KTM METALTITE® BALL VALVES - FLOATING TYPE
InstallatIon and operatIon manual
Before installation these instructions must be fully read and understood
1 SAFETY PRECAUTIONS
Precautions for using KTM valves safely are
highlighted with the following two warning
signs to indicate 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
Please read through this manual completely
before operating the valves.
Floating Type Metaltite
for high temperature fluid, corrosive fluid,
slurry and solid containing 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.
®
Ball Valves are usable
avoided, may result in minor or moderate injury.
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.
The content of this manual is effective as of
April 2015.
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.
Emerson.com/FinalControl
© 2017 Emerson. All Rights Reserved. VCIOM-02481-EN 18/11
KTM METALTITE® BALL VALVES - FLOATING TYPE
InstallatIon and operatIon manual
For the standard specifications, refer to the table below and the catalog.
Example: EB11 M 31 AY A15 10
Valve codes
EB11 ASME 150 EB12 ASME 300
JIS10K JIS20K
JPI 150 JPI 300
Sub-codes
M Metal seat
Body codes
31 CF8/ SCS13A
32 CF8M / SCS14A
62 WCB / SCPH2
Trim codes
Ball hard facing Temperature range
A Hard chrome plating Y -29º~250ºC
B Ni alloy overlay G -29º~350ºC
X -29º~500ºC
Flange codes
A15 ASME 150 J20 JIS20K
A30 ASME 300 P013 JPI 150
J10 JIS10K P033 JPI 300
Size DN and NPS
DN 15 - DN 200; NPS ½ - NPS 8
* The lowest temperature for models with body material SCPH2 is -5°C.
3 RANGE OF APPLICATION
Pressure/temperature ratings
Floating type Metaltite ball valves have a range
17/4
stem
SCPH2 (-5°C)
Min. limited line
CF8M Class 300
WCB Class 300
of application defined by temperature and
pressure. Please operate the valve within the
range shown below.
CF8 Class 300
Operating the valve outside that range may
result in failure of valve body or parts and
Pressure (MPa)
DN 50, 80, 100, 125
leakage of the fluid.
(The pressure/temperature rating is
defined by body, ball and stem material.)
CF8 Class 150
CF8M Class 150
WCB Class 150
TYPE: FLOATING
Range of production: Class 150 - 300, Size DN 15 - DN 200; NPS ½ - NPS 8
Backup seal Range of temperature Hard facing Trim code Typical application
Reinforced PTFE -29°C~250°C
(-20~480°F)
Graphite -29°C~350°C
(-20~662°F)
-29°C~500°C
(-20°C~932°F)
Ball: hard chrome plated AY For slurries, paper and pulp, fluids containing solid particles etc.
Seat: stellited
Ball: nickel alloy overlay BY On-off and throttling.
Seat: stellited
Ball: hard chrome plated AG For high temperature fluids, slurries, pulp stocks, steam,
Seat: stellited
fluidscontaining solid particles etc.
Ball: nickel alloy overlay BG On-off, throttling, fire-safe
Seat: stellited
Ball: nickel alloy overlay BX For high temperature, high pressure fluids and high frequency.
Seat: stellited
Fire-safe
WCB (SCPH2)(425°C)
DN 15, 20, 25, 40, 65
DN 150, 200
Temperature(°C)
Max. limited line
AY·BY type
max. limited line
AG·BG type
max.limited line
2
KTM METALTITE® BALL VALVES - FLOATING TYPE
InstallatIon and operatIon manual
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. (Detailsonthe 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.
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.
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 the 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
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 valve 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 any other things, 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
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.
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.
3
KTM METALTITE® BALL VALVES - FLOATING TYPE
InstallatIon and operatIon manual
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,
thevalves should be installed with the ball
in open position to ensure that the seat rings
arenot 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 Figure 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
orfailure 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 the pressure test,
returnto 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.
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 arrow-indicator (Figure 3).
