KTM Series EB7 Unibody Floating Ball Valves, KTM-EN Manuals & Guides

KTM SERIES EB7 UNIBODY FLOATING BALL VALVES

InstallatIon and operatIon manual

NOTE

• For valves stored in the fully closed position due
to spring failure mode of the actuator, the surface
of the ball should be free of dust or any other
contaminants before cyclic operation.

• 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

1 STORAGE

6 months.

The valves ball, seats and end connections
should be adequately protected against
damage. The protective end covers should not
be removed until ready for installation.
For long term storage of ball valves the
manufacturer would recommend the following
procedures be adopted:

• Protection for carbon steel valves, internals
of valve should be sprayed with WD-40 or
similar. To achieve this, turn the valve to the
half open position and direct the atomized
spray mist into the open valve cavity. Repeat
from the other side of the valve.

• Operation carbon steel and stainless steel
valves should be cycled every three months.
Thecycle operation should be to the full close
then to the full open position.

• Storage all valves should be stored in the fully
open position or fully closed position. End
protection caps or covers should remain on
the valve at all times.

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
half-open position for an extended period of
time could cause seat leakage.

1.1 Pipe compatibility

KTM ball valves are suitable for installation
into most piping systems. The standard end
connections are:

• Flanged ANSI Class 150 and Class 300

1.2 Selection

Ensure the valve’s materials of construction
and pressure/temperature limits shown on
the nameplate are suitable for the process
fluid and conditions. If in doubt contact the
manufacturer.

1.3 Unpacking

On receipt, all valves should be inspected
for loose or damaged parts, and if necessary
claims promptly submitted. Valves are shipped
on pallets or sealed wooden frame cases.
Protective end coverings should remain on
valves until ready for installation.
Valves with spring return actuators are shipped
in the ‘open’ or ‘closed’ position depending
on failure mode of actuator. They should
be stored under cover. Caution should be
exercised to ensure that they are not subjected
to moisture, dirt, sand or foreign matter. Valves
should never be left for any period of time in
an intermediate position between ‘open’ and
‘closed’.

Emerson.com/FinalControl © 2017 Emerson. All Rights Reserved.

VCIOM-00201-EN 18/03

KTM SERIES EB7 UNIBODY FLOATING BALL VALVES

InstallatIon and operatIon manual

2 SAFETY PRECAUTIONS

Whenever a valve is being installed or removed
from the pipeline, ensure the line is not
pressurized and any hazardous medium is
drained away.
Slowly cycle the valve several times to relieve
the cavity area and leave in the open position.
Check that the seat and body pressure ratings
are suitable for the service prior to installation.
Theseratings must not be exceeded.

General

The Unibody valves are all bi-directional valves,
controlling flow in either direction. They can
be installed in any position, horizontally or
vertically. Gaskets are required to fit between
valve flanges and pipeline. Check gaskets are
suitable for duty.

WARNING

For safety reasons, it is important to take the
following precautions before working on the valve:

1. Personnel making any adjustments to the

valve should utilize equipment and clothing
normally used to work with the process where
the valve is to be installed.

2. The line must be depressurized, drained and

vented before installing the valves.

3. Handling and installation of all valves,

operators and actuators must be carried
out by personnel trained in all aspects of
installation and manual/mechanical handling
techniques.

4. Ensure the valve pressure/temperature

limitations marked on the nameplate are
above or equal to the service conditions.

5. Double seated valves on liquid service,

which may be subjected to rapidly increasing
temperatures in the closed position, will need
a positive means of relieving for excessive
cavity pressures. For further information,
contact the manufacturer.

2.1 Line installation

Caution should be exercised to prevent
damage of the valve sealing mechanism during
installation. The following steps will assist
in complying with the correct installation
procedure.

Remove the protective end covers prior to
installation. This should be done preferably in a
dust free environment. The gasket faces should
be wiped with clean solvent to ensure gasket
faces are clean.
Substantial supports should be provided for
the free ends of the pipeline and for the valve
during installation. Unsupported pipelines hung
from valves can originate high stress in valve
body causing leaks or possible damage.
Where possible, leave valve in ‘open’ position
until entire construction work has been
completed, pipeline cleaned and plant is ready
for start up. Valves should never be left for
any period of time on an intermediate position
between ‘open’ and ‘closed’, as this could
cause permanent damage tothe resilient
seating material.

2.2 Orientation

Valves are fully bi-directional and can be fitted
either way. For optimum flow performance, one
piece Unibody flanged valves should be fitted
with the removable insert end upstream, if the
flow is predominately in one direction only.
Full bore valves have no preferred orientation
relative to flow.

