KTM SERIES E01 TRUNNION MOUNTED BALL VALVE
INSTALLATION AND MAINTENANCE MANUAL
Before installation these instructions must be fully read and understood
1 INTRODUCTION
1.1 This product is suitable for gas and liquid
media pipelines and regulating devices, with
the advantages of small flow resistance, quick
switch, flexible quick opening and closing, long
life, being safe and reliable.
1.2 Range of application: oil, chemical,
petroleum refining, natural gas,
metallurgy, paper making, pharmaceutical,
instrument and others.
2 RANGE OF APPLICATION
The manual applies to the high-pressure
trunnion mounted ball valve listed in the table.
Model Oracle model code Pressure class Size range (DN)
Full bore
E0125 E01 ASME Class 150 50-200
E0126 E01 ASME Class 300 50-200
E0105 E01 ASME Class 150 250-600
E0106 E01 ASME Class 300 250-600
E0108 E01 ASME Class 600 50-500
E0109 E01 ASME Class 900 40-500
E0110 E01 ASME Class 1500 40-250
Reduced bore
E0821 E01 ASME Class 150 80-250
E0822 E01 ASME Class 300 80-250
E0801 E01 ASME Class 150 300-650
E0802 E01 ASME Class 300 300-650
E0804 E01 ASME Class 600 80-600
E0807 E01 ASME Class 900 50-600
Emerson.com/FinalControl VCIOM-04474-EN 22/08
© 2017 Emerson. All Rights Reserved.
KTM SERIES E01 TRUNNION MOUNTED BALL VALVE
INSTALLATION AND MAINTENANCE MANUAL
3 KEY PARAMETERS
3.1 Technical parameters
Maximum operating pressure
Model Pressure class
Full bore
E0125 ASME Class 150 275 (2)
E0126 ASME Class 300 720 (5)
E0105 ASME Class 150 275 (2)
E0106 ASME Class 300 720 (5)
E0108 ASME Class 600 1440 (10)
E0109 ASME Class 900 2160 (15)
E0110 ASME Class 1500 3600 (25)
Reduced bore
E0821/E0801 ASME Class 150 275 (2)
E0822/E0802 ASME Class 300 720 (5)
E0804 ASME Class 600 1440 (10)
E0807 ASME Class 900 2160 (15)
rating value psig (MPa)
4 PRODUCT DISASSEMBLY, ASSEMBLY AND TEST METHOD
4.1 Valve exploded view (Varies among different models)
FIGURE 1
Connect to actuator
• The rating value of the maximum operating
pressure in the table below corresponds to the
value at temperatures from -29°C to 38°C. Its unit
is psig. The conversion between psig and MPa is:
1 psig - 0.006984757 MPa
• Other pressure classes shall be in accordance to the
relevant standard
PARTS
No. Name
1 Body
2 Cap
3 Ball
4 Upper stem
5 Lower stem
6* Seat
7* Seat retainer
8 Spring
9* O-ring
10* Gasket
11* Upper stem bearing
12* Lower stem bearing
13* Gland packing
14* Thrust bearing
15 Gland
16 Gland flange
17 Packing adaptor
18 Setting ring
19 Thrust washer
20 Lower cover
21 Drain plug
22* Shim
23 Stud
24 Nut
25 Key
26 Pin
NOTE
* Standard repair kit inclusions
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KTM SERIES E01 TRUNNION MOUNTED BALL VALVE
INSTALLATION AND MAINTENANCE MANUAL
4.2 Disassembly
4.2.1
NOTES
Pay attention to the following points when
disassembling the valve:
• Fully relieve the valve cavity. Even if the pressure of
the piping has been discharged and there is still the
possibility of residual pressure left in the valve. The
valve must be opened and closed several times to
fully release the pressure in the cavity. After making
sure there is no residual pressure, the valve can be
removed from the pipeline.
• If the media is harmful for humans, or is
inflammable and explosive, make sure that no
residual media is left inside of the valve (especially
in the cavity). Then fully inject water inside to clean;
after making sure there is no residual media,
remove it from the pipeline; then fully open and
close the valve several times.
4.2.2 Disassembly method
• Rotate the stem (4) clockwise, positioning the
ball to the 'off' position.
• Remove the lever (or gearbox), remove the
elastic ring and stopper.
