Emerson KTM VIRGO N Series Manual

VCIOM-10876-EN 20/10Emerson.com/FinalControl © 2018 Emerson. All Rights Reserved.
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Before installation these instructions must be fully read and understood
TABLE OF CONTENTS
1. Scope.............................................................. 1
2. Receipt, handling and storage...................... 1
3. Installation..................................................... 3
4. Operation ....................................................... 4
5. Gear operator instructions ........................... 5
6. Emergency sealant injection system........... 6
7. Preventive / periodic maintenance .............. 7
8. Possible misuse of ball valve ....................... 7
9. Trouble shooting ........................................... 8
10. Ordering spares............................................. 8
11. Disassembly and re-assembly..................... 9
12. Body cavity relief operation ........................ 21
13. Gland packing assembly procedure .......... 21
14. Recommended tightening torques for
fasteners and plugs .................................... 22
15. Service of valves with API monogram........ 23
16. Information for PED 2014/68/EU
compliant valve............................................ 23
17. Warranty ...................................................... 24
18. Factory address for correspondence......... 24
1 SCOPE
This manual is provided to ensure proper
installation, operation and maintenance for
KTM Virgo Series N Soft Seated Trunnion
Mounted Side Entry Ball Valves manufactured
and supplied by Emerson.
WARNING
Always use Personal Protective Equipment (PPE)
when carrying out above activities.
2 RECEIPT, HANDLING AND STORAGE
• Identify the valve contained in the box using
the packing list fixed on the box.
• While loading and unloading the box, check
for handling instructions/symbols marked
on the box and handle the box accordingly.
Ensure lifting of valve box in upright position
using fork lift as shown in Figure 1. Do not
drag the box.
• Before removing the valve from the box,
ensure valve is not fastened/fixed inside the
box with wooden battens and bolts which are
provided to prevent the valve from toppling or
moving inside the box during transportation.
• Remove the valve from the box using proper
D-Shackle or lifting hooks and straps. These
must be sized depending upon the weight
that must be lifted at lifting points (lifting
lugs) provided on valve as shown in Figure 2.
Do not use chains or hooks in contact with
the machined or painted surfaces.
FIGURE 1
Typical box and lifting position
Top support
Bottom
support
Lift
Lift
Swing
Forklift lifting forks
near bottom support
FIGURE 2

2
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
• If lifting lugs are not provided on the valve,
hold the valve with lifting strap around neck
area and gently lift it as shown in Figure 3.
Ensure the lifting strap is sized appropriately
for the weight that must be lifted and is
holding the neck area of valve firmly, to
prevent damages.
WARNING
• If the valve is supplied with an operator (gear
operator or actuator) do not use the operator
or the operator lifting lugs to lift the valve
assembly.
• For stem extension valve, use proper support
as shown in Figure 4 to prevent toppling of
valve.
• During handling, pay attention to prevent
any damage to the flange faces, butt weld
ends, operator, auxiliary fittings and piping
(as applicable). Do not drag the valve during
handling.
• The identification of the valve is given on the
body or on the nameplate or both. (Figure 5).
• If a tag number is specified by the customer,
identify the valve using tag number stamped
on the name plate or tag plate affixed to the
valve.
Lifting
straps
2-piece ball valve
Body marking Body marking
Name plate
Size matl
heat no.
Size matl
heat no.
Name plate
3-piece ball valve
WARNING
Do not lift from the
top flange of stem
extension
Always use lifting
hooks for lifting of
stem extension
Provide proper
support from here
to prevent toppling
Lifting
straps
FIGURE 3
FIGURE 5
FIGURE 4
• After removing from box, always store the
valve under roof and in a dry and clean
atmosphere, protected from rain and storm.
• Always place the valve on ‘soft’ surface like
rubber sheets or wooden planks free of dirt/
debris/hardware like nails and moisture to
avoid damage to the valve surfaces.
• Ensure that valve ends are covered with
protective end caps. Do not remove any
protection from the valve during storage
period.
