Emerson KTM Virgo Installation Manual

KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Before installation these instructions must be fully read and understood

TABLE OF CONTENTS

1. Scope .............................................................. 1

2. Receipt, handling and storage...................... 1

3. Installation ..................................................... 3

4. Operation ....................................................... 4

5. Gear operator instructions ........................... 5

6. Emergency sealant injection system ........... 6

7. Preventive / periodic maintenance .............. 7

8. Possible misuse of ball valve ....................... 7

9. Trouble shooting ........................................... 8

10. Ordering spares............................................. 8

11. Disassembly and re-assembly ..................... 9

12. Body cavity relief operation ........................ 21

13. Gland packing assembly procedure .......... 21

14. Recommended tightening torques for

fasteners and plugs .................................... 22

15. Service of valves with API monogram ........ 23

16. Information for PED 2014/68/EU

compliant valve ............................................ 23

17. Warranty ...................................................... 24

18. Factory address for correspondence ......... 24

1 SCOPE

This manual is provided to ensure proper installation, operation and maintenance for KTM Virgo Series trunnion ball valve, manufactured and supplied by Emerson. (Applicable to Soft / Metal seated, Cast / Forge, NL, NG, ML, MG subseries)

2 RECEIPT, HANDLING AND STORAGE

• Identify the valve contained in the box using the packing list fixed on the box.

• While loading and unloading the box, check for handling instructions/symbols marked on the box and handle the box accordingly. Ensure lifting of valve box in upright position using fork lift as shown in Figure 1. Do not drag the box.

• Before removing the valve from the box, ensure valve is not fastened/fixed inside the box with wooden battens and bolts which are provided to prevent the valve from toppling or moving inside the box during transportation.

• Remove the valve from the box using proper D-Shackle or lifting hooks and straps. These must be sized depending upon the weight that must be lifted at lifting points (lifting lugs) provided on valve as shown in Figure 2. Do not use chains or hooks in contact with the machined or painted surfaces.

FIGURE 1

Typical box and lifting position

Forklift lifting forks

near bottom support

FIGURE 2

Lift

Top support

Bottom support

Lift

Swing

WARNING

Always use Personal Protective Equipment (PPE) when carrying out above activities.

KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

• If lifting lugs are not provided on the valve, hold the valve with lifting strap around neck area and gently lift it as shown in Figure 3. Ensure the lifting strap is sized appropriately for the weight that must be lifted and is holding the neck area of valve firmly, to prevent damages.

WARNING

• If the valve is supplied with an operator (gear operator or actuator) do not use the operator or the operator lifting lugs to lift the valve assembly.

• For stem extension valve, use proper support as shown in Figure 4 to prevent toppling of valve.

• During handling, pay attention to prevent any damage to the flange faces, butt weld ends, operator, auxiliary fittings and piping (as applicable). Do not drag the valve during handling.

• The identification of the valve is given on the body or on the nameplate or both. (Figure 5).

• If a tag number is specified by the customer, identify the valve using tag number stamped on the name plate or tag plate affixed to the valve.

• After removing from box, always store the valve under roof and in a dry and clean atmosphere, protected from rain and storm.

• Always place the valve on ‘soft’ surface like rubber sheets or wooden planks free of dirt/ debris/hardware like nails and moisture to avoid damage to the valve surfaces.

• Ensure that valve ends are covered with protective end caps. Do not remove any protection from the valve during storage period.

• In case of automated valve assembly, refer to actuator/accessory manufacturer instructions for handling and storage.

• Always keep the valve either in fully open or fully closed position. Full open position is preferred. The valve is normally shipped in the full open position (exception is valve with a ‘fail close’ spring return actuator arrangement)

FIGURE 3

FIGURE 5

Lifting straps

FIGURE 4

Lifting straps

WARNING

Do not lift from the

top flange of stem

extension

2-piece ball valve

Body marking Body marking

3-piece ball valve

Always use lifting

hooks for lifting of

stem extension

Provide proper support from here to prevent toppling

Size

matl

heat no.

Name plate

Size

matl

heat no.

Name plate

KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

3 INSTALLATION

WARNING

• To prevent personal injury or property damage resulting from the bursting of pressure retaining parts, be certain the service conditions do not exceed the limits given on name plate / tag plate of valve.

• Personal injury could result from packing leakage. The valve packing was tightened before shipment however; the packing might require some readjustment to meet specific service conditions.

• Check with your process or safety engineer for any additional measures that must be taken to protect against process media.

• Before valve installation, ensure that the pipeline is free from dirt, debris, scale, weldslag etc. to prevent damage to the internal trim parts and seals of the valve.