• Loosen the gland bolt (23), remove the gland
flange (16) and gland (15).
• Loosen the lower cover bolt (23), remove the
lower cover (20), lower cover gasket (10),
adjusting shim (22), thrust bearing (12), pull
out the lower stem (5), remove the gasket
(O-ring) and the lower stem bearing
• Loosen the flange coupling screw, remove the
flange, flange gasket, adjusting shim, thrust
bearing (11).
• Pull out upper stem (4), remove O-ring (9) or
gland packing (13), upper stem bearing (11).
• Loosen the coupling screw, separate the
body and cap, remove the ball (3), seat (6),
seat retainer (7), seat spring (8), flat or spiral
springs, junction gasket (10) (O-ring) from
the body. Be careful not to collide nor drop
the ball and seat, to avoid damaging the
sealing surface.
• Remove the seat, seat holder, seat seal
washer, flat or spiral springs.
• If the valve has a manual operator, then
during the disassembling, the manual
operator shall be removed first.
Once all the above is complete, the disassembly
can be considered to be finished.
4.3 Assembly
After removing all parts from the valve, wipe
the dust and clean it. After removing the dust
and grime, ensure that there is no scratch on
surface sealing of the ball and seat and stem
assembly, replace any defective or obviously
worn parts; no scratches should be on the
junction and on the surface of the seats of the
body and cap; Assemble in the following order:
• Put the spring, seat (seat holder, O-ring), ball,
anti-static spring into the body, put gasket
into the locating recess of the body.
• Put the ball into the body.
• Mount O-ring (if any) on the stem, then put
stem bearing on the stem.
• Insert upper stem into the upper stem hole,
the stem top is in 'off' position, then insert it
into the ball.
• Put the spring, seat (seat holder, O-ring) into
the left body, combine the surfaces between
body and cap.
• Tighten the nuts uniformly and symmetrically.
• Mount the cap gasket (O-ring), mount lower
stem bearing on lower stem, insert lower
stem into lower stem hole.
• Assemble upper stem in place, then mount
thrust bearing, gland packing or O-ring,
gasket, flange, gland on stem, gland flange in
order, screw in gland bolts and tighten. Screw
the bolts by hand, then use the tool to tighten
accordingly.
NOTE
When tightening the bolts, do not tightly tighten
one by one, this will potentially misalign the
gland flange and gland packing, and may cause
leakage. The right way should be, slightly tighten
one, then do another one, and so forth, until
the gland flange and gland are compressed to
ensure the uniform and aligned compression.
Turn the stem to ensure a smooth rotation.
Please refer to gland flange and center flange
tightening torque matrix tables in Section 5.
• Mount the stopper, resilient retainer, lever; if
the valve has manual operator, then mount it
last. This completes the assembly process.
4.4 Test method: The test should be done
according to the test pressure and holding time
of the relevant standards. For the pressure
test, we recommend the following methods:
• Shell test: close both ends of the valve,
leaving it in the half open state, inject the
media (liquid) with the required pressure,
after holding for some time, check the
junction, gland packing and shell for leakage.
• Liquid high-pressure closure test: close both
ends of the valve, leaving it in the half open
position, fill it with the media (liquid) with
the required pressure from one end, close
the valve, making the cavity be open to the
atmosphere, check leak detection port for
media leakage.
• Gas low-pressure closure test: close both
ends of the valve, leaving it in the half open
state, provide with the gas with required
pressure from one end, close the valve,
making the cavity be open to atmosphere,
check leak detection port for gas within the
stipulated time. Judging if valve qualified or
not should be based on relevant standards.
• No visible leakage is allowed for strength
test, low-pressure gas seal test and highpressure seal test within stipulated time
(standardized materials seat).
• Seal the valve with the sealing plate after
pressure test; if it is a water pressure test,
dry residual moisture content on the surface,
regarding carbon steel valve, paint, anti-rust
and oil then. Install sealing plate.
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KTM SERIES E01 TRUNNION MOUNTED BALL VALVE
INSTALLATION AND MAINTENANCE MANUAL
5 TIGHTENING TORQUE OF BOLTS / NUTS FOR KTM SERIES BALL VALVE
5.1 Requirements of tightening torque
The tightening torque of Class 150-300 packing gland bolts is shown in Table 5.1.1.
