Emerson Ktm series Quick guide

Before installation these instructions must be read fully and understood

KTM SERIES POWDER DISCHARGE SYSTEM (PDS) BALL VALVES

OPERATING AND SAFETY INSTRUCTION

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 opera-

tional 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.

KTM SERIES POWDER DISCHARGE SYSTEM (PDS) BALL VALVES

OPERATING AND SAFETY INSTRUCTION

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.

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.

KTM SERIES POWDER DISCHARGE SYSTEM (PDS) BALL VALVES

OPERATING AND SAFETY INSTRUCTION

Hand bar

FIGURE 1

Stem Body

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.

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

1. No leakage is allowed from the gasket

seal, gland, and other sections.

Seat leakage test 1. Test pressure: ANSI/FCI 70-2 Class 5

2. Test duration: 1min

1. ANSI/FCI 70-2 Class 5

0.076cc/min/inch/ΔP<Mpa>(Liq)

Working test 1. Fill the pneumatic torque cylinder with

compressed air having an operational

pressure of 0.35 Mpa

1. Visually make sure the valve can act

normally.

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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

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construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed

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