Emerson KTM OM-2 GRATITE Installation And Operation Manual

KTM OM-2 GRATITE® SEAT BALL VALVES

INSTALLATION AND OPERATION MANUAL

Before installation these instructions must be fully read and understood

The contents of this manual is effective as of
August 2007.
KTM reserves the right to discontinue the
manufacture of, change or modify design
and/or construction of any KTM product during
the manufacturing procedure, without incurring
any obligation to accept for credit, to replace or
furnish or install such changes or modifications
on products previously or subsequently sold.
This document is subject to changes without
notice.

1 SAFETY PRECAUTIONS

Precautions for using KTM valves safely are

Please read through this manual completely
before operating the valves.
OM-2 Gratite Seat Ball Valves are usable for toxic
or high temperature/high pressure fluid.
Please use the valves according to warnings and
cautions described in this document. Failure to
do so could result in an accident due to wrong
storage, installation, operation, maintenance and
disassembling and/or serious damage.
Please keep this manual in a handy place for
immediate reference; be sure to provide it to
purchaser, contractor, piping designer, user,
operator or maintenance technician.

highlighted with the following two warning
signs according to the level of danger posed.
Please read the postscript carefully to ensure
safety and prevent any damage before starting
to use the product.

WARNING

A potentially hazardous situation which, if not
avoided, could result in death or serious injury.

CAUTION

A potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.

SELECTION GUIDE

Example: EB11 G 31 CC A15 15
Valve codes
EB11 ASME 150 EB12 ASME 300

JIS10K JIS20K
JPI 150 JPI 300

Sub-codes
G Gratite Seat
Body codes
31 CF8 / SCS13A 32 CF8M / SCS14A 62 WCB / SCPH2
Trim codes
CC Standard trim materials
Flange codes
A15 ASME 150 J10 JIS10K P013 JPI 150
A30 ASME 300 J20 JIS20K P033 JPI 300
Size

15 mm ~ 200 mm (½" ~ 8")

© 2017 Emerson. All Rights Reserved.Emerson.com/FinalControl VCIOM-02453-EN 19/04

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KTM OM-2 GRATITE® SEAT BALL VALVES

INSTALLATION AND OPERATION MANUAL

WCB Class 300

GRATITE SEAT RATING

CF8 Class 300

CF8 Class300

Pressure (MPa)

CF8 Class 150

WCB Class 150

CF8 Class 150

050 100 200 300 400 500150 250 350 450

32 132 232 332 432 532 632 732 832 932

This body rating is according to ASME B16.34.

2 SPECIFICATION

The safety of the valves and conformity with
your equipment should be checked by the
design engineer or those who determine the
specification based on the catalog or other
technical data.
Upon arrival, the applicable conditions
(temperature, pressure, fluid-characteristics,
environmental conditions, mounting gauge
etc.) should be first checked to make sure they
arecorrect.

For the standard specifications, refer to the table
below and the catalog.

GRATITE SEAT RATING

WARNING

Do not use valves beyond specifications or limits
indicated in the catalog.

CAUTION

1. These models may be used indoors or
outdoors. If however used in an environment
exposed to gas, an appropriate type and
material should be used to prevent corrosion
or rusting. (Details on the component
materials are provided in the catalogs.)

2. To prevent accidents, custom-made valves
for special treatment and operation should be
ordered for specific applications using oxygen
and hydrogen peroxide.

3 RANGE OF APPLICATION

Pressure/Temperature Rating
OM-2 Gratite seat ball valves have a range
of application defined by temperature and
pressure. Please operate the valve within the
range shown below. Operating the valve outside
that range may result in failure of valve body or
parts and leakage of the fluid. (The pressure/
temperature rating is defined by body material
and seat material.)

CAUTION

The maximum temperature for applications to
oxidative fluids and in oxidative environment is
449˚C.
The maximum temperature for models with
nominal diameters 6” (150 mm) and 8” (200 mm)
is normally 350˚C.