TABLE 5.1.1 CLASS 150-300 PACKING GLAND BOLTS TORQUE VALUES (N.m)
Basic torque
Packing material
PTFE Graphite
Valve size (DN) Bolt size
15-20 M6 2 2.5
25 M8 3.5 4.5
32 M8 3.5 4.5
40-50 M10 7 9
65-80 M14 16 20
100 M14 19 23
125-150 M12 19 23
200-250 M14 32 40
300-350 M16 60 400-500 M20 110 -
ASME CL 150, 300 ASME CL 150, 300
The tightening torque of Class 600 packing gland bolts is shown in Table 5.1.2.
TABLE 5.1.2 CLASS 600 PACKING GLAND BOLTS TORQUE VALUES (N.m)
Basic torque
Packing material
Valve size (DN) Bolt size
15, 20* M8 (M10) 4 (5) 5 (6.25)
25, 40* M10 (M12) 8 (9.6) 11(13.2)
50 M14 20 27
80 M14 23 31
100* M12 (M14) 30 (35) 40 (47)
150 M16 50 65
200 M20 100 120
250 M22 150 200
300* M16 (M20) 90 (112.5) 110 (137)
350 M20 115 135
400 M22 150 200
450 M20 90 110
500 M20 90 110
NOTE
* The basic torque data in brackets must be used if the valve uses the gland bolt size in brackets.
PTFE, H Graphite
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KTM SERIES E01 TRUNNION MOUNTED BALL VALVE
INSTALLATION AND MAINTENANCE MANUAL
The tightening torque of Class 900 packing gland bolts is shown in Table 5.1.3.
TABLE 5.1.3 CLASS 900 PACKING GLAND BOLTS TORQUE VALUES (N.m)
Basic torque
Packing material
Valve size (DN) Bolt size
15 M10 12 15
20 M12 18 23
25 M12 18 23
40 M14 30 40
50 M14 36 48
80 M16 50 65
100 M16 60 75
150 M12 45 60
200 M14 72 90
250 M18 130 165
300 M18 130 165
350 M22 195 245
400 M22 205 255
H Graphite
The tightening torque of Class 1500 packing gland bolts is shown in Table 5.1.4.
TABLE 5.1.4 CLASS 1500 PACKING GLAND BOLTS TORQUE VALUES (N.m)
Basic torque
Packing material
Valve size (DN) Bolt size
15 M10 12 15
20 M12 18 23
25 M12 18 23
40 M14 30 40
50 M14 36 48
80 M16 56 73
100 M14 56 73
150 M20 132 173
200 M22 210 275
H Graphite
5
KTM SERIES E01 TRUNNION MOUNTED BALL VALVE
INSTALLATION AND MAINTENANCE MANUAL
The tightening torque of Class 150-1500 ball valve joints, adapter plates and bottom cover bolts /
nuts is shown in Table 5.1.5. The basic torque in the table is the theoretical value, while the actual
torque is the torque range that must be reached when tightening
TABLE 5.1.5 CLASS 150-1500 BALL VALVE JOINTS, ADAPTER PLATES AND BOTTOM COVER
BOLTS / NUTS TORQUE VALUES (N.m)
Pressure rating
Class 150 Class 300-1000
Valve size (DN)
M8 16 14-17 20 19-22
M10 32 29-33 40 38-45
M12 54 49-57 70 65-76
M14 85 76-89 110 100-120
M16 130 120-140 170 150-180
M18 170 160-190 230 210-250
M20 240 230-260 330 300-350
M22 330 300-350 440 400-470
M24 420 390-450 560 510-610
M27 610 570-660 820 750-890
M30 860 800-930 1150 1050-1240
M33 1160 1070-1250 1540 1410-1670
M36 1530 1410-1640 2030 1860-2200
M39 1970 1820-2130 2630 2410-2850
M42 2480 2290-2670 3310 3030-3580
M45 3080 2840-3310 4100 3760-4450
M48 3770 3480-4060 5020 4600-5440
M52 4810 4440-5180 6410 5880-6950
M56 6010 5550-6470 8010 7340-8680
M60 7420 6850-7990 9890 9060-10700
M64 9000 8310-9690 12000 11000-13000
Basic torque Actual torque Basic torque Actual torque
6
KTM SERIES E01 TRUNNION MOUNTED BALL VALVE
INSTALLATION AND MAINTENANCE MANUAL
6 APPLICATION METHOD
6.1 Operation
When operating the valve by the lever,
handwheel (or manual operator), in principle,
if rotating clockwise it is 'Open→Close',
otherwise, 'Close→Open'.
