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KTM SERIES POWDER DISCHARGE SYSTEM (PDS) BALL VALVES
OPERATING AND SAFETY INSTRUCTION
Before installation these instructions must be read fully and understood
1 SCOPE OF APPLICATION
This instruction manual applies to the PDS ball
valve.
2 HANDLING SUMMARY
2.1 Piping summary
In order to keep using the valve in good
condition for long, carry out piping in
ac-cordance with the following procedure.
a. Before installing the delivered product,
collate whether it meets specified operational conditions (e.g. temperature,
pressure, fluid property, environment,
piping standard).
b. Check each section of the valve for
components such as bolts, and nuts. Make
sure there is no loosening of each section
caused by transportational vibration, etc.
If a loose section is found, tighten it as
required.
c. Since both flanges of the valve are covered
with dustproof seals, peel them off.
d. Before installing the valve, carry out
adequate flashing of pipe lines (inside
of pipe line) to remove foreign matters.
Installing and operating the valve to open
and close leaving welding or cut chips
unremoved inside pipes may threaten to
cause damage to the ball and seat of the
valve.
e. The valve can be mounted to a horizontal
or vertical pipe, or can be installed in any
direction such as turning it sideways, except
that the mounting attitude of the valve may
be limited for maintenance or automatic
operation.
f. When fastening flange bolts, alternately
fasten each pair of those opposite to each
other toward the center of the flange by
applying uniform strength with care for
uneven fastening. Uneven fastening of
flange bolts causes pipe stress, thereby
damaging the flange, or inducing an
excessive operating torque.
2.2 Checkup and maintenance
To make the valve perform its intrinsic function
to the utmost end without fail, carry out
periodic checkup and maintenance of it as
required.
a. Valve seat
The valve seat is made of stainless steel
deposited of stellite. In case unusu-ally
excessive leakage occurs from the valve
seat disassemble the valve to check for
leakage from the surface of seat and ball.
Since a scratch or flaw on the surface of
ball or seat may cause excessive leakage
from the vale seat, it is necessary to replace
the seat or ball as re-quired. (Since the
allowance for leakage from the valve seat
is prescribed by the ANSI/FC170-2bCLASS
5, the KTM employs the allowance as
standard.)
In addition, when reassembling the valve,
replace the gasket with a new one.
b. Mating face between the body and the
body cap
The mating face between the valve body and
the body cap uses a gasket. Make sure there
is no leakage from the mating face. In case
slight leakage occurs from the mating face,
retighten bolts and nuts for the body cap.
In case even slight leakage still continues,
disassemble the valve, check the gasket
to make sure of the presence or absence
of abnormality, and replace the gasket as
required.
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KTM SERIES POWDER DISCHARGE SYSTEM (PDS) BALL VALVES
OPERATING AND SAFETY INSTRUCTION
c. Gland seal
The seal for the gland uses a packing made
of reinforced PTFE or Graphite. Since the
gland is the sliding section of the stem,
execute periodic checkup on the gland to
make sure there is no leakage from the
gland seal. In case even slight leakage
occurs from the gland seal, retighten gland
bolts uniformly to make sure the leakage
has been stopped. In case the leakage still
contin-ues, disassemble the valve to check
for the packing, make sure of the pres-ence
or absence of abnormality, and replace the
packing as required.
d. Mating face between the valve body and the
lower cover
The mating face between the valve body and
the lower cover uses a gasket. Make sure
there is no leakage from the mating face.
In case even slight leakage occurs from the
mating face, retighten bolts and nuts for
the mating face. In case the leakage still
continues, disassemble the valve, check for
the gasket to make sure of the presence
or absence of abnormality, and replace the
gasket as required.
2.3 Cautions for disassembly and assembly
of the valve
For the valve structure, see the drawing of
delivery.
When disassembling and assembling the valve,
be careful for the following matters.
a. Since fluid (gas or liquid) pressure may be
left as it is inside the cavity of the valve body,
discharge the pressure by open the drain
plug, or open or close the valve to discharge
the pressure from the cavity. After making
sure there is no pressure inside the cavity
any longer, disassemble the valve.
b. If fluid for use in the valve is physically
harmful, or strongly inflammable, clean
the valve and pipes adequately so that no
fluid remains inside the cavity of the valve
body. After making sure there remains no
fluid used inside, disassemble the valve.
In this case, too, it is effective to repeat
opening and closing the valve a number of
times before disassembling and assembling
the valve.
c. Handle the spherical surface of the ball and
each seal with care not to dent or flaw them.
d. In order to protect the spherical surface
of the ball and the seat from being dented
or flaw, fully close the valve before
disassembling or assembling it.
e. When assembling the valve, replace all the
gaskets, stem bearing and thrust bearing
with new ones.
2.4 Disassembly
The following provides a procedure for
disassembling the valve required for
maintenance and checkup, or troubleshooting
of the valve.
1. Removal of the actuator (pneumatic torque
cylinder).
See drawing AE0106-7437
a. Shut off operational pneumatic pressure
and operational electric power supply,
and remove the pneumatic piping and
electric wiring from the ac-tuator.
b. Remove all of the attachments that
may threaten to be damaged by the
disassembly.
c. Mark both yoke (2) and valve (1) with tally.
d. Unfasten Hex Socket Head Bolt (7) from
connector and remove con-nector (3)
from the valve stem.
e. Unfasten anchor nuts to remove both
actuator (4) and yoke (2) together from
valve (1).
2. Disassembly of the valve.
See drawing HE0106-7477
a. Remove key (41) from stem (4), unfasten
nut (32) to remove gland flange (31)
from the valve. Next, unfasten nut (37) to
remove EXT. bonnet (13) from the valve.