2.3 Long term storage

Valves which have been stored in the open
position may take time to reseat when first
installed. To assist in obtaining tight shut-off
after storage the procedure steps outlined
below should be followed:

1. Remove protective end cover from valve.

2. Wipe internal bore with clean rag to remove
dust etc.

3. Cycle valve to the closed position and leave
for 24 hours sitting in close position.

4. Prior to installation open valve.

2.4 Flanged valves

Fit gaskets of suitable material, place in
position on the flanges, install bolts and run
up nuts. Tighten flange nuts to correct torque,
working diagonally opposite nuts in sequence
around the periphery.

2

KTM SERIES EB7 UNIBODY FLOATING BALL VALVES

InstallatIon and operatIon manual

2.5 Low temperature valves

Low temperature ball valves are supplied with
valve end protection caps or covers. These
protective covers should remain on the valve
until installation. As dust, grit and moisture will
affect the performance and sealing capabilities
of these valves, every effort should be made to
protect and preserve these valves from adverse
conditions including moisture.

2.6 Testing installations

When pipeline or vessel installations are being
tested it is desirable to have all ball valves in
the ‘open’ position. DO NOT USE ball valves as
block valves when testing pipelines or vessels
as sealing mechanism may be seriously
damaged by foreign matter. Should valves be
used for such testing, the manufacturer takes
NO RESPONSIBILITY for any damage which
may affect the valves sealing mechanism
and all guarantees are withdrawn. If the user
decides to test such installations with the
valves ‘closed’, caution should be exercised
to ensure that the sealing mechanism is not
subjected to pressure differentials in excess of
the maximum operating pressure of the valve
seat design.

2.7 Operating instructions

Opening and closing is readily accomplished by
a quarter turn rotation of the valve shaft.
Valve shafts are milled with two flats, the
parallel sides of which are in line with the bore
of the valve or circular with one key with arrows
stamped on top of the shaft to indicate ball
boreposition.
‘Stops’ are provided at each extremity to full
‘open’ or full ‘closed’. When valves are supplied
with gear operators or actuators, the ‘stops’
within such units are factory adjusted and
synchronised with the ball valve ‘stop’. Should
gear operators or actuators be field fitted,
caution should be exercised to ensure that
‘stop’ adjustment is checked and synchronised
with the valve ‘stop’.

Valves may be fitted with actuators and other
accessories with speed controls factory
set to achieve an operating speed to meet
the requirements of client’s specification.
On installation, should you desire a slower
operation, speed controls covering both
the open and closed operating speeds can
be adjusted to your requirements. Refer to
specific electrical pneumatic circuit diagrams
for details of speed controls.
All valves have been tested in the factory.
Therefore we do not consider it necessary for
any additional tests to be carried out on site.

2.8 Recommended spares for commissioning

Commissioning spares should not be required
if all of Emerson’s recommendations are
followed for installation. Recommended spare
part holdings would typically be 10% but will
vary depending of installation base.
Spare part kits are available through Emerson
Sales Offices.

3 MAINTENANCE

The only routine maintenance required is
periodical checks and adjustment to the
shaft assembly. Adjustment to the gland
nut is recommended after the first 3000 and
5000cycles thereafter to compensate for the
bedding of thrust and gland seal and ensure
leak free operation.
When tightening the gland nut, do not exceed
recommended torques. See table overleaf.
After reaching recommended gland nut torque,
back off to nearest flat on nut. Bend the lock
washer over the nut in this position. When
fitting actuators to valves follow the mounting
instructions supplied with the mounting kit.

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KTM SERIES EB7 UNIBODY FLOATING BALL VALVES

InstallatIon and operatIon manual

4 DISASSEMBLY INSTRUCTIONS FOR DN 15
TO 40 (NPS ½ TO 1½)

1. Remove the valve from the pipeline by
undoing the flange bolts and discard the
old flange gaskets. Ensure that there
is no hazardous matter in the valve. If
this is a possibility, the valve needs to be
decontaminated prior to disassembly.

2. Turn the ball to the closed position and
holding the valve body (001) firmly, withdraw
the body insert (002) using a suitable tool
to engage with the hex drive recess in the
insert. The insert is unscrewed by rotating
in an anticlockwise direction.

3. Using a pointed scriber, pick out and remove
both PTFE insert seal (003) and the graphite
fire safe seal (026) from within the valve
body. The insert end seat (101) can now be
removed.

4. The ball (100) can now be removed. This
may necessitate turning the valve so that it
can be gently tapped with a soft object so as
not to dent the face of the ball. Care should
be taken that the ball does not fall from the
valve, thus causing damage.

5. The other body seat (101) can then be
removed from the body. Care should be
taken when doing this so not to damage the
firesafe edges on firesafe valves.