6.2 Determination of open-close state and
opening degree
Distinguish the on-off state of the valve based
on the position of the lever and the direction of
flat head or key block on stem top. When the
lever is parallel to the pipeline, then the valve
is in the 'Open' state, when it is in a right angle,
then it is in the 'Close' state, arrow panel will
indicate that if having manual operator.
7 REPAIR AND MAINTENANCE
The valve should be maintained regularly
so that it functions properly. During repair
and maintenance, the following points are
essential:
7.1 Gland packing sealing
In case of slight leakage from the gland packing,
under the condition of not affecting the torque,
appropriately tighten the gland bolts. If there
are still issues, disassemble the valve to check
for any abnormalities. In case the gland packing
is damaged, replace it with a new set. If stem
seal is an O-ring, replace the O-ring. If the gland
packing portion of a valve with manual operator
needs to be checked and replaced, firstly remove
the operator, then disassemble the valve. After
parts replacement and assembly, check whether
the valve is opened and closed in the right
position. If the position is incorrect, then it needs
to be adjusted.
7.2 Body sealing
The junction between the body and the cap uses
the gasket and the O-ring. In case of leakage,
tighten the junction nuts. If there are still
problems, disassemble the junction to check
the gasket or O-ring for any abnormalities: if
any, replace them with new parts.
7.3 Seat sealing
In case of any leakages on the seat seal,
disassemble the valve, check the ball, seat,
O-ring (U-ring) for damages or deformation.
If any, replace them with new parts.
When replacing the seat, O-ring or ball, no
foreign matters should get into the body cavity.
7.4 Lower cover sealing
In case of any leaks on the lower cover, tighten
the lower cover bolts. If it fails to prevent the
leaks, you should loosen the bolts, remove the
gasket or O-ring, check gasket or O-ring for
damages. If any, replace them.
8 TRANSPORTATION, STORAGE AND
INSTALLATION
8.1 Transportation
During transportation and removal of packing
cases, try to avoid impact on the valves, so that
their normal functions are not affected.
8.2 Storage
During storing the valves, the cap at the flow
orifice of end flange must be well sealed,
without being stacked. The valve should be
in a full open position and be stored in a dry
and ventilated room. It is recommended that
the valve be operated every 6 months at a
minimum.
8.3 Installation
8.3.1 Installation environment
This product can be used both indoor and
outdoor. However, in case of corrosive media
and since it can be easily rusted, make sure
to choose the appropriate combination of
materials: please refer to our sample for details.
Please contact the factory when being used in
special working conditions.
8.3.2 Install essentials
To ensure the valve is used correctly and can
extend its service life, install it according to the
following essential points:
• Prior to installation, check whether it meets
operating requirements based on the casting
mark and nameplate on the valve.
• Prior to installation, remove and clean all the
defects and dirt caused during transportation.
• Prior to installation, check all fasteners of the
valve; due to vibration during transportation,
check whether there are any loose connecting
bolts and nuts, tighten them in this case.
• Two flange surfaces are equipped with
sealing covers/protectors, which should be
removed during installation.
• Prior to installation, fully inject water into
the piping, remove debris, any residual
welding and cutting slags inside the valve
or adjourning pipework that can damage
the seat.
Our company will not take any responsibilities
for quality problems caused by inappropriate
installation and commissioning.
• The valve can be installed in vertical and
horizontal directions, while the maintenance
and convenient operation for lever, as well
as limit to the piping of automatic valve, shall
be taken into consideration (please refer to
the Installation and Maintenance Manual for
Pneumatic Ball Valve for details).
• Tighten connecting flange bolts with proper
strength, working the diagonally opposite
nuts in sequence, be careful not to tighten
unilaterally or do uneven one-sided tightening
Potentially, the flange can be damaged due to
the piping stress, which results in excessive
operating torque.