• Ensure that the valve end protectors are removed and the valve ends and bore are cleaned before installation.

• The mounting stand attached to the body to adapter joint shall not be removed while installing the valve on the pipeline (refer Figure 6).

• If mounting Stand or Support stand of valve is provided on end flange they shall be removed before installation on the pipeline (refer Figure 7).

• Mounting/support stand is only for handling and transportation and not for carrying piping loads. Hence Emerson recommends to give supports to the pipeline appropriately and shall not exceed following recommendations.

- For sizes, up to DN 100 (NPS 4), support to

be provided at a distance of ‘2D’ to ‘3D’ from both valve ends

- For sizes, DN 150 (NPS 6) and higher,

support to be provided at distance ‘D’ from both valve ends, where ‘D’ is the nominal diameter of pipeline.

•

For removing mounting/support stand from valve assembly, lift the valve above ground level by using appropriate material handling/lifting equipment. Refer handling section of this IOM. Loosen and remove the nuts from respective mounting stand bolts/studs and remove the stands. Fasten the nuts and bolts/studs only to the mounting stand again and store the entire set appropriately to reuse whenever required for maintenance, storage etc.

• To reinstall the mounting/support stand from valve, position the valve above ground level by using appropriate material handling/ lifting equipment. Refer handling section of this IOM. Loosen and remove the nuts and bolts/studs from mounting stand set. Position the stand aligning its holes with valve flange holes and retighten the nuts with bolts/studs as shown in Figure 7.

• Examples of valve support configurations are shown in Figure 8.

• The valve should preferably be in fully open condition during installation. Exception being the 'fail close' valves.

• Never install the Valve with the Actuator upside down on the pipeline, refer Figure 9.

FIGURE 6

Mounting stand attached to body flange

WARNING

Do not remove while installing the valve

FIGURE 8

Support from overhead Foot support

(ground support)

FIGURE 7

Mounting stand attached to end flange

Remove while

installing the valve

Foot support (ground support)

KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Installation of valve in vertical pipeline

• Place the valve with end flange resting on ‘soft’ surface like rubber sheets or wooden planks free of dirt/debris/hardware like nails and moisture.

• Hook the valve at end flange bolt holes as shown in Figure 10 and lift with the help of suitable crane.

• Alternately, valve can be lifted with the help of fork lift as shown in Figure 11.

• Mount the valve on the pipeline end flange with the flange gaskets appropriate for the application and assemble with suitable fasteners.

• Refer to tables in Section 14 of this IOM for recommended tightening torques.

• Do not allow valve body temperature in seat area to exceed 200 °F (94 °C) during welding of valve to the pipeline in case of butt weld end valves.

FIGURE 9

4 OPERATION

• For lever operated valve, the lever is either shipped loose or assembled with valve depending upon the size of the valve / lever. Rotation of lever in the clockwise direction closes the valve and counter clockwise rotation opens the valve.

• For gear operated valve, the gear operator open / close adjustment has been done prior to shipment and must not be changed. Rotation of hand wheel in the clockwise direction closes the valve and counter clockwise rotation opens the valve.

• It is recommended that the valve should be opened and closed slowly to prevent hammering effect on the valve and pipeline.

• If the valve is not operating to fully open or fully close position and/or leaking, do not apply excessive force to operate the valve. This can damage the valve internals and/or the operator parts.

• Do not apply extra force using inappropriate extensions to levers and handwheel like pipes or bars.

Note: national standards typically restrict

the input force on lever/handwheel rim to max. of 360N and the valves are designed accordingly.

• For valve with pneumatic and gas actuator, do not exceed the operating pressure of actuator.

• Always use dry, moisture free air while operating the valve with pneumatic actuator.

WARNING

Do not mount in this position

FIGURE 10

Lifting hooks

Valve end flange

Valve

Pipeline end flange

FIGURE 11

Valve

Valve end flange

Forklift lifting location

Pipeline end flange

KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

5 GEAR OPERATOR INSTRUCTIONS

5.1 Assembly of gear operator with bracket and coupling

• It is recommended that the valve should be kept in upright position (stem vertical).

• Valve shall be fully open.

• Place the bracket over valve top mounting flange and fasten it with suitable fasteners. Refer to tables in Section 14 of this IOM for recommended tightening torques.

• Fit the key in stem keyway slot and then mount coupling over stem.

• Fit the key in the coupling keyway slot and assemble the gear operator on the bracket with suitable fasteners ensuring that gear operator position indicator matches the open position of the valve.

• Gear operator setting should be done as given in Section 5.3.

5.2 Assembly of gear operator without

bracket and coupling

• It is recommended that the valve should be kept in upright position (stem vertical).

• Valve shall be fully open.

