KTM Ball Valves Series Meta-Seal IOM Owner's manual

Brand: KTM

Model: Ball Valves Series Meta-Seal IOM

Type: Owner's manual

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

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).

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.

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

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.

27 28

16415

37 3835

131

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

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Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.

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