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KTM HINDLE META-SEAL METAL SEATED TRUNNION MOUNTED BALL VALVES
OperatiOn, installatiOn and Maintenance instructiOns
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 on-
site 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.
2.2 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 anti-
extrusion 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.
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.
Before installation these instructions must be fully read and understood
Emerson.com/FinalControl © 2017 Emerson. All Rights Reserved. VCIOM-02389-EN 18/09
2
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.
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.
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.
KTM HINDLE META-SEAL METAL SEATED TRUNNION MOUNTED BALL VALVES
OperatiOn, installatiOn and Maintenance instructiOns
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).
3
KTM HINDLE META-SEAL METAL SEATED TRUNNION MOUNTED BALL VALVES
OperatiOn, installatiOn and Maintenance instructiOns
FIGURE 1 - Loosening the compression ring
FIGURE 2 - Special stem tool
FIGURE 3 - Re-machining of seat
16. Remove the stem bearing (13) followed by
the stem spring (11) and gland (12) from the
top of the upper cover.
17. Remove the primary (32) and secondary (33)
stem seals, making sure that the sealing
faces are not damaged and that all traces
of packing material is removed from the
grooves.
18. Thoroughly clean all components.
6 INSPECTION
6.1 Stem
Check stem for any distortion or twisting.
Replace as necessary.
6.2 Bearings (stem, trunnion and coupling)
Check for galling and wear. Replace if
necessary. DO NOT MACHINE.
6.3 Ball
Check for chips and scratching, especially in
the mouth area. If no damage is apparent and
only cleaning is required; lap the ball with a
seat assembly and fine diamond lapping paste
400 grit, in a circular motion to remove surface
adhesions. Polish to a smooth shiny surface
using silicon carbide abrasive paper, 600 grit
maximum. Thoroughly clean ball to remove all
traces of lapping paste.
NOTE
After this lapping operation the seat assembly used is
scrap, except for use in re-lapping work.
6.4 Seats
For valves fitted with replacement seat inserts,
it may be possible to re-furbish by taking a
light skim across the seat face (surface finish
Ra 0.8 microns). It is recommended that the
seat material is not machined to such an
extent as to remove the steps shown in Figure
3. For valves fitted with solid seat rings made
from nickel fused alloy, it may be possible to
lap the seat ring to ball using fine diamond
lapping paste in a circular motion to remove
surface adhesions and scratches. Polish to a
smooth shiny surface prior to inspection using
engineers blue dabbed on the seat ring. If in
doubt it is recommended that new seats are
fitted.
7 ASSEMBLY
7.1 Seat to body
1. The ball and seats are precision ground
components which are individually inspected
prior to dispatch for trueness and ability to
mate together to form a line contact seal and
therefore they should be handled with care.
2. All seals and gaskets should be replaced.
Care should be taken when fitting seals not
to damage them in any way.
3. Carry out a trial assembly of the valve
coupling (17) and coupling bearing (18)
to the ball. Also check assembly of the
trunnion bearing (15) to the ball to check fits
are a close push fit.
4. After this initial assembly, assemble the
spring spacers (9), springs (8), compression
ring (7), compression ring wire (40), seat
seal (34), seat wire (41) and seat (6) into
body. Once in position, using a soft mandrel
apply a light load to press the seat into the
body without damaging the seat insert. This
ensures correct seating of the seat seal.
7.2 Seat to connector
1. Assemble the seat spring spacers (9) into
the connector (2), followed by the springs
(8), compression ring (7), compression ring
wire (40), seat seal (34), seat wire (41) and
seat (6) into body.
Fit the seat assembly into the connector
recess. Once in position, using a soft
mandrel apply a light load to press the seat
holder into the connector without damaging
the seat insert. This ensures correct seating
of the seat seal.
FIGURE 4 - Blue ring location
Not acceptable Acceptable
Blue ring location
6.5 Compression rings
Check fit for mating parts, if distorted replace.
6.6 Body and connector
Examine recesses for damage. If severe
damage or corrosion/erosion has occurred in
the seal area, fluid leakage will occur in service
and a bubble tight seal will not be achievable.