• In case of automated valve assembly, refer to
actuator/accessory manufacturer instructions
for handling and storage.
• Always keep the valve either in fully open
or fully closed position. Full open position
is preferred. The valve is normally shipped
in the full open position (exception is valve
with a ‘fail close’ spring return actuator
arrangement)

3
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
3 INSTALLATION
WARNING
• To prevent personal injury or property
damage resulting from the bursting of
pressure retaining parts, be certain the
service conditions do not exceed the limits
given on name plate / tag plate of valve.
• Personal injury could result from packing
leakage. The valve packing was tightened
before shipment however; the packing might
require some readjustment to meet specific
service conditions.
• Check with your process or safety engineer
for any additional measures that must be
taken to protect against process media.
• Before valve installation, ensure that the
pipeline is free from dirt, debris, scale, weld-
slag etc. to prevent damage to the internal
trim parts and seals of the valve.
• Ensure that the valve end protectors are
removed and the valve ends and bore are
cleaned before installation.
• The mounting stand attached to the body
to adapter joint shall not be removed while
installing the valve on the pipeline (refer
Figure 6).
• If mounting Stand or Support stand of valve is
provided on end flange they shall be removed
before installation on the pipeline (refer
Figure 7).
• Mounting/support stand is only for handling
and transportation and not for carrying piping
loads. Hence Emerson recommends to give
supports to the pipeline appropriately and
shall not exceed following recommendations.
- For sizes, up to DN 100 (NPS 4), support to
be provided at a distance of ‘2D’ to ‘3D’ from
both valve ends
- For sizes, DN 150 (NPS 6) and higher,
support to be provided at distance ‘D’ from
both valve ends, where ‘D’ is the nominal
diameter of pipeline.
• For removing mounting/support stand from
valve assembly, lift the valve above ground
level by using appropriate material handling/
lifting equipment. Refer handling section of
this IOM. Loosen and remove the nuts from
respective mounting stand bolts/studs and
remove the stands. Fasten the nuts and bolts/
studs only to the mounting stand again and
store the entire set appropriately to reuse
whenever required for maintenance, storage
etc.
FIGURE 6
FIGURE 8
FIGURE 7
Mounting stand
attached to body flange
Support from overhead Foot support
(ground support)
Foot support
(ground support)
Mounting stand
attached to end flange
WARNING
Do not remove while
installing the valve
Remove while
installing the valve
• To reinstall the mounting/support stand
from valve, position the valve above ground
level by using appropriate material handling/
lifting equipment. Refer handling section of
this IOM. Loosen and remove the nuts and
bolts/studs from mounting stand set. Position
the stand aligning its holes with valve flange
holes and retighten the nuts with bolts/studs
as shown in Figure 7.
• Examples of valve support configurations are
shown in Figure 8.
• The valve should preferably be in fully open
condition during installation. Exception being
the 'fail close' valves.
• Never install the Valve with the Actuator
upside down on the pipeline, refer Figure 9.

4
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Installation of valve in vertical pipeline
• Place the valve with end flange resting on
‘soft’ surface like rubber sheets or wooden
planks free of dirt/debris/hardware like nails
and moisture.
• Hook the valve at end flange bolt holes as
shown in Figure 10 and lift with the help of
suitable crane.
• Alternately, valve can be lifted with the help
of fork lift as shown in Figure 11.
• Mount the valve on the pipeline end flange
with the flange gaskets appropriate for the
application and assemble with suitable
fasteners.
• Refer to tables in Section 14 of this IOM for
recommended tightening torques.
• Do not allow valve body temperature in seat
area to exceed 200 °F (94 °C) during welding
of valve to the pipeline in case of butt weld
end valves.
FIGURE 9
FIGURE 10
Lifting hooks
Forklift lifting location
Valve end flange
Valve end flange
OR
Valve
Valve
Pipeline end flange
Pipeline end flange
WARNING
Do not mount
in this position
FIGURE 11
4 OPERATION
• For lever operated valve, the lever is either
shipped loose or assembled with valve
depending upon the size of the valve / lever.