4 STORAGE AND PRESERVATION BEFORE
INSTALLATION

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

1. Storage warehouse should be clean and dry.

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

3. Do not remove the bore protection
cover until installation to avoid rust and
contamination with foreign substances.

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

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KTM OM-2 GRATITE® SEAT BALL VALVES

INSTALLATION AND OPERATION MANUAL

CAUTION

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

2. Do not place consignment package directly on
the ground.

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

4. 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).

5. Store in a dry and well ventilated condition.

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

5 TRANSPORTATION

WARNING

1. 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.

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

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

4. 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 brake off or be disconnected from the
valve, resulting in possible valve damage or a
person’s injury.

5. Avoid lifting over people’s heads, equipments
or anything else that can possibly be damaged
or cause of injury in the event that the lifted
load falls off the handling equipment.

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

6 INSTALLATION

The following instructions will make for a
satisfactory and long life service of the valve.

1. Remove the valve from the shipping package
(box or pallet) carefully to avoid any damage
to the valve and actuator (plus accessories
where applicable).

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

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

4. Fasteners like bolts and nuts at each
connecting portion on the valve should
be checked and retightened in case
they were loosened due to shock during
transportation. When tightening nuts, use a
closed wrench for safety.

5. Before installation, the protection cover on
the bore must be removed.

6. Manually operated valves, may be installed
on pipes at any angle, horizontally, vertically
or any other direction. It is however
recommended to consider facilitating
maintenance and operation of the valve.

7. Maintenance space must be provided.

CAUTION

1. Ensure that there are no solid objects such as
pieces of wood, plastic or packing materials
within the valve or on the valve seat. It is
recommended to flush pipes before installing
the valve. If this is not possible, the installed
valve must be in its open position before
flushing takes place.

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

3. Use appropriate gaskets which comply with
standards or specifications.

4. Tighten the flange bolts with a closed wrench,
using a ‘crisscross’ pattern that alternately
tightens the bolts located 180 degrees apart
(see Fig. 1). Unequal partial tightening places
stress on lined pipes which may damage the
flange or produce excessive operation torque.

5. Failure to fabricate pipes without excessive
stress will result in leakage, poor operation
or failure of the valves.

6. When conducting a pressure test of the pipe
system, the valves should be in a partially open
position. Testing at closed position will impose
too much load and will cause leakage from
seats. Check for any leakage from the joint
flange and gland portion during the pressure
test. After conducting pressure test, return to
fully open/closed position at once.

7. 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 measures should be taken:

• Use corrosion inhibitor with water to

pressurize the piping system.

• After testing, the piping system should be

depressurized and the test water completely
drained.

• Ensure that the corrosion inhibitor does not

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

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KTM OM-2 GRATITE® SEAT BALL VALVES

INSTALLATION AND OPERATION MANUAL

FIGURE 1
Tightening of bolts

7 OPERATION

7.1 Operation Instruction

Valve adjustment is performed through lever
handle/gear operation. Turning the stem
clockwise shuts the valve. Check the operation
of the valve by stroking it to “fully open” and
“fully closed”. Either the hand lever or the
direction of the parallel flats on the top of the
stem indicate the open or close position of the
KTM ball valves (Figure 2). For gear operated
valves, the position is indicated by the arrow­indicator (Figure 3).

CAUTION

Avoid using the valves at half-open position, since
it may result in seat deformation and leakage.

FIGURE 2
Lever handling valve

Valve opened

Valve closed

7.2 Gear operated valve adjustment

If the gear-operated mechanism indicator
does not correctly indicate whether the valve
is completely open or shut, adjust the opening
with the adjustment screw. For details, refer to
document No. C325-330, “Instruction Manual of
A, B, C and D typed Gear Operational Valves”.

7.3 Key-lock (option)

A locking device at the open and shut positions
can be provided to prevent unauthorized
or incorrect operation. Unlock and detach
the padlock when you open/shut the valves,
otherwise padlock and stopper might break.
To lock the OM-2 Gratite seat ball valves, use
locks of the sizes indicated in the table below.