• If purchasing acceptance test is necessary, it
shall be carried out according to the relevant
standards. Our company will not take any
responsibilities for quality problems of the
valve caused by inappropriate approach or
human factors
• During the installing of the piping, hard
objects (such as welding dregs, scrap iron
and stone, etc.) should not get into the body,
in order not to scratch the surface of the
ball nor the seat, otherwise it can affect the
sealing performance of the valve
Our company will not take any economic
responsibilities for all the losses caused due to
the above reasons.
7
Adjusting bolt
KTM SERIES E01 TRUNNION MOUNTED BALL VALVE
INSTALLATION AND MAINTENANCE MANUAL
9 ADJUSTMENT AFTER THE MAINTENANCE
OF MANUAL BALL VALVE WITH MANUAL
OPERATOR
This adjustment has an effect on the openclose state of the valve (may result in that the
opening and closing of the valve is not in place).
After the installation, check the opening-closing
position of the valve. If improper, resolve
according to the following methods:
9.1 Adjust the opening position, loosen the
adjusting bolts, place the valve in the fully open
position, then tighten the adjusting bolts.
9.2 Adjust the closing position, loosen the
adjusting bolts, place the valve in the fully
closed position, then tighten the adjusting bolts.
10 NOTES
1. Don't place the valve in half-open state for a long
time (t≤120min). Open and close the valve properly
to avoid affecting the seat sealing performance.
2. When the valve is under the dangerous
working conditions, then the locked mode is
recommended. In order to avoid accidents caused
by misoperation.
3. During pressure test, be sure to lay the valve flat
so as not to make the valve lean, otherwise the
future performance of the valve could be affected.
4. Pressure test shall be done through appropriate
approach based on the relevant standard.
5. The role of the resilient retainer on the stem is to
fix the stopper.
6. In case of special requirements on lubrication,
please specify them while placing your order.
7. In order to prevent accidents, it is very important
that oil and water is not used to clean and operate
the valve whose fluid media is oxygen, oxozone and
hydrogen.
Conventional products can't be used (if used in
oxygen, hydrogen peroxide and hydrogen media,
please specify while placing your order).
8. During installing piping, hard objects (such as
welding dregs, scrap iron and stone, etc.) should
not get into the body cavity, so that they do not
scratch the surfaces of the ball nor the seat,
otherwise the sealing performance of the valve will
be affected.
9. During maintenance, all fastenings must be
tightened uniformly and symmetrically, to prevent
additional stress.
10. During the overhaul, do not make mistakes with
the setting direction of the gland packing, to avoid
leakages of the gland packing portion.
FIGURE 2
WORM GEAR / WORM OPERATOR
Adjusting
bolt
Indicator
Indicator
11. Be careful not to scratch the sealing surfaces of
the seat, ball and stem during maintenance.
Our company will not take any responsibilities for all
losses caused by the above reasons.
11 FAULTS AND TROUBLESHOOTING
VALVE PORTION FAULTS
Faults
Stem rotation doesn't work 1. Pressed gland packing too tight 1. Loosen the bolts and readjust
If a leakage between the ball and
sealing surface of the seat, or seat
and body occurs
Leakage on stem gland packing 1. Insufficient gland packing force 1. Tighten the gland bolts
Leakage on junction 1. Loose flange bolts at junction 1. Tighten the flange nuts
Leakage on cap
Reasons
2. There is damage or accumulated dirt on the junction between the stem
and its connected parts
3. Open and close repeatedly 3. Disassemble to clean and remove the dirt
1. Insufficient preload 1. Increase preload
2. There is damage or dirt on sealing surface 2. Trim or grind the sealing surface and remove dirt
3. Deformation or failure on sealing elements 3 Replace the sealing elements
4. O-ring is damaged 4. Replace O-ring
2. Damaged or invalid gland packing 2. Replace gland packing
2. Damaged or invalid gasket or O-ring at junction 2. Replace gasket or O-ring
1. Loose cap bolts
2. Damaged gasket or O-ring 2. Replace gasket or O-ring
Troubleshooting
2. Disassemble to fix and remove the dirt
1. Tighten the bolts
Manual, pneumatic, electric and other operating modes can be realized for high-pressure large-diameter trunnion mounted ball valve, actuator can
be replaced very easily (please refer to the product manuals for the usage and replacement method of the actuator).
8
KTM SERIES E01 TRUNNION MOUNTED BALL VALVE
INSTALLATION AND MAINTENANCE MANUAL
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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
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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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