Rotation of lever in the clockwise direction
closes the valve and counter clockwise
rotation opens the valve.
• For gear operated valve, the gear operator
open / close adjustment has been done
prior to shipment and must not be changed.
Rotation of hand wheel in the clockwise
direction closes the valve and counter
clockwise rotation opens the valve.
• It is recommended that the valve should
be opened and closed slowly to prevent
hammering effect on the valve and pipeline.
• If the valve is not operating to fully open or
fully close position and/or leaking, do not
apply excessive force to operate the valve.
This can damage the valve internals and/or
the operator parts.
• Do not apply extra force using inappropriate
extensions to levers and handwheel like pipes
or bars.
Note: international standards typically restrict
the input force on lever/handwheel rim to
max. of 360N and the valves are designed
accordingly.
• For valve with pneumatic and gas actuator,
do not exceed the operating pressure of
actuator.
• Always use dry, moisture free air while
operating the valve with pneumatic actuator.

5
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
5 GEAR OPERATOR INSTRUCTIONS
5.1 Assembly of gear operator with bracket
and coupling
• It is recommended that the valve should
be kept in upright position (stem vertical).
• Valve shall be fully open.
• Place the bracket over valve top mounting
flange and fasten it with suitable fasteners.
Refer to tables in Section 14 of this IOM for
recommended tightening torques.
• Fit the key in stem keyway slot and then
mount coupling over stem.
• Fit the key in the coupling keyway slot and
assemble the gear operator on the bracket
with suitable fasteners ensuring that gear
operator position indicator matches the
open position of the valve.
• Gear operator setting should be done as
given in Section 5.3.
5.2 Assembly of gear operator without
bracket and coupling
• It is recommended that the valve should
be kept in upright position (stem vertical).
• Valve shall be fully open.
• Fit the key in the stem keyway slot and mount
the gear operator on valve top mounting
flange and fasten it with suitable fasteners
ensuring that gear operator position indicator
matches the open position of the valve.
Refer to tables in Section 14 of this IOM
for recommended tightening torques.
• Gear operator setting to be done as given
in Section 5.3.
5.3 Procedure for gear operator setting
CAUTION
If the valve has been supplied by Emerson with
the gear operator assembled on the valve -
open / close adjustment has been done prior
to shipment and must not be changed. In case
of gear operator replacement or mounting of
new gear operator on bare shaft valve, the steps
below shall be followed.
• Figure 14 shows the open and close positions
of position indicator, adjustment bolts and
lock nuts.
• Loosen the lock/check nut and unscrew
both left and right side bolt by minimum
one rotation.
• Match ball bore with valve bore. Fully tighten
the right-side bolt and then tighten the lock
nut.
• Rotate the ball by 90 degrees. Fully tighten
the left-side bolt and then tighten the
lock nut.
5.4 Possible orientations of gear operator
Figure 15 below illustrates the two possible
orientations for a gear operator when
assembled together with the Virgo Series N
trunnion mounted ball valve.
FIGURE 12
FIGURE 13
Handwheel
Handwheel
Position indicator
Position indicator
Gear operator
Gear operator
Coupling key
Stem key
Stem key
Stem
Coupling
Bracket
Assembly with bracket and coupling
Assembly without bracket and coupling
FIGURE 14
Open position Close position
Adjust right bolt for open position
Adjust left bolt for close position
Lock nut / check nut
Gear operator setting
FIGURE 15
Orientation 1
Pipe line axis Pipe line axis
Orientation 2

6
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
6 EMERGENCY SEALANT INJECTION SYSTEM
Typically provided on DN 150 (NPS 6) and larger
valves
• Emergency Sealant injection system is
provided on valve seat and/or stem packing
area to temporarily reduce seat leakage when
the valve is in the closed position or to reduce
packing leakage.
