Kitz F14A User manual

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 1 of 13
2002-12-05 1 D.Sampietro J.Muñoz General revision. Added figures
Date Rev. Created Approved Notes
F14A

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 2 of 13
CONTENTS
1.- INTRODUCTION
2.- HANDLING OF VALVES
3.- ASSEMBLY TO THE PIPING
4.- OPERATION
5.- MAINTENANCE AND PERIODICAL INSPECTION
6.- DISASSEMBLY AND ASSEMBLY PROCEDURES
7.- ACCEPTANCE TESTS
8.- ANNEXES
Fig. 1 Parts List
Fig. 2 Bolting Torque table
Fig. 3 Break Torque table
Fig. 4 Test pressure table

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 3 of 13
1.- INTRODUCTION
In order to achieve safe and effective operation in industrial installations, not only
must operators have a broad understanding of engineering and operation of all
machinery and equipment, but they must also perform continuous and proper
maintenance of the equipment.
Improper operation or maintenance of one single valve may affect the overall
operation of the plant.
In order to help achieve trouble-free operation of the valves, we provide the
information contained herein for optimal operation and conservation of the FIG.
F14A ball valves.
This operation manual covers only manually operated ball valves NPS ½” to 6”, in
Class A150, A300 or A600.For valves actuated electrically, pneumatically or
hydraulically, please consult the actuator operation manual supplied by the
corresponding manufacturers.
2.- HANDLING OF VALVES
•Before shipping, the inlet and outlet of each valve are capped in order to protect
it from any mechanical damage while keeping out dust and foreign objects during
shipping and handling. Do not remove these caps until the valve is installed.
•The valves must be kept in a well-ventilated dry area, free from dust. Take
special care not to damage the valve shafts during handling. Avoid placing the
valves directly on the floor. Under no circumstances should the valves be stored
outdoors.
•All valves (except spring return actuated valves) are shipped with the sphere in
the fully open position, in order to protect the sphere surface and soft valve
seats. Always store them in this position.
3.- ASSEMBLING TO THE PIPING.
•First of all, check the plates, labels or any other type of identification of the
valve and make sure you have ready the exact valves specified in your
distribution plan.
•Normally, areas where valves are installed are very dusty. For this reason be
sure to keep the protective caps on the valves until they are ready to be
fitted.

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 4 of 13
•Once the dust caps are removed, carefully clean the inlets and outlets of both
fittings and valves, so that all flange faces are free from any dirt or grime
which would inhibit proper sealing.
•The pipe flanges must be correctly aligned with the valve flanges, as uneven
tightening of the bolts may result in undesired stress elements both in the
bolts and in the valve body.
•Tighten the bolts gradually and evenly, each a bit at a time. Make sure that
the bolts protrude beyond the nuts. After fitting the valve, check the bolts
again and retighten any loose ones.
•Finally, the inside of the fittings and valves must be cleaned, using for
example water under pressure, in order to remove any foreign objects which
might cause leakage in the future. Actually, a very common phenomenon at
new plants is leakage as a direct result of foreign objects in the valve seats
which were not removed at the time of installation.
•For valves fitted at the ends of the pipes, installation of a drainage device is
generally recommended.
4.- OPERATION.
A quarter-turn of the valve shaft fully opens or closes it. To close the valve, turn it
clockwise, and turn it counter clockwise to open it.
The turning force required is less when the valve is partially open than when it is
fully open or closed.
At the first use of the valve, check for any leaks in the area of the gland packing and
the flange or body gaskets.
•To solve any leakage problems through the flange gaskets, all of the flange
bolts must be tightened gradually and evenly, each a bit at a time. If
retightening does not solve the problem, the gasket must be replaced with a
new one.
•In the event that there are leaks in the area of the packing, retighten the stem
nut or proceed with changing the shaft gaskets as described in section 6.
The pressure-temperature ratings published by each manufacturer should normally
be considered as a guideline for the maximum temperature and/or pressure that the
valves can withstand.
Nevertheless we recommend consulting the manufacturer in order to be on the safe
side, thus protecting your valves from deformation or damage to the sealing
materials, when they are subject to the following conditions:
•When the valves are closed for long periods under high temperature and/or
pressure.