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
ofthe handle may result in damage or injury
ifthe handle slips out.
2. Excessive handle operation may break the
lever, injure the operator, and/or deform
thestopper or the stem, which may also
resultin seat leakage.
3. Be careful in handling the valve where high
temperature fluid flows in the pipeline.
Theheated valve may cause burn injury
ofbarehands.
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 locking pins and stopper might
break.
To lock the floating type Metaltite ball valves,
use locks of the sizes indicated in the table
below.
FIGURE 1
Tightening of bolts
3
2
4
FIGURE 2
Lever handling valve
Valve closed
FIGURE 3
Gear operated valve
Indicator
1
Valve opened
4
KTM METALTITE® BALL VALVES - FLOATING TYPE
InstallatIon and operatIon manual
8 MAINTENANCE
The following instructions will contribute
to along 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
Figures6 to 8.
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.
PAD LOCK DIMENSIONS (mm)
Valve nominal diameter
(Full bore)
15-25 25 4.9 1000-25 m/m
40-50 31 6.5 1000-25 m/m
65-100 39 8.0 1000-25 m/m
125-200 * * 1000-25 m/m
* Not necessary
FIGURE 4
Lock pin and pad lock
Pin dimensions
FIGURE 5
Locking example
(for reference)
Padlocktype alpha no.L d
CAUTION
The sealing portion between body and body cap
is provided with reinforced PTFE or a graphite
gasket as shown in Figure 8. In case of slight
leakage, the fastening bolts should be moderately
tightened.
5
KTM METALTITE® BALL VALVES - FLOATING TYPE
InstallatIon and operatIon manual
FIGURE 6
EB11M 15 mm ~ 100 mm (½”~4”)
EB12M 15 mm ~ 100 mm (½”~4”)
Gland bolt
Stopper
Stopper
Gland bolt
Gland flange
Gland packing
Stem
FIGURE 7
EB11M 125 mm ~ 200 mm (5”~8”)
FIGURE 8
Body sealing structures
EB12M 125 mm ~ 200 mm (5”~8”)
Stopper
Gland bolt
Gland cover
Stopper
Gland bolt
Gland flange
Gland packing
Stem
Nut
Gasket
9 TROUBLESHOOTING
Trouble examples Causes Countermeasures
Unsmooth operation 1. Jamming due to solids or slurry in the fluid 1. Clean the inside of the valve.If necessary, replace parts
(ball, seats, stem bearing, thrust bearing).
2. Ball is corroded by fluid. 2. Replace with ball made of corrosion resistant material.
3. Fluid sticks to ball and seats. 3. Clean the inside of the valve. If necessary, replace ball or 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 when
shutting the valve during abnormal pressure rise in the piping
Seat leakage 1. Fluid sticks to ball and seats. 1. Clean the inside of the valve. If necessary, replace ball or seats.
2. Ball is corroded by fluid. 2. Replace with ball that is made of corrosion resistant material.
4. Take measures to prevent abnormal pressure rise in pipe.
1. The fastening nuts or bolts at gasket and gland packing are required
to be lightly tightened, or gasket and gland packing replaced.
2. Take measures to prevent pressure rise and replace seats, gaskets
and gland packing.
6
KTM METALTITE® BALL VALVES - FLOATING TYPE
InstallatIon and operatIon manual
10 VALVE DISASSEMBLY
Assemble/disassemble the valves in a clean,
well-lit and well ventilated place.
WARNING
Before removing the valve from the piping,
ensurethat 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
thevalve.
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 a 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 sure 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.
Refer to below construction drawing for
disassembly. The numbers of parts vary slightly
depending on the valve size, but the basic
structures are identical.
[Sending the valves back to us and requesting
repair]
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
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.
11 WARRANTY
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.
FIGURE 9
Parts construction (nominal diameter - 50 mm)
7
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.
Emerson.com/FinalControl
8
Loading...