• Typically, for valve size DN 350 (NPS 14) and
above, 1 sealant injection fitting is provided
for stem and 2 fittings for each seat. For valve
sizes DN 300 (NPS 12) and below, 1 sealant
injection fitting is provided for stem and
1 fitting for each seat.
• This emergency sealant injection system
is to be used only when valve is not able to
achieve the desired shutoff due to damage /
wear and tear on the seats and seals and it is
not possible to take the valve off the line for
repair and maintenance.
• Always flush the sealant port with suitable
cleaner/solution, before injecting sealant.
Sealant / cleaning agents shall be selected
based on service fluid / condition.
References can be drawn from
manufacturers like Climax Lubricants and
Equipment Co®, Sealweld®etc.
Sealant injection fitting - Type A
(standard supply)
See Figure 16
Seat sealant injection
• Fully close the valve.
• Remove the fitting end cap and slide
giant buttonhead coupler (Climax®model
1699/1700) on sealant fitting. Inject sealant
into each of the sealant fitting. Injection
pressure shall be more than pipeline
pressure but shall not exceed 1.5 times the
pipeline pressure at operating temperature.
• Fully open the valve. Inject sealant into each
of the sealant fitting.
• Again, close the valve to uniformly distribute
the sealant over the ball surface.
• Repeat above steps multiple times until
desired sealing is achieved. Ensure last
injection is always made with valve in close
position.
Stem sealant injection
• Remove the fitting end cap and slide giant
buttonhead coupler on sealant fitting. Inject
sealant into the sealant fitting. Injection
pressure shall be more than pipeline
pressure but shall not exceed 1.5 times the
pipeline pressure at operating temperature.
• Cycle valve once to uniformly distribute the
sealant around the stem.
FIGURE 16
Sealant injection fitting - Type A (standard supply)
Check valve
Sealant fitting
Type A (marking)
Slot for sealant gun adapter
Body / adapter / housing
End cap
Giant buttonhead coupler

7
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
7 PREVENTIVE / PERIODIC MAINTENANCE
Preventive / periodic maintenance is essential
as the failure to do so may result in inadequate
performance of the valve or also failures like
seat leakage, environmental leakage, increased
torque, jerky operation etc.
All valves in operation should be periodically
inspected thoroughly to evaluate the condition
of ball, seats and seals as these parts are
subject to normal wear and tear. The frequency
of inspection depends upon the severity of
service conditions and location of the valve
and should be conducted during partial or
total shutdown.
Special attention is to be paid to inspect for
damage and / or wear due to corrosion or
erosion.
Periodic inspection of valve typically includes
following activities:
• Inspection for any visible defect or failure
such as packing or body joint leakage
• Tightening of bolts/nuts to recommended
torques
• Valve stroking to prevent jamming and
corrosion every six months
Section 11 describes the procedure for
disassembly and reassembly of the valve.
Once a valve is refurbished / repaired it should
undergo a complete set of tests to make sure
that the valve is fit to use for the intended
working conditions. Hydrostatic or Pneumatic
tests should be carried out as per the
specifications relevant to the valve.
Gear operators are packed with grease.
It is recommended that the grease should
be changed after approximately 5-7 years
if operated frequently or after 10-12 years
if operated infrequently. Contact factory for
appropriate grease grades if grease needs
to be changed
8 POSSIBLE MISUSE OF BALL VALVE
Sr. No. Possible misuse Actions to prevent misuse
1Exceeding the pressure and / or temperature limits
of the valve.
Do not exceed pressure and / or temperature limits mentioned on name plate affixed to the valve.
2Valve material not suitable for service fluid. Check Tag number (as applicable) and ensure correct valve is used as per process diagram.
Verify valve material mentioned on Name plate is suitable with service fluid.
3Use for control application. These ball valves are designed for on/off application and should not be used for control / throttling.
4Mounting of valve upside down. Follow ‘Installation’ section of this document.
5Wrong installation in case of uni-directional valve. Verify flow direction on valve body or on additional plate affixed to valve.
