KTM HINDLE META-SEAL METAL SEATED TRUNNION MOUNTED BALL VALVES
OperatiOn, installatiOn and Maintenance instructiOns
Before installation these instructions must be fully read and understood
1 FOREWORD
KTM Hindle design considerations have centred
on reliability and safety being of principle
importance to all modern process industries.
The ‘Meta-Seal’ range of metal seated ball
valves are designed and manufactured to
withstand extremes of temperature and
pressure under a wide range of chemical/
petrochemical and offshore duties. The seats
are available in either carbon/metal composite
material, or hard nickel fused alloy. Seals are
pure graphite and the seat springs are Belleville
type. All components are produced to tight
tolerances and some are specially treated to
withstand demanding service conditions.
The excellent design features are complemented
by KTM Hindle established quality
assurance system, which is approved by major
end users.
Although it is possible to carry out onsite maintenance of this type of valve, it is
recommended that the valves are serviced at:-
Emerson
Victoria Road, Leeds LS11 5UG
Tel. : 44 (0) 113 2443741
Fax : 44 (0) 113 2833743
Where this is not possible, it is important that
the following procedures are adopted.
When ordering service spares, it is essential
to specify the individual valve identification
number, stamped on the body.
KTM Hindle ball valves are more reliable, more
intrinsically safe and have a longer service life
than is commonly found amongst top quality
ball valves.
2 MAIN CHARACTERISTICS
2.1 Full bore or reduced bore
Full bore valve and trim offer the following:
• Highest possible C.v. per inch of valve size,
due to it’s full opening. This can result in
easier installation and lower cost when used
as a control valve.
• Identical flow characteristics give dynamic
stability and reliable closing and sealing in
both directions.
• Minimum flow resistance which saves on
pumping energy.
• Lends itself well to ‘pigging’ of the pipeline.
2.2 Trunnion mounting and stem/ball drive
The trunnion is an integral part of the ball, and
the stem drive to the ball is positively achieved
via a keyed coupling, or a drive boss. This offers
the following advantages:
• No dead band or hysteresis.
• No lost motion during control.
• The positive drive makes it possible to operate
the valve when filled with highly viscous
material, solids or high consistency slurries.
• Eliminates ‘camming’ action, a risk of
jamming with any design which depends on
the ball moving off center towards the down
stream seat when in the closed position.
• Avoids uneven wear on the stem,
ball and seats.
• Absorbs the thrust from the pressure,
preventing excess friction between the
ball and seats, so even at high pressures
operating torque remains low.
• Nitrox ‘P’ treated bearings give positive
support to the stem and trunnion with seals
ensuring no ingress of media to bearing
faces, giving longer life.
2.3 Seat design
• Seat/ball contact is designed for tangential
line contact which also assists with low
torque and gives complete interchangeability.
• Pre-energized belleville disc springs ensure
leak-tight operation at low torque.
• Upstream sealing allows downstream cavity
relief. An increase of pressure within the body
cavity reverses the positive action seats and
forces the seat from the ball to equalize the
pressure.
• Sealing of the seat holder is via preformed
flexible graphite seals retained with antiextrusion rings. The proven self-lubricating
properties and efficient sealing capabilities
ensures prolonged, trouble free service in the
most adverse environments.
• The compression ring can also incorporate
a spring protector for powder and abrasive
media, which ensures free operation of the
seat springs at all times.
2.4 Stem design
• The separate stem optimizes material
selection.
• Unique pressure energized primary and
secondary gland seals coupled with spring
loaded non-adjustable gland means no
routine maintenance is required.
Emerson.com/FinalControl © 2017 Emerson. All Rights Reserved. VCIOM-02389-EN 18/09
KTM HINDLE META-SEAL METAL SEATED TRUNNION MOUNTED BALL VALVES
OperatiOn, installatiOn and Maintenance instructiOns
3 PRE-COMMISSIONING
3.1 Replacement of valve components
Restore the paint work of any components
which have been damaged in transportation.
4 INSTALLATION
4.1 Pre-installation
Ensure flange protectors on valve are removed
and inspect internally to ensure the valve is
free from foreign matter. Check the valve
will operate and the position of the ball/bore
alignment is correct. Ensure no external
damage has occurred in transit.
Orientation
The valves referred to in this manual are
bi-directional flow and therefore may be
installed in the line either way round.
4.2 Installation procedure
NOTE
Ensure that the valve assembly is properly supported
using adequate lifting hooks and cables where
necessary.
1. Lift the valve into the installation, ensuring
that the adjacent pipe flanges are aligned
so that no pipe work stress is imposed upon
the valve body. The valve should be lifted by
the body and connector flanges, not by the
actuator.
2. When the pipe work flanges are properly
located, fit suitable gaskets to the flange
faces and assemble flange bolting.
3. Tighten flange bolts in a diagonal sequence
to ensure even compression of the gasket
and equal bolt loading.
4. Leave the valve in the open position for
hydrostatic test of the pipe work system
before plant start up.
5. KTM Hindle actuator bracketry is designed
for valves fitted in horizontal pipe-work
with the valve stem in the vertical position.
When fitted otherwise it is the end users
responsibility to ensure adequate support of
the actuator is given to prevent any undue
stress to the valve and ensure smooth
operation.
5 MAINTENANCE
5.1 Valve
Before attempting any maintenance, ensure
that the system has been depressurized and if
necessary, drain off all dangerous chemicals.
General
Ensure that the valve is properly supported,
if it is required to be taken out of the line use
adequate lifting hooks and cables.
5.2 Cleaning methods
1. When corrective maintenance is being
carried out on the valve, care must be taken
to ensure no debris grease is present in
the body housing. Clean using a degreasing
agent, in particular wipe all friction sealing
contact surfaces with a clean cloth.
5.3 Routine maintenance
1. The KTM Hindle ‘Meta-Seal’ metal seated
ball valve range has been designed to
give long service life with little or no
maintenance. Every six months the valve
should be checked for correct working
of main and associated components
functioning.
5.4 Dismantling valve - actuator/gearbox
operated
1. Operate valve into closed position.
2. Mark orientation of actuator/gearbox
mounting pedestal and valve upper cover,
and remove operator. Remove the stem
keys.
3. Mark orientation of the body (1) and
connector (2). Mark orientation of the upper
cover (3) and body.
4. Remove the upper cover nuts (27) to
allow removal of the complete stem (10)
and upper cover assembly. The valve
coupling(17) will remain fixed to the ball.
Remove coupling keys (22).
5. Remove coupling spring (20). Remove
coupling retaining screw (21) followed by
the coupling (17) and coupling washer (19).
Remove ball keys (23).
6. Remove lower cover nuts (30).
7. Remove the lower cover (4) followed by the
trunnion spring (16), trunnion bearing (15)
and gasket (38).
8. Remove the connector nuts (26) and remove
the connector (2).
9. Carefully remove the ball (5) and place on a
soft, non-metallic surface.
10. Remove upper cover gasket (36) and lower
cover gasket (37).
11. Place a lever at the back of the seat and
loosen the compression ring (7) in both
the body and the connector. (See Figure 1:
Loosening the compression ring).
12. Remove seat/spring assemblies from the
body and connector recesses.
13. Place the special stem tool over the
stem (10) and insert threaded bar
through the tool into the top of the stem.
(See Figure 2: Special stem tool).
14. Tighten nut to compress the stem spring
(11). Remove the split stem retaining rings
(14). Remove the special stem tool.
15. Push the stem (10) through the upper
cover(3).
2
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