(Then, removing the gland packing from
the valve makes the removal work easy.)
b. Extract stem (4) from valve body (1)
(Since there is a female threaded hole
on the top of stem (4), screwing an
eyebolt, or the like in the hole makes
the extraction easy. Moreover, the use
of a jig as shown in Figure 1 makes the
extraction easier.)
c. Unfasten nut (39) to remove lower cover
(14) and shim (44). Next, extract lower
stem (5) from valve body (1).
(Since there is a female threaded hole
on the under surface of lower stem (5),
screwing an eyebolt, or the like in the hole
makes the extraction easy. Moreover, the
use of a jig as shown in Figure 1 makes
the extraction easier.)
d. Unfasten nut (35) to remove body cap
(2) from valve body (1). After that, ball
(3) from valve body (1) with care not to
scratch or flaw the spherical surface of
the ball.
e. Remove seat (6), O-ring (9), spring holder
(7) and spring (8) from the valve body.
Then, be careful for spring (8) set in the
back of spring holder (7) not to be lost.
f. Also, disassemble seat (6) attached to
body cap (2) in the same manner as the
procedure described in step (e) above.
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KTM SERIES POWDER DISCHARGE SYSTEM (PDS) BALL VALVES
OPERATING AND SAFETY INSTRUCTION
2.5 Assembly
The following is a procedure for reassembling
the valve which was once disas-sembled for
maintenance and check up, or troubleshooting.
1. Assembly of the valve.
See drawing HE0106-7477 and HE0106-7467
a. Check up of the valve for every
component.
Wipe away or clean fouling from every
component of the valve. After removing
dust, fouling, etc., make sure there is
neither scratch nor flaw on components.
Since broken pieces of packing are apt to
adhere to gasket attachment sur-faces of
the valve body and body cap, remove the
broken pieces with care not to scratch or
flaw the metallic contact surfaces.
b. Insert powder proof (11), (12), spring
holder (7), spring (8), and O-ring (9)
together in valve body (1). Then, using
grease or the like to plaster spring (8)
to spring holder (7) makes the work
easy. Next, insert seat (6) with powder
proof (10).
c. Fix seat (6) to body cap (2) in the same
manner as the procedure described in
step (b) above.
d. Press fit lower stem bearing (20) in the
ball (3).
e. Insert thrust washer (22) V ring (powder
proof) (25) in valve
f. Insert stem bearings (18) and (19) in valve
body (1).
g. Insert ball (3) in valve body (1) keeping
the ball in the closed state and making
the stem hole of ball (3) having a keyway
coincide with the stem hole of body (1).
h. Attach key (40) and thrust bearing (23)
and (47) to stem (3), and push key (40)
and thrust bearing (24), (47) into the stem
hole of ball (3) by about 1cm deep through
body (1). Then, avoid pushing them into
the utmost end of the stem hole.
i. Attach gasket (15) to body (1), incorporate
body cap (2) in body (1), and fasten the
body cap with studs (34) and nuts (35).
Then fasten them diagonally.
j. Push stem (4) into the stem hole of ball
(3) while lightly hitting the head of stem
(4) around using a plastic hammer or the
like until stem (4) touches body (1).
k. Insert lower stem (5) with O-ring (27)
and backup ring (28) in ball (3) through
body (1), and push it into the ball using
a plastic hammer or the like until it
touches body (1).
l. Attach gasket (16) to the gland section
of body (1), and fix EXT. bonnet (13) with
O-ring (26) to the gland section using
studs (36) and nuts (37). Then, fasten
nuts (37) diagonally. Next, insert gland
packing (30) lantern ring (29) and gland
flange (31) in this order in the gland
section, and fasten them using gland
bolts (32) and nuts (33).
m. Attach gasket (17) to body (1), attach
shim (44) to lower cover (14), and fasten
them using studs (38) and nuts (39).
Then, fasten nuts (39) diagonally.
n. Turn stem (4) to make sure ball (3) can
smoothly move.
(In case the ball cannot smoothly
move, readjust it in accordance with
the procedure for disassembly and
assembly.)
2. Mounting the actuator (pneumatic torque
cylinder).
See drawing AE0106-7437
a. Incorporate both actuator (4) and yoke
(2) together in the main body of valve (1),
make the tallies marked when they were
disassembled coincide with each other,
and fasten them with bolts/nuts.
b. Attach the key and connector (3) to the
valve stem.
c. Fasten Hex Socket Head Bolt (7).
d. Attach to the actuator the attachments,
pneumatic piping, and electric
wirings which were all removed when
disassembling the driving section.
3. The procedure for assembling the actuator
has now been completed.
FIGURE 1
Hand bar
Stem Body
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KTM SERIES POWDER DISCHARGE SYSTEM (PDS) BALL VALVES
OPERATING AND SAFETY INSTRUCTION
2.6 Test and inspection
After assembling the valve, execute air tightness test, seat leakage test, and valve action test
to make sure they are all normal. In addition, execute those tests taking the matters as listed
in the following table as a rule of thumb.
Item Content Criteria
Tightness test 1. Test pressure: Compressed air or
nitrogen gas which is 1.1 times the
operational pressure.
2. Test duration: 10min
Seat leakage test 1. Test pressure: ANSI/FCI 70-2 Class 5
2. Test duration: 1min
Working test 1. Fill the pneumatic torque cylinder with
compressed air having an operational
pressure of 0.35 Mpa
1. No leakage is allowed from the gasket
seal, gland, and other sections.
1. ANSI/FCI 70-2 Class 5
0.076cc/min/inch/ΔP<Mpa>(Liq)
1. Visually make sure the valve can act
normally.
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