• Fit the key in the stem keyway slot and mount the gear operator on valve top mounting flange and fasten it with suitable fasteners ensuring that gear operator position indicator matches the open position of the valve. Refer to tables in Section 14 of this IOM for recommended tightening torques.

• Gear operator setting to be done as given in Section 5.3.

5.3 Procedure for gear operator setting

CAUTION

If the valve has been supplied by Emerson with the gear operator assembled on the valve open / close adjustment has been done prior to shipment and must not be changed. In case of gear operator replacement or mounting of new gear operator on bare shaft valve, the steps below shall be followed.

• Figure 14 shows the open and close positions of position indicator, adjustment bolts and lock nuts.

• Loosen the lock/check nut and unscrew both left and right side bolt by minimum one rotation.

• Match ball bore with valve bore. Fully tighten the right-side bolt and then tighten the lock nut.

• Rotate the ball by 90 degrees. Fully tighten the left-side bolt and then tighten the lock nut.

5.4 Possible orientations of gear operator

Figure 15 below illustrates the two possible orientations for a gear operator when assembled together with the Virgo Series N trunnion mounted ball valve.

FIGURE 12

Assembly with bracket and coupling

Handwheel

FIGURE 13

Assembly without bracket and coupling

Handwheel

Position indicator

Gear operator

Coupling key

Coupling Bracket Stem key

Stem

Position indicator

Gear operator

Stem key

FIGURE 14

Adjust left bolt for close position

Open position Close position

Gear operator setting

Adjust right bolt for open position

Lock nut / check nut

FIGURE 15

Pipe line axis

Orientation 1

Pipe line axis

Orientation 2

KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

6 EMERGENCY SEALANT INJECTION SYSTEM

Typically provided on DN 150 (NPS 6) and larger valves

• Emergency Sealant injection system is provided on valve seat and/or stem packing area to temporarily reduce seat leakage when the valve is in the closed position or to reduce packing leakage.

• Typically, for valve size DN 350 (NPS 14) and above, 1 sealant injection fitting is provided for stem and 2 fittings for each seat. For valve sizes DN 300 (NPS 12) and below, 1 sealant injection fitting is provided for stem and 1 fitting for each seat.

• This emergency sealant injection system is to be used only when valve is not able to achieve the desired shutoff due to damage / wear and tear on the seats and seals and it is not possible to take the valve off the line for repair and maintenance.

• Always flush the sealant port with suitable cleaner/solution, before injecting sealant. Sealant / cleaning agents shall be selected based on service fluid / condition.

References can be drawn from

manufacturers like Climax Lubricants and Equipment Co

, Sealweld® etc.

Sealant injection fitting - Type A (standard supply)

See Figure 16

Seat sealant injection

• Fully close the valve.

• Remove the fitting end cap and slide giant buttonhead coupler (Climax

model 1699/1700) on sealant fitting. Inject sealant into each of the sealant fitting. Injection pressure shall be more than pipeline pressure but shall not exceed 1.5 times the pipeline pressure at operating temperature.

• Fully open the valve. Inject sealant into each of the sealant fitting.

• Again, close the valve to uniformly distribute the sealant over the ball surface.

• Repeat above steps multiple times until desired sealing is achieved. Ensure last injection is always made with valve in close position.

Stem sealant injection

• Remove the fitting end cap and slide giant buttonhead coupler on sealant fitting. Inject sealant into the sealant fitting. Injection pressure shall be more than pipeline pressure but shall not exceed 1.5 times the pipeline pressure at operating temperature.

• Cycle valve once to uniformly distribute the sealant around the stem.

FIGURE 16

Body / adapter / housing

Sealant injection fitting - Type A (standard supply)

Check valve

Sealant fitting

Giant buttonhead coupler

End cap

Slot for sealant gun adapter

Type A (marking)

KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

7 PREVENTIVE / PERIODIC MAINTENANCE

Preventive / periodic maintenance is essential as the failure to do so may result in inadequate performance of the valve or also failures like seat leakage, environmental leakage, increased torque, jerky operation etc. All valves in operation should be periodically inspected thoroughly to evaluate the condition of ball, seats and seals as these parts are subject to normal wear and tear. The frequency of inspection depends upon the severity of service conditions and location of the valve and should be conducted during partial or total shutdown. Special attention is to be paid to inspect for damage and / or wear due to corrosion or erosion.

Periodic inspection of valve typically includes following activities:

• Inspection for any visible defect or failure such as packing or body joint leakage

• Tightening of bolts/nuts to recommended torques

• Valve stroking to prevent jamming and corrosion every six months

Section 11 describes the procedure for disassembly and reassembly of the valve. Once a valve is refurbished / repaired it should undergo a complete set of tests to make sure that the valve is fit to use for the intended working conditions. Hydrostatic or Pneumatic tests should be carried out as per the specifications relevant to the valve.