6. The handle can now be removed, by undoing
the nut (301) and removing the wrench (300).

7. Straighten out the lock washer (258) and
remove the gland nut (207).

8. Remove the shaft spring (206) and
gland(213) from the shaft and push the
complete shaft through into the body of the
valve from where it may be withdrawn.

9. For DN 15 to 25 (NPS ½ to 1) valves the
shaft seals (201 and 202) gland packing(217)
and thrust washer (204), for DN 40 (NPS 1½)
valve the weather seal (251) and auxiliary
shaft seal (235) can then be removed from
the valve body both internally and externally
from the shaft bore taking care not to
damage the machined faces.

10. The components should then be cleaned
and checked for wear and damage. If
replacement parts are required other
than the seat and shaft seal kit, refer to
Emerson Sales Office for part numbers and
availability.

Note: DN 25 (NPS 1) valve illustrated

202

201

200

314

301

300

207

Pentair

213

204

217

- DN 15

- DN 20

- DN 25

Size - DN 40 only Sizes

223

251

235

258

206

004

023

501

641

002

003

101

100

101026

001

501

500

641

4

KTM SERIES EB7 UNIBODY FLOATING BALL VALVES

InstallatIon and operatIon manual

5 ASSEMBLY INSTRUCTION FOR DN 15 TO 40
(NPS ½ TO 1½)

1. Check that all components are clean and
that there is no damage, which will affect
the performance of the rebuilt valve.
Specific care should be taken in inspecting
the firesafe lip to ensure that it is free from
nicks or other imperfections. Lubricate
external surface of ball and seal sealing
faces with a lubricant compatible with
service conditions.

2. Insert the seat (101) into the cavity of the
valve.

3. Place the primary shaft seal (201) and
firesafe shaft seal (202) onto the base of
the shaft (200). Insert the shaft (200) into
the valve body (001) from inside the bore
of thevalve.

4. Whilst holding the shaft in position, fit
the gland packing (217) and upper thrust
washer (204). Note for DN 40 (NPS 1½)
valves fit auxiliary shaft seal (235) and
weather seal (251).

5. Fit the gland (213) and spring washer (206).

6. Fit the lock washer (258). Lubricate thread
with anti-seize compound and screw down
the gland nut (207) hand tight.

7. Ensure that the shaft (200) is in the closed
position and slip the ball (100) into position
in the valve body (001). Ensure that the
antistatic spring (531) is in position as the
ball is inserted.

8. Place the other seat (101) in position and
fit the body seal (003) into the body recess.
A flat bladed screw driver can be used to
assist in positioning the insert seal within
the recess.

9. Position the auxiliary body seal (026) into
flange face recess. Great care should be
taken with the auxiliary body seal as it is
manufactured from flexible graphite and
can be easily damaged.

10. Lubricate the thread on the body insert with
a copper based grease.

11. Screw in the body insert clockwise, and
tighten down to recommended torque.

12. Tighten down the shaft nut to recommended
torque and back off until the flat lines up
with the tab on the lock washer. Bend up the
lock washer to lock the nut in this position.

13. Refit the handle (300) and handle nut (301).

14. Check the valve for operation and if
possible, perform a pressure test on the
bench to ensure that the valve has been
correctly reassembled.

TORQUE VALUES (METRIC)

Body insert
Valve size Gland torque
(DN) (Nm)* (Nm)

15 12 160
20 30 300
25 30 350
40 40 400

torque

TORQUE VALUES (IMPERIAL)

Body insert
Valve size Gland torque
(NPS) (in/lb)* (in/lb)

½ 106 1416
¾ 266 2655
1 266 3098
1½ 354 3540

NOTE

* Tighten to correct torque and back off to nearest

flat on nut.

torque

Note: DN 25 (NPS 1) valve illustrated

202

201

200

314

301

300

207

Pentair

213

204

217

- DN 15

- DN 20

- DN 25

Size - DN 40 only Sizes

223

251

235

258

206

004

023

501

641

002

003

101

100

101026

001

501

500

641

5

KTM SERIES EB7 UNIBODY FLOATING BALL VALVES

InstallatIon and operatIon manual

6 DISASSEMBLY INSTRUCTIONS FOR DN 50
TO 200 (NPS 2 TO 8)

1. Remove the valve from the pipeline by
undoing the flange bolts and discard the
old flange gaskets. Ensure that there
is no hazardous matter in the valve. If
this is a possibility, the valve needs to be
decontaminated prior to disassembly.

2. Turn the ball to the closed position and
holding the valve body (001) firmly, withdraw
the body insert (002) using a suitable tool
to engage with the drive slots in the insert.
The insert is unscrewed by rotating in an
anticlockwise direction. Completely remove
the insert together with the body insert
seal(003) and seat (101).