6Use of improper actuator when customer automates
valve on site.
Contact factory for correct sizing of actuator.
7Opening/closing of valve by using inappropriate
extensions like pipes/bars etc.
Operate valve only with levers, gear operator, hand wheel or actuator provided / recommended
by Emerson.
8Any modification by customer in valve e.g. drilling,
tapping, change of valve ends etc.
Unauthorized modifications are not allowed. Modification voids warranty. Contact factory if any such
case arises.
9Testing the valve with water without corrosion
inhibitor.
Corrosion inhibitor shall be used to prevent corrosion of valve components. Requirements of
international standards such as API 6D, API 598, BS EN 12266 etc. should be followed.
10 Inadequate draining and drying of valve after
hydro test.
When valves are hydro tested onsite, they shall be drained and dried completely before installing on
pipeline to prevent corrosion of parts and contamination of service fluid.
11 Not using lock open/close feature. Ensure to use this provision (as applicable) based on process requirement.
12 Improper long term storage. For long term storage and preservation of valves at site refer Emerson procedure QAC/KM-028.
Contact Factory.
13 Damage to valve fittings during handling. Follow handling instructions.

8
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Problem Possible cause Remedy
Leakage across closed valve 1. Damaged ball surface. 1. Refurbish or replace the ball.
2. Damaged seats / seat seals. 2. Refurbish or replace seats.
Replace seat seals.
3. Ball not closed fully. 3. Check and reset ball.
Open/close settings.
4. Seat not moving freelyresulting in inadequate contact
between ball and seat.
4. Open valve, check for accumulation of dirt, debris,
corrosion between seat and body, clean and re-assemble.
Valve too hard to operate / valve
torque too high / stick-slip operation
1. Damaged seats / seat seals /ball. 1. Refurbish or replace the seats /seat seals / ball.
2. Seat not moving freely due to accumulation of dirt,
debris, corrosion between seat and body or seat and ball.
2. Open valve, clean and reassemble.
3. Operator not sized properly, damaged operator parts. 3. Select correct operator and replace.
4. Actuator not sized properly, damaged actuator
parts, insufficient input air/gas pressure to actuator,
restriction/clogging of actuator vent.
4. Select correct actuator and replace. Check input air
supply, clean actuator vent.
Leakage through stem 1. Loose gland fasteners. 1. Tighten the fasteners.
2. Damaged stem, stem sealing surface. 2. Refurbish or replace the stem.
3. Damaged stem seal. 3. Replace the stem seal.
4. Accumulation of dirt, debris, corrosion between stem
and housing.
4. Open valve, clean and reassemble.
Leakage through body to adapter
joint; body to housing joint
1. Damaged seal/gasket. 1. Replace seal/ gasket.
2. Relaxation of joint fasteners. 2. Retighten the fasteners evenly in criss-cross manner.
3. Accumulation of dirt, debris, corrosion between body
and adapter.
3. Open valve, clean and reassemble.
Leakage through drain, vent and
sealant fittings.
1. Loosening of fittings. 1. Retighten. If leakage persists may require fresh thread
sealant or replacement of fitting. Do not remove fittings
when valve / body cavity is under pressure.
9 TROUBLESHOOTING
Size Available on name plate or body of the valve
Class Available on name plate or body of the valve
Batch number / serial number Available on name plate or body of the valve
Manufacturing date Available on name plate or body of the valve
Part number Available on general arrangement drawing
Part name Available on general arrangement drawing
Purchase order number Available on general arrangement drawing
10 ORDERING SPARES
When ordering spares, please furnish the following information.