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 5 of 13
•When the valves are frequently operated for long periods under high
temperature and/or pressure.
•When the valves are subjected to frequent temperature changes, especially if
the valve seats are working very near the maximum values indicated in the
pressure-temperature ratings. Similar care is necessary for low flow, low
temperature and low viscosity fluids under thermal cycles or high pressure at
low temperatures.
Ball valves are not generally recommended for flow regulation, as constant
circulation of fluid between the valve seat and the lower edge of the sphere could
deform or damage the soft seats and cause them to drip even though they are fully
closed.
The risk of deformation or damage to the valve seat is greater when the valve is
used for extremely high flow rates and/or highly abrasive fluids, such as slurry or
fluids with particles which may get stuck along the way.
For this reason, ball valves must be used essentially for fully opening or closing
purposes.
5.- MAINTENANCE AND PERIODICAL INSPECTION.
To ensure safe and satisfactory operation of the valve, it is very important to perform
a periodical inspection at fixed intervals, depending on the difficulty or risk
associated with the service it performs. Below are the main points which require this
inspection.
•Fluid leakage
-Coming from the shaft seal area.
-From the installation fittings
-From the union between the body and the connector
-From the valve body surface
•Generation of unusual noise
-Coming from the valve itself
-Coming from loose bolts
-Coming from vibrating pipes
•Visual inspection
-Of the proper working position of the valve

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 6 of 13
-To ensure that the bolts are perfectly tightened
-Of wear on the shaft and sphere and corrosion of the body or
nuts and bolts
If any of the above problems are detected, corrective action must be taken
immediately.
6.- DISASSEMBLY AND ASSEMBLY PROCEDURES.
WARNING: ALWAYS DEPRESSURIZE THE LINE AND VALVE BEFORE
DISASSEMBLING PARTS WHICH ARE UNDER PRESSURE.
Even after the fluid has been released from the pipe, there may be residual pressure
in the body cavity (the space made up of the body interior, sphere and valve
seats).Make sure that it is relieved by operating the valve once pressure has been
released.
Before decoupling the valves from the pipes, the valve flanges and the pipe
coupling flanges must be marked to indicate their original position. This will help
to avoid confusion or errors when refitting the valve.
For disassembly of the external components, proceed as follows:
•Place the valve in a vertical position with the body (01) at the bottom and
the sphere in the closed position, on a soft and clean surface.
•First remove the handle (30 / 31), according to the size of the valve:
-NPS. <= 1”; Loosen and remove the nut (12) and then pull out the
handle.
-NPS > = 1½”; Remove the upper bolt , the washer and bolts and
then pull out the handle.
For disassembly of the internal parts, proceed as follows:
•Fix the body and, with the valve closed, mark the body and the end
connector, indicating their relative position, in order to reassemble them
in the same position later.
•Loosen and remove the bolts or nuts (18). The number varies according to
the size of the valve.
•Remove the end connector (04) vertically.
•Remove the body gasket (24).

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 7 of 13
•Remove the sphere (21) from inside the body, taking care not to bump or
scratch it. The sphere surface must be kept in optimal condition for
proper operation of the valve.
If the stem seals shall be removed, follow next steps:
•Unscrew and remove the stem nut (12). Pull out the two Belleville washers (11).
•Remove the stop plate (09) in the case of valves with a nominaldiametergreater
than 1”. For those with a diameter of less than 1” the function of stop plate (a
quarter turn) is performed by the handle itself.
•Remove the stem (05) by pushing it inside the valve body. If the shaft does not
move manually, lightly tap the shaft end with a soft mallet. Neveruseahammer
for this purpose.
•Remove the O-ring (40) from the stem, taking extreme caution not to scratchthe
outside of the stem or the O-ring seat.
•Remove the two friction rings (26) from the stem. Then remove the gland ring
(06) fromits recess on the valve body. Then remove the packing rings (25) from
the same recess. Be careful not to damage the body.
•Remove the seats (22) from the body and the end connector. This operation
must be performed with utmost care so as not to scratch the Fire Safe lip,
the walls and the bottom of the seat.
To inspection valve components,
•The dirty interior of the valve must be cleaned with water, steam, acid or oil prior
to inspection. Examine the internal non-visible area with an inspection tube or
with a small mirror and a light. A liquid penetration testor X-ray inspection may
also be performed if deemed necessary.
•Worn or corroded areas must be inspected carefully, with a magnifying glass if
necessary. Any wear or corrosion found on the limited area of the valve is
extremely dangerous, as it could quickly result in very dangerousleaks. Special
care must be taken in detecting cracking.
•The wall thickness must be checked periodically to track any undesired
variations which may result over time.
To reassembly the valve,
•Once all of the components have been cleaned and any needed replacement
parts such as bushings, seals, seats etc. have been obtained, the valves are
reassembled as explained below. After cleaning and before reassembly of the
components, we recommend the application of a suitable anti-rust agent on the
body interior of carbon steel valves.