3. The ball (100) can now be removed. This
may necessitate turning the valve handle so
that the ball can be gently tapped with a soft
object so as not to dent the face of the ball.
Care should be taken that the ball does not
fall from the valve, thus causing damage.

4. The other seat (101) can then be removed
from the body. Care should be taken when
doing this not to damage the fire safe edges
on fire safe valves.

5. The handle (300) can now be removed;
a) On valve sizes up to and including DN 50

(NPS 2) this entails undoing the nut (301)
and removing the wrench (300).

b) On sizes DN 80 (NPS 3) and above,

the wrench retainer bolt (301) needs
to be removed whereupon the wrench
head(303) can be removed.

6. Straighten out the lock washer (258)
(DN50(NPS 2) valve only) and remove
thegland nuts(207).

7. Remove the shaft spring (206) and
gland(213) or shaft seal follower (223)
from the shaft and push the complete shaft
through into the body of the valve from
where it may be withdrawn.

8. The shaft seals (201) and (202), auxiliary
shaft seal (235) and shaft thrust
washer(204) can then be removed from the
valve body both internally and externally
from the shaft bore taking care not to
damage the machined faces.

9. The components should be cleaned
and checked for wear and damage. If
replacement parts are required other
than the seat and shaft seal kit, refer to
Emerson Sales Offices for part numbers
and availability.

Note: DN 50 (NPS 2) valve illustrated

641

002

003

202

201

200

101

532

100

101

207

Pentair

300

004

004

001

258

206

223

251

235

501

500

501

641

6

KTM SERIES EB7 UNIBODY FLOATING BALL VALVES

InstallatIon and operatIon manual

7 ASSEMBLY INSTRUCTION DN50TO 200
(NPS 2 TO 8)

1. Check that all components are clean and
that there is no damage that will affect the
performance of the rebuilt valve. Specific
care should be taken in inspecting the fire
safe lip to ensure that it is free from nicks
or other imperfections. Lubricate external
surface of ball and seat sealing faces with a
lubricant compatible with service conditions.

2. Cantilever seat. Place seat (001) in each seat
pocket body (001) and body insert (002).

3. Place the primary shaft seal (201) and fire
safe shaft seal (202) onto the base of the
shaft (200). Insert the shaft (200) into the
valve body (001) from inside the bore of the
valve.

4. Whilst holding the shaft in position, fit
auxiliary shaft seal (235), followed by
weather seal (251), followed by shaft seal
follower (223), followed by stop plate (205).

5. Fit the shaft spring (206).

6. Fit the lock washer (258) (DN 50 (NPS 2)
valve only). Lubricate thread with anti­seize compound and screw down the shaft
nut(207) hand tight.

7. Ensure that the shaft (200) is in the closed
position and slip the ball (100) into position
in the valve body (001).

Note: for DN 50 (NPS 2) valve ensure that

the Antistatic Device (532) is in position as
the ball is inserted.

8. Place the other seat into position and fit the
body insert seal (003) into the body cavity.

9. Lubricate the thread on the body insert with
copper-based grease.

10. Screw in the body insert (002) and tighten
down to recommended torque – refer table
or until the insert is level with the flange
face, but no more than 0.25 mm (0.1 inch)
below.

11. For DN 50 (NPS 2) valves, tighten down the
shaft nut (207) to recommended torque and
backoff until the flat lines up with the tab
on the lock washer (258). Bend up the lock
washerto lock the nut in this position.

12. For DN 80 (NPS 3) and larger valves,
tension shaft until the shaft spring is fully
compressed, then back off a quarter of
a turn and lock into position with upper
shaft nut.

13. Refit wrench assembly.

14. Check the valve for operation, it should be
smooth and firm during the cyclic operation.
If possible, perform a pressure test on the
bench to ensure that the valve has been
correctly reassembled.

TORQUE VALUES (METRIC)

Body insert
Valve size Gland torque
(DN) (Nm)* (Nm)

50 40 400
80 95 600
100 95 700
150 150 900
200 150 1300

torque

TORQUE VALUES (IMPERIAL)

Body insert
Valve size Gland torque
(NPS) (in/lb)* (in/lb)

2 354 3540
3 841 5310
4 841 6196
6 1328 7966
8 1328 11506

NOTE

* Tighten to correct torque and back off to nearest

flat on nut.

torque

Note: DN 150 (NPS 6) valve illustrated

641

002

003

532

532

200

201

101

202

100

300

101

304

304

300

205

004

001

207

207

206

223

251

235

501

641

500 501

7

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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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