9
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
11 DISASSEMBLY AND RE-ASSEMBLY
Sections
11.1 Warnings
11.2 Notes
11.3 Series N trunnion mounted ball
valve with gland
Construction: Two-Piece
Type: External trunnion
11.3.1 Disassembly procedure
11.3.2 Re-assembly procedure
11.3.3 Exploded view
11.4 Series N trunnion mounted ball
valve with gland
Construction: Two-Piece
Type: Support plate
11.4.1 Disassembly procedure
11.4.2 Re-assembly procedure
11.4.3 Exploded view
11.5 Series N trunnion mounted ball
valve without gland
Construction: Two-Piece
Type: External trunnion
11.5.1 Disassembly procedure
11.5.2 Re-assembly procedure
11.5.3 Exploded view
11.6 Series N trunnion mounted ball
valve without gland
Construction: Two-Piece
Type: Support plate
11.6.1 Disassembly procedure
11.6.2 Re-assembly procedure
11.6.3 Exploded view
11.7 Series N trunnion mounted ball
valve without gland
Construction: Three-Piece
Type: Support plate
11.7.1 Disassembly procedure
11.7.2 Re-assembly procedure
11.7.3 Exploded view
11.1 Warnings
For removal of valve from pipeline, disassembly,
re-assembly
• Pay attention to prevent personal injury or
equipment damage from sudden release of
process pressure or uncontrolled movement
of parts.
• Always wear PPE like protective gloves,
safety shoes, helmet, clothing, eyewear and
other PPE as mandated by site/project when
performing any maintenance operations to
prevent personal injury.
• Do not remove the operator from the valve
while the valve is still pressurized.
• In case of an actuated valve, before removal
of actuator, disconnect any operating lines
providing air pressure, electric power, or a
control signal to the actuator. Be sure the
actuator cannot accidently open or close the
valve.
• In case of spring return actuators ensure that
the spring is at its uncompressed position.
• Use bypass valves or completely shut off the
process to isolate the valve from process
pressure. Relieve process pressure from both
sides of the valve. Drain the process media
from both sides of the valve.
• Double block and bleed valves can retain
pressure and process fluid even after process
pressure has been removed from both sides
of the valve. Relieve this pressure before
disassembling or removing the valve from the
line. Take additional care if the process fluid
is hot, flammable, caustic, or hazardous.
• Carefully secure the valve in an upright
position. The roundness of the flanges and
valve body allow it to easily roll from side-
to-side. The combined weight of the valve
and actuator assembly could cause injury
or property damage when falling to the side.
• Use lock-out procedures to be sure that the
above measures stay in effect while you work
on the equipment.
• Exercise caution when working on the valve
stem packing as it may contain process
fluids that are pressurized, even when the
valve has been removed from the pipeline.
Process fluids may spray out under pressure
when removing the packing hardware or
packing rings.
• Prevent injury by keeping hands, tools and
other objects away from the ball while
stroking the valve.
• Check with your process or safety engineer
for any additional measures that must be
taken to protect against process media.

10
KTM VIRGO SERIES N TRUNNION MOUNTED BALL VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
11.2 Notes
• Ensure clean environment during
disassembly and re-assembly of valve.
• Use appropriate material handling / lifting
equipment. Refer handling section of
this IOM.
• Prior to disassembly, it is recommended to
mark mating parts like body and adapter,
body and housing, body and trunnion,
gear operator or actuator and ISO pad or
housing to ensure same orientation during
re-assembly.
• Before dis-assembly, it is recommended to
keep the ball in fully closed position and then
remove the operator from valve assembly.
• Valve shall be positioned on clean and flat
surface with adapter end flange on top as
shown in Figure 17.
• It is recommended to use original spares.
• Graphite gaskets shall be replaced.
• Elastomer and plastomer seals can be re-
used, however it is recommended to replace
them to maximize valve service life.
• Protect every sealing surface from nicks,
dents and damages.
• Lubricate the O-ring and seals and lip seals
before re-assembly.
• During re-assembly, refer to tables in
Section 14 of this IOM for recommended
tightening torques.
• Assembly drawing shows the standard
configuration for valve with O-ring seals but
can be considered as a reference for lip-seal
configuration also.
FIGURE 17
2-piece ball valve
3-piece ball valve
Body-adapter sealing