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 8 of 13
•Insert the seats (22) in their respective locations in the body and the end
connector. Remember that the seats are not reversible, that is, that they are
intended for placement in one direction only.
•Place the O-ring (40) on the stem. Lightly grease the O-ring. Place the two
friction rings (26) through the stem (05), sliding them until they make contact
with the O-ring.
•Place the stem in position through the body cavity. Press the end of the stem
shaft from inside until it is seated in position in the body. The friction rings (26)
will be under the O-ring.
•Place the packing rings (25) in position, along the outside of the stem. The
number of rings is determined by the size of the valve.
•Place the gland ring (06) over the packing rings (25).Move thestemtothevalve-
closed position.
•Place the stop plate (09) on the stem.
•Place the two Belleville spring washers (11), contacting on the outer diameter,
on top of the indicator.
•Turn the nut (12) down onto the stemuntil it contacts thewashers and continue
tightening until some resistance is felt; see the recommended torque on the
following table. Fully open and close the valve in order to check for smooth
operation.
NPS Torque (Nm)
½”, ¾” and 1” 10
1-1/2” 15
2” and 3” 25
4” and 6” 45
Table 1
•Place the sphere (21) in the body, lining up the notch on the sphere with the
milled head of the shaft. This shaft position for insertingthespherecorresponds
to the closed valve.
This operation must be performed with utmost care so as not to scratchor
bump the sphere. It must be inserted gently and slowly. Never let it drop
by its own weight as its outer surface could be damaged.
•Fully open and close the valve, checking the alignment of the sphere in the fully
open position.

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 9 of 13
•Place the body gasket (24) in the body recess. Fit the end connection (04),
lining up the flange holes of the body and end connection. Make sure that the
marks made before disassembly of the valve line up properly.
•Lubricate the studs or bolts (17). The nuts (18) must be tightened gradually
following a star pattern. The number of nuts varies according to the size of the
valve. See the corresponding table for the final torque values for the nuts.
(Fig.2)
•Fit the handle (30 / 31) according to the size of the valve:
-ND <= 1”; Fit the handle and then thread and tighten the nut (12).
-ND> = 1½”; Fit the handle followed by the washer , then thread and
tighten the top bolt and then the side bolt.
7.- ACCEPTANCE TESTS
Check the service conditions of the valve by fully opening and closing it several times.
The first movements will probably require more effort, which should decrease as the
valve is opened and closed a few more times. Make sure that the indicator does
indeed reflect the working position of the valve.
All of the valves after reassembly must undergo shell pressure test and seating test
with to ensure correct operation of the valve and final acceptance.(Fig. 4)
8.- ANNEXES
Fig. 1 Parts List
Fig. 2 Bolting Torque table
Fig. 3 Break Torque table
Fig. 4 Test pressure table

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 10 of 13
Fig. 1 Parts list
Fig.2 BOLTING TORQUE TABLE (ITEM 17)

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 11 of 13
Values in Nm
CARBON STEEL STAINLESS STEEL
METRIC
8.8 DIN 267
ASTM A193
B7
ASTM A193
B7M
A2-70 DIN
267/11
A4-70 DIN
267/11
A2-80 DIN
267/11
A4-80 DIN
267/11
ASTM A193
B8/