat Soft (E) Gratite Metal
Gland Packing PTFE Soft carbon PTFE or Soft carbon PTFE or Soft carbon
Valve size mm (inch) Standard valve torque* (Nm)

15 (½) 2 - 6 5 - 10 ⋁ 15 ⋁ 7
20 (¾) 3 - 8 6 - 12 ⋁ 19 ⋁ 7
25 (1) 3 - 9 8 - 14 ⋁ 23 ⋁ 11
40 (1½) 6 - 16 19 - 29 ⋁ 38 ⋁ 20
50 (2) 8 - 22 21 - 35 ⋁ 55 ⋁ 25
65 (2½) 14 - 40 39 - 65 ⋁ 88 ⋁ 35
80 (3) 20 - 60 45 - 85 ⋁ 125 ⋁ 40
100 (4) 37 - 110 76 - 149 ⋁ 225 ⋁ 55
150 (6) 104 - 310 170 - 374 ⋁ 525 ⋁ 100
200 (8) 167 - 500 265 - 598 ⋁ 1000 ⋁ 150

* Torque measured after 2-3 times of operations under no load in a dry form before pressure test

Stem

Stem bearing
Thrust bearing

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KTM OM-2 SPLIT BODY FLOATING BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

PARTS LIST

No. Part name Qty.

1 Body 1
2 Cap 1
3 Ball 1
4 Stem 1
5 Seat 2
6 Stem bearing 1
7 Stem bearing 1
8 Stopper 1
9 Snap ring (C-type) 1
10 Thrust washer 1
11 Gland packing 1 set
12 Gland flange 1
13 Gland bolt 2
14 Stud bolt 4
15 Hexagon nut 4
16 Hexagon bolt 1
17 Gasket 1
18 Spring 1
19 Sp. washer 1
20 Pl. washer 1
21 Pk. washer 1
22 Handle 1
23 Live loading spring 2

CONSTRUCTION - Soft (E) seat ball valves (½” to 1”)

PARTS LIST

No. Part name Qty.

1 Body 1
2 Cap 1
3 Ball 1
4 Stem 1
5 Seat 2
6 Stem bearing 1
7 Stem bearing 1
8 Thrust bearing 1
9 Stopper 1
10 Snap ring (c-type) 1
11 Gland packing 1 set
12 Gland flange 1
14 Gland bolt 2
15 Stud bolt 6
16 Hexagon nut 6
17 Hexagon bolt 1
18 Gasket 1
19 Spring 1
21 Sp. washer 1
22 Pl. washer 1
23 Pk. washer 1
24 Handle 1
28 Live loading spring 2

CONSTRUCTION - Soft (E) seat ball valves (1-½” to 2-½”)

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KTM OM-2 SPLIT BODY FLOATING BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

PARTS LIST

No. Part name Qty.

1 Body 1
2 Body cap 1
3 Ball 1
4 Stem 1
5 Seat 2
6 Seat retainer 2
7 Inner ring 2
8 Cushion 2
9 Stem bearing 1
10 Stem bearing 1
11 Thrust bearing 2
12 Gland packing 1 set
13 Pk. washer 1
14 Gland flange 1
15 Gasket 1
16 Stud bolt 4-12
17 Hexagon nut 4-12
18 Gland bolt 2
19 Live loading spring 2
20 Stopper 1
21 Sp. washer 1
22 Hexagon bolt 1
23 Handle 1
24 Snap ring 1
25 Pl. washer 1

CONSTRUCTION - Gratite seat ball valves

Gland packing

(3pcs)

Gland packing set

Adapter
(2pcs)

PARTS LIST

No. Part name Qty.

1 Body 1
2 Body cap 1
3 Ball 1
4 Stem 1
5A Seat (A) 1
5B Seat (B) 1
6 Gasket 1
7A Stem bearing (A) 1
7B Stem bearing (B) 1
8 Thrust bearing 2
9 Pk. washer 1
10 Gland packing 1 set
11 Gland flange 1
12 Live loading spring 2
13 Gland bolt 2
14 Stud bolt 4-12
15 Hexagon nut 4-12
16A Seat gasket (A) 1
16B Seat gasket (B) 1
17 Spring holder 1
18 Spring 1
19 Stopper 1
20 Hexagon bolt 1
21 Sp. washer 1
22 Handle 1
23 Snap ring 1
24 Pl. washer 1

CONSTRUCTION - Metal seat ball valves

Gland packing

(3pcs)

Gland packing set

Adapter
(2pcs)

NOTE

Before assembling, ball and seats shall be lapped with each other.
Fine compound of approximately #1500 is recommended for the lapping.

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Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.

KTM is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions, Emerson and
the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by
our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without
notice.

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