In such a case damage component will have to
be replaced.
4
KTM HINDLE META-SEAL METAL SEATED TRUNNION MOUNTED BALL VALVES
OperatiOn, installatiOn and Maintenance instructiOns
7.3 Trunnion and ball
1. Fit lower cover gasket (37) into the body.
2. Fit the ball (5) into the body in the closed
position and locate on the seat already in
position in the body.
3. Push the ball onto the seat thereby loading
the seat springs (8) (using the method
shown in Figure 5) until the ball trunnion
bore is located centrally in the lower cover
bore. Note that the ball must only be
contracted by soft material.
4. Fit the trunnion into the ball. Fit the
trunnion bearing (15) and gasket (38) onto
the trunnion. Fit the trunnion spring (16)
and lower cover (4) to the body. Fit lower
cover nuts (30). Tighten nuts in a diagonal
sequence to ensure even compression of
the gasket and equal bolt loading.
7.4 Stem unit
1. Insert a new primary stem seal (32) into the
upper cover recess (3).
2. Smear suitable anti-seize compound into
the stem groove only.
3. Place the stem (10) through the primary
stem seal in the upper cover (3).
4. Fit a new secondary stem seal (33) over the
stem (10) into the upper cover.
5. Fit the gland (12) followed by the stem
spring (11) over the stem.
6. Using the stem assembly tool, pull the stem
against the upper cover to ensure correct
compression of the spring and seating of the
stem seals. With the stem assembly tool in
place fit the split stem retaining rings (14).
7. Using the correct size spanner, or suitable
wrench head, check the rotation of the stem
for ease of operation. Return the stem to the
closed position ready for assembly.
7.5 Coupling and upper cover
1. Check alignment of the ball keyways with
the upper cover (3) location in the body.
2. Fit the coupling bearing gasket (39) and
coupling bearing (18) to the coupling.
3. Fit the ball keys (23) and the coupling (17) to
the ball.
4. Fit the coupling washer (19) and screw (21)
to the ball.
5. Fit the coupling keys (22) to the stem.
6. Fit new upper cover gasket (36) into the body
recess. Fit coupling spring (20) onto the
coupling (17).
7. Fit the upper cover (3) and stem assembly
to the body ensuring that the engagement
of the keys in the stem and the coupling is
such that the operator open/closed position
and operation will be correct. Ensure the
coupling does not foul on the upper cover.
8. Fit upper cover nuts (28) and tighten
in a diagonal sequence to ensure even
compression of the gasket and equal bolt
loading.
9. Mount actuator/gearbox onto the upper
cover with the stem keys, ensuring
orientation is as the original build. Check
operator open/closed positions correspond
with those of the valve.
5
24
14
3
11
33
27 28
32
18
23
19
5
2
25
26
29
30
16415
41
34
40
7
9
8
37 3835
13
12
10
36
20
39
17
21
6
131
22
KTM HINDLE META-SEAL METAL SEATED TRUNNION MOUNTED BALL VALVES
OperatiOn, installatiOn and Maintenance instructiOns
PARTS LIST
Part Description
1 Body
2 Connector
3 Upper cover
4 Lower cover
5 Ball
6 Solid seat
7 Compression ring
8 Seat spring
9 Seat spring spacer
10 Stem
11 Stem spring
12 Gland
13 Stem bearing
14 Stem retaining ring
FIGURE 5 - General arrangement - (typical)
15 Trunnion bearing
16 Trunnion spring
17 Coupling
18 Coupling bearing
19 Coupling washer
20 Coupling spring
21 Coupling screw
22 Coupling key
23 Ball key
24 Stem key
25 Connector stud
26 Connector nut
27 Upper cover stud
28 Upper cover nut
29 Lower cover stud
30 Lower cover nut
31 Drain plug
32 Primary stem seal
33 Secondary stem seal
34 Seat seal
35 Connector gasket
36 Upper cover gasket
37 Lower cover gasket
38 Trunnion bearing gasket
39 Coupling bearing gasket
40 Compression ring wire
41 Seat wire
Part Description
Part Description
6
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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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