Kitz 150 SCTBZ Series User manual

Document No.：KE-1027-00
Operation Manual
For
Ｔwo Peace Type Steel Ball Valves
150/300SCTBZ,UTBZ
（Flanged ends）
Thank you for having chosen KITZ products.
For safe and trouble-free function and performance of the
product, ensure to read and understand all items of this manual
before valve mounting and operation.
Keep this manual in a convenient place for your valve operators’
easy access.

Document No.：KE-1027-00
This manual covers the normal use of Class 150/300 SCTBZ/SCTBZM & UTBZ/UTBZM Series,
split body, side entry design floating ball valves manufactured by KITZ Corporation, as a general
guidance to users.
This manual is prepared for manual valve operation.
For electric or pneumatic valve operation, refer to the operation manual prepared by the
manufacturers of relevant valve actuators.
CAUTION AND WARNING
To ensure safe and trouble-free function and performance of the product, please read all items of
this manual before handling, transportation, mounting and operation of valves. Keep this manual
in a convenient place for your valve operations’easy access.
The signal words “WARNING”and “CAUTION”are defined as follows:
Indicates a potentially hazardous situation which, if not avoided, will result
in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTES TO USERS
This manual covers the normal usage of the product. Technical data and instructions for operation,
maintenance and inspection of the product are prepared in consideration of safety. However, they
are good only to cover typical applications as a general guideline to users. If technical assistance
beyond the scope of this manual is required, contact KITZ Corporation or its distributors.
The illustrations given in this manual do not introduce all details. If more detailed data are needed,
refer to our relevant valve assembly drawings.
※Any information provided in this operation manual is subject to revision at any time without
notice. This edition cancels all previous issues.

Document No.：KE-1027-00
C O N T E N T S
Sheet
ⅠConstruction and Design Features ･･････････････････ 1
ⅡValve Operation Device ･････････････････････････････ 4
ⅢShipping, Handling and Storage of Valves ･･･････････ 7
ⅣValve Installation ･･････････････････････････････････ 10
ⅤValve Operation ･･･････････････････････････････････ 15
ⅥPeriodic Inspection and Maintenance of Valves ･･････ 20
ⅦDisassembly and Reassembly of valves ･････････････ 24

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CHAPTER Ⅰ
Construction and Design Features

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Ⅰ Construction and Design Features
1. Construction and Design Features
1.1 The typical valve design is as illustrated below.
1.2 Range of operation from full opening to full closing is 90°.
1.3 The ball is supported by both ball seats. When the valve is pressurized, the ball moves
against the downstream seat to complete the seal, shutting off flow of the line fluid.
1.4 This ball valve design may be used on applications where a bi-directional flow is needed.
This illustration represents a typical construction.

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Ⅰ Construction and Design Features
2. Design Features
2.1 Split Body, Side Entry Design
The valve is Split Body, Side Entry Design with the coupling flanges fastened by bolts and
nuts.
2.2 Fire safe provision
KITZ ball valves can be optionally provided with graphite packing and body to body-cap
flange gaskets for use in the areas of production facilities where external leakage may be
caused by plant fires. These graphite components will contain the line media where PTFE or
other lesser materials may burn away, feeding fuel increasing the magnitude of the fire. KITZ
ball valves provided with graphite sealing components are identified as the
SUPER-FIRESAFE version in our product catalogs.
The integral, secondary seats on the body and body-cap minimize internal leakage, when
resilient ball seats are deteriorated in case of a plant fire.
2.3 Anti-static provision
Anti-static devices are provided to ensure electrical continuity between ball, stem and body.
2.4 Valve Application
The ball valve may be used on application where a bi-directional flow is needed.
2.5 Actuator Mounting Pads
ISO 5211 actuator mounting pad is integrally provided for uniformity simplified mounting of
any actuators provided with valve mounting flanges designed to ISO 5211 dimensional
requirement.
2.6 Low Fugitive Emission Feature
The surface of stem and stuffing box, and interface clearance of stem-to-gland bush,
stem-to-body and gland-to-stuffing box are precision controlled on machining and assembly
for low emission service.

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CHAPTER Ⅱ
Valve Operation Device

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Ⅱ Valve Operation Device
1. Lever Type Operator
1.1 Levers are mounted directly on the valve stem.
1.2 Rotating the lever clockwise by 90 °will close the ball, and moving the lever
counterclockwise by 90°opens it.