FIGURE 3
Gear operated valve

Indicator

FIGURE 4
Lock pin and pad lock

WARNING

1. Operate the valve taking up a stable posture,
after checking that the specified handle is
fastened by bolts/ nuts or snap ring/ set
screw. Also, when operating the valve with
a spare handle, please make sure that the
handle is reliably inserted into the stem’s end.
Insufficient insertion and forced operation of
the handle may result in damage or injury if
the handle slips out.

2. Excessive handle operation may break the
lever, injure the operator, and/ or deform the
stopper or the stem, which may also result in
seat leakage.

3. Be careful in handling the valve where high
temperature fluid flows in the pipeline.
The heated valve may cause burn injury of
bare hands.

PAD LOCK DIMENSIONS (mm)

(for reference)
Valve nominal diameter Pin dimensions
(Full bore) L d Alpha No.

15~25 25 4.9 1000-25
40~50 31 6.5 1000-25
65~100 39 8 1000-25
125~200 * 1000-25

* Unnecesary

Pad lock type (m/m)

FIGURE 5
Locking example

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KTM OM-2 GRATITE® SEAT BALL VALVES

INSTALLATION AND OPERATION MANUAL

FIGURE 6

Fully opened Fully closed

The cavity

8 ABNORMAL PRESSURE RISE

CAUTION

Malfunction or damage of sealing material of the
ball valves may occur due to abnormal pressure
rise caused by fluid trapped in the cavity (Fig. 6)
between the body, ball and seat.
KTM is taking measures to ensure that pressure
in both cavity and the pipes will be equalized when
the valves are at opened position.

Abnormal pressure rise can be caused by:

1. Rapid heating of valve exterior

2. Exposure to high temperature fluid after the
valve is closed

3. Location near a heat source

Please contact us concerning countermeasures
for these problems, such as providing a pressure­relieving hole on the surface of a ball that is
subject to high pressure.

9 MAINTENANCE

CAUTION

If leakage is observed through the gland packing,
tighten the gland bolts slowly and evenly until
the leakage stops. This must be accomplished
without affecting the torque. Do not over-tighten
the packing gland bolts, since this will increase
the torque required to operate the valve.
This procedure should be performed every 3000
operation cycles or every six months of service.
When gland packing is expected to be loosened
due to the heat cycle, retighten the screws every
two months of service or every 1000 operational
cycles.

Gland seals on gear operational valves are
almost same as nominal diameters 125 mm
to 250 mm. The stems have 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.

FIGURE 7
EB11G 15 mm ~ 100 mm (½”~4”)
EB12G 15 mm ~ 100 mm (½”~4”)

Gland bolt
Stopper

Stopper

FIGURE 8
EB11G 125 mm ~ 200 mm (5”~8”)
EB12G 125 mm ~ 200 mm (5”~8”)

Stopper

Gland bolt

Gland cover

Stopper

Gland bolt
Gland flange
Gland packing
Stem

Gland bolt
Gland flange
Gland packing
Stem

The following instructions will contribute to a
long life service of the valve. Periodical checks
and maintenance are required to keep valves
in good working condition. Parts to be checked
periodically and maintenance items are shown
in below Figures 7 to 9.

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KTM OM-2 GRATITE® SEAT BALL VALVES

INSTALLATION AND OPERATION MANUAL

FIGURE 9
Body sealing structures

Gasket

Nut

Body 1

Stud 1

CAUTION

The sealing portion between body and body cap
is provided with a graphite gasket as shown in
Figure 9. In case of slight leakage, the fastening
bolts should be moderately tightened.

10 TROUBLESHOOTING

Trouble examples Causes Measures

Unsmooth operation 1. Jamming due to solids or slurry in the fluid. 1. Clean the inside of the valve. If neccesary, replace parts (ball,

seats, stem bearing, thrust bearing).

2. Ball is corroded by fluid. 2. Replace with ball made off corrosion resistant material.

3. Fluid sticks to ball and seats. 3. Clean the inside of the valve. If neccesary, replace ball or seats, or
replace with ball valve equipped with metal seats.

4. Unusual pressure rise exceeding seat rating limit when shutting

the valve.