Gear operators are packed with grease. It is recommended that the grease should be changed after approximately 5-7 years if operated frequently or after 10-12 years if operated infrequently. Contact factory for appropriate grease grades if grease needs to be changed.

8 POSSIBLE MISUSE OF BALL VALVE

Sr. no. Possible misuse Actions to prevent misuse

1 Exceeding the pressure and / or temperature limits of

the valve.

2 Valve material not suitable for service fluid. Check Tag number (as applicable) and ensure correct valve is used as per process diagram.

3 Use for control application. These ball valves are designed for on/off application and should not be used for control / throttling. 4 Mounting of valve upside down. Follow ‘Installation’ section of this document. 5 Wrong installation in case of uni-directional valve. Verify flow direction on valve body or on additional plate affixed to valve. 6 Use of improper actuator when customer automates

valve on site.

7 Opening/closing of valve by using inappropriate

extensions like pipes/bars etc.

8 Any modification by customer in valve e.g. drilling,

tapping, change of valve ends etc.

9 Testing the valve with water without corrosion inhibitor. Corrosion inhibitor shall be used to prevent corrosion of valve components. Requirements of

10 Inadequate draining and drying of valve after hydro test. When valves are hydro tested onsite, they shall be drained and dried completely before installing on

11 Not using lock open/close feature. Ensure to use this provision (as applicable) based on process requirement. 12 Improper long term storage. For long term storage and preservation of valves at site refer Emerson procedure QAC/KM-028.

13 Damage to valve fittings during handling. Follow handling instructions.

Do not exceed pressure and / or temperature limits mentioned on name plate affixed to the valve.

Verify valve material mentioned on Name plate is suitable with service fluid.

Contact factory for correct sizing of actuator.

Operate valve only with levers, gear operator, hand wheel or actuator provided / recommended by Emerson. Unauthorized modifications are not allowed. Modification voids warranty. Contact factory if any such case arises.

international standards such as API 6D, API 598, BS EN 12266 etc. should be followed.

pipeline to prevent corrosion of parts and contamination of service fluid.

Contact Factory.

KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

9 TROUBLESHOOTING

Problem Possible cause Remedy

Leakage across closed valve 1. Damaged ball surface. 1. Refurbish or replace the ball.

2. Damaged seats / seat seals. 2. Refurbish or replace seats. Replace seat seals.

3. Ball not closed fully. 3. Check and reset ball. Open/close settings.

4. Seat not moving freelyresulting in inadequate contact

between ball and seat. Valve too hard to operate / valve torque too high / stick-slip operation

Leakage through stem 1. Loose gland fasteners. 1. Tighten the fasteners.

Leakage through body to adapter joint; body to housing joint

Leakage through drain, vent and sealant fittings.

1. Damaged seats / seat seals /ball. 1. Refurbish or replace the seats /seat seals / ball.

2. Seat not moving freely due to accumulation of dirt, debris, corrosion between seat and body or seat and ball.

3. Operator not sized properly, damaged operator parts. 3. Select correct operator and replace.

4. Actuator not sized properly, damaged actuator parts, insufficient input air/gas pressure to actuator, restriction/clogging of actuator vent.

2. Damaged stem, stem sealing surface. 2. Refurbish or replace the stem.

3. Damaged stem seal. 3. Replace the stem seal.

4. Accumulation of dirt, debris, corrosion between stem and housing.

1. Damaged seal/gasket. 1. Replace seal/ gasket.

2. Relaxation of joint fasteners. 2. Retighten the fasteners evenly in criss-cross manner.

3. Accumulation of dirt, debris, corrosion between body and adapter.

1. Loosening of fittings. 1. Retighten. If leakage persists may require fresh thread

4. Open valve, check for accumulation of dirt, debris, corrosion between seat and body, clean and re-assemble.

2. Open valve, clean and reassemble.

4. Select correct actuator and replace. Check input air supply, clean actuator vent.

4. Open valve, clean and reassemble.

3. Open valve, clean and reassemble.

sealant or replacement of fitting. WARNING: Do not remove fittings when valve / body cavity is under pressure.

10 ORDERING SPARES

When ordering spares, please furnish the following information.

Size Class Batch number / serial number Manufacturing date Part number Part name Purchase order number

Available on name plate or body of the valve Available on name plate or body of the valve Available on name plate or body of the valve Available on name plate or body of the valve Available on general arrangement drawing Available on general arrangement drawing Available on general arrangement drawing

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