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Ⅱ Valve Operating Device
2. Worm Gear Operator
2.1 The worm gear operator is mounted on the valve.
2.2 According to the arrow or letter on the handwheel, turning the handwheel clockwise closes
the valve, and turning the handwheel counterclockwise opens the valve.
2.3 Handwheel operating torque depends on the size and opening position.
2.4 Worm gear operator is to transmit a large torque to valve stems, converting a torque from
drive shaft by means of reduction gearing unit using worm gears.
.

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CHAPTER Ⅲ
Shipping, Handling and Storage of Valves

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Ⅲ Shipping, Handling and Storage of Valves
1. Shipping and Handling Valves
1.1 Care for Shipping and Handling Valves
(1) Keep off the valve lifting area to prevent personal injury caused by unsecured
valves.
(1) Take care not to damage coated surface of valves during shipment. This may
cause rust or other types of corrosion to form on valves. Any damaged
surface should be adequately treated before installation.
(2) Take care the handling and storage of carton packed. The high humidity may
damage the cartons, which may lead to damaging valves.
1.2 Shipping and Handling Valves
1.2.1 Maintain original packing condition during shipment. If the protective covers are found
missing during transportation, provide appropriate type of protective covers.
1.2.2 Handle valves carefully so that they may not fall or drop on the ground. Any
extraordinary mechanical impact should be avoided.

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Ⅲ Shipping, Handling and Storage of Valves
2. Storage
2.1 Care for Valve Storage
(1) DO NOT storage valves in the corrosive environment, which may cause
corrosion on threaded portions of valves.
(2) DO NOT remove protective covers until installation. As they will prevent the
intrusion of any foreign object, the removal of covers could cause damage to
the closure elements such as ball and seats.
(3) DO NOT fall, drop, give mechanical impact or place any other objects on
valves, and DO NOT step on them, which may damage valves.
(4) DO NOT carelessly pile up products to avoid risk of product damage and
personal injury caused by unstable piling.
(5) Keep the valves in the open position during storage. Storing the valves in
halfway position may deform the ball seats, leading to the internal leakage.
And storing the valves in the fully closed position may damage the ball, when
the flange protections or covers are torn or removed.
2.2 Storage
2.2.1 Indoor storage of valves in a dust-free, low humidity and well ventilated places is
recommended.
2.2.2 Storage of valves directly on the ground or concrete floor is not recommended. Place
packed valves on the racks for storage.
2.2.3 Take appropriate measures to prevent valves from direct exposure to dust, rain and
sunlight, if valves should be stored outdoors.

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CHAPTER Ⅳ
Valve Installation

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Ⅳ Valve Installation
1 Care for choice of location for Valve installation
(1) Check the valve specifications with the identification plate or tag and the
relevant catalog, to ensure that the exact valves specified in your piping
arrangement plan was provided. The service fluid, pressure and temperature
determine the compatibility of sealing materials. Incorrect application of a
specific valve could be hazardous.
(1) Keep a secure footing for valve installation and operation.
(2) Sufficient lighting should be prepared for valve operation.
(3) Piping should be properly supported, if needed.
1.1 Allow sufficient room for operation, installation and subsequent maintenance of valves,
considering the valve height and the stem direction.
1.2 Take appropriate measures for smooth operation, inspection and maintenance of valves
if they are forced to be installed in small spaces.
1.3 Try not to install valves in the places where valve functions may be hampered by such
outer forces as vibrations.
1.4 It is recommended to install valves in horizontal piping with the stem in upright position.

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Ⅳ Valve Installation
2 Care for Valve inspection
(1) Keep off the valve lifting area to prevent personal injury caused by unsecured
valves.
(2) Take care not to catch fingers in flanges during mounting work.
(3) Take care not to damage flanges, ball and ball seats surfaces.
(4) Pipes should be properly supported, if needed.
(5) Pressure applied to the gland packing may be lowered due to the stress
relaxation taking place during transportation or storage, which may cause
leakage. Retighten gland packing before operation
(6) Be sure to insert new gaskets for valve mounting.