Outside leakage 1. Sealing performance of gasket and gland packing decreases

gradually when operation frequency is high or the high
temperature fluid flows

2. Sealing performance of gasket and gland packing decreases by

abnormal pressure rise in the cavity.

3. Sealing performance of gasket and gland packing decreases when

shutting the valve during abnormal pressure rise in the piping.

Seat leakage 1. Ball and seats are damaged by solids and slurry in the fluid.

Fluidsticks to ball and seats.

2. Ball is corroded by fluid. 2. Replace with ball made of corrosion resistant material.

3. Seat and cushion deformation due to abnormal pressure rise in

the cavity.

4. Unusual pressure rise exceeding seat rating limit is when shutting

the valve leads to seat deformation.

4. Take measures to prevent abnormal pressure rise in pipe and
replace seat.

1. The fastening nuts or bolts at gasket and gland packing are
required to be lightly tightenend, or gasket and gland packing
replaced.

2. Replace by ball equipped with small purge hole for releasing
abnormal pressure rise.

3. Take measures to prevent pressure rise and replace seats,
gaskets and gland packing.

1. Clean the inside of the valve. If necessary, replace ball or seats, or
replace with ball valve equipped with metal seats.

3. Replace by ball equipped with small purge hole to release
abnormal pressure rise.

4. Take measures to prevent abnormal pressure rise and replace
seats.

11 VALVE DISASSEMBLY

Assemble/disassemble the valves in a clean,
well-lit and well ventilated place.

WARNING

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. Maintenance
of the valves must be performed only by qualified
personnel. Never operate/disassemble the valves
before checking the safety. The valve is extremely
heavy; ensure a stable position to prevent it from
falling down when assembling/disassembling.
There is a cavity inside the ball valve when
the ball is fully open or fully closed. For a safe
disassembly, following instructions must be
carried out.

1. Half open the valve when still installed in
piping, and make no pressure remains in the
cavity. Failure to do so may result in injury,
explosion or fire caused by the remaining
pressure.

2. Before disassembling the valve, make sure
that it has been decontaminated of any
harmful gasses or fluids, and disassembly is
done at a well ventilated place and within a
safe temperature range for maintenance.

3. Pressure of flammable gas and other
dangerous fluids must be checked only at well
ventilated places outdoors, far away from any
fire source.

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KTM OM-2 GRATITE® SEAT BALL VALVES

INSTALLATION AND OPERATION MANUAL

Refer to below construction drawing for disassembly. The numbers of parts
vary slightly depending on the valve size, but the basic structures are identical.

FIGURE 10
Parts construction (Nominal diameter: 80 mm)

27

28

29

22

21

20

15

11

14

13

4

10

12

5

7

3

8

6

9

1

2

18

19

DN 40, 50 HANDLE

DN 65, 80 HANDLE

16

17

DN 100 HANDLE

PARTS LIST

Part Name

1 Body
2 Body cap
3 Ball
4 Stem
5 Seat
6 Seat retainer
7 Inner ring
8 Cushion
9 Gasket
10 Stem bearing
11 Stem bearing

25

23

26

24

12 Thrust bearing
13 Gland packing
14 Packing washer
15 Gland flange
16 Gland bolt
17 Live loading spring
18 Stud
19 Nut
20 Stopper
21 Snap ring
22 Handle (DN 40,50)
23 Handle (DN 65,80)
24 Handle head (DN 100)
25 Pipe (DN 65,80)
26 Pipe (DN 100)
27 Hexagon bolt
28 Spring washer
29 Washer

(Sending the valves back to us and requesting repair) 12 WARRANTY

CAUTION

1. The ball valve has a cavity in its interior when
a ball is fully open or fully closed. Since some
pressure and fluid may remain inside the

The warranty period is one year from the date
of installation by the first use of the goods, or
eighteen (18) months from the date of shipment
to the first user, whichever occurs first.

cavity, be sure to release pressure and purge
fluids completely by keeping the valve half­open when removing the valve from the piping
or sending them back to us.

2. Please return the valve without disassembling.

Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product.
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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