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Ⅳ Valve Installation
2.2 Check the following items before installation for safe operation of valves.
2.2.1 The service conditions should be within the range of the relevant valve specification.
2.2.2 Valve flanges should correspond with pipe flanges.
2.2.3 Gasket contact surfaces of pipes and valve flanges must be thoroughly inspected.
No scratch or other indications of flaw should be found.
2.2.4 The appropriate space should be kept between pipe flanges for the valve
face-to-face dimensions including the gasket thickness.
2.2.5 Pipes and valves should be accurately aligned.
2.2.6 Pipe flanges should face parallel to each other. The bolt holes of flanges should be
symmetrically lined up against the center line of flanges.
2.3 Before installation, the connecting pipes should be cleaned to remove any foreign object
such as sand, dust or welding spatters.
2.4 Handle valves carefully so that they may not fall or drop on the ground. Any
extraordinary mechanical impact should be avoided.
2.5 Remove flange covers from valves just before installation.
2.6 Check all threaded areas after installation and retighten them, if needed.
2.7 Piping should be flushed before test operation with the valve fully open, to assure
removal of any foreign object that could damage valves. Do not operate the valve during
flusing.

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Ⅳ Valve Installation
3 Installation Procedures
3.1 Make sure that pipes should be aligned accurately.
3.2 The appropriate space should be kept between pipe flanges for the valve face-to-face
dimensions including the gasket thickness.
3.3 Place the valve between the pipe flanges. Insert bolts through the bottom bolt holes and
tighten them lightly.
3.4 Insert gaskets between the valve and pipe flanges. It is recommended to evenly apply a
little paste to gasket faces.
3.5 Make sure the correct alignment of gaskets, which are held in place with the bottom
bolts.
3.6 Thread bolts through the other holes of flange and lightly tighten them.
3.7 Evenly tighten the bolts alternately in a star pattern as shown below. Once the bolting is
properly tightened, both ends of each bolt should evenly protrude beyond the nuts.
3.8 Gradually raise the line temperature and pressure during test duration. Retighten valve
bolting, if needed.

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CHAPTER Ⅴ
Valve Operation

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Ⅴ Valve Operation
1. Care for valve operation.
(1) DO NOT apply too excessive force to operate the valves by such methods as
using a pipe or any other device.
(2) Never loosen bolts or nuts used in the gland, cap flanges and end threads of
pressurized valves.
(3) DO NOT use valves in an intermediate position. Such use may damage ball
seats and cause internal through-bore leakage.
(4) Retighten the gland bolts and nuts before operation of valves. Check a handle
torque while retightening the bolts and nuts so that the operation won’t
become too difficult due to over-tightening. Gland bolts should be alternately
tightened with an even force.
(5) Valve should be kept fully open during the line test or pressure test. Fully
closing valves during the test may deform the ball seats, leading to the
occurrence of internal through-bore leakage.
(6) In case service temperature fluctuates, retighten gland bolts and nuts after the
temperature is stabilized due to the occurrence of stress relaxation of the
gland packing.
(7) Gradually open valves to prevent damage of pipes, when high temperature
fluids such as steam are handled.
(8) Take some appropriate measures to prevent freezing, as needed.
2. Operation
2.1 Lever handle
Rotation of the valve stem by 90°fully opens or closes the valve. To close the valve, turn
the operating handle clockwise according to the letters and the mark indicating the
direction . Counterclockwise rotation will open the valve.
2.2 Worm gear operation
According to the arrow or letter on the handwheel, turning the handwheel clockwise closes
the valve, and turning the handwheel counterclockwise opens the valve.

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Ⅴ Valve Operation
3. Daily Inspection
In order to operate your valves safely and satisfactorily, the daily inspection is very
important. Here are the inspection items.
Inspection
items Areas to be inspected Inspection Method Remedial Measure
Gland Area Visual Check with soap
solution
Retighten gland bolts.
Replace the gland packing as
needed
Flange Areas Visual Check
with soap
solution
Retighten flange bolts.
Replace gaskets as needed.
Threaded Portions Visual Check with soap
solution
Retighten each threaded areas.
Replace valve components as
needed.
External
Leakage
Body Visual Check with soap
solution Replace the valve.
Valve body Auditory check Consult a piping engineer.
Loosened bolting Auditory check Retighten bolting.
Abnormal
Noises Pipe vibration Auditory check Consult a piping engineer
Loosened
Bolting Bolts and Nuts Visual and Tactile check Retighten bolts and nuts.
Internal
thru-bore
leakage ――
Remove foreign object.
Disassemble and inspect the
valve components.
(Replace the ball seats)
Replace the valve.
Valve operating
position
Visual Check
Make sure that the valve is in predetermined position.
Valve
operation Disturbed operation Visual and
Tactile check Disassemble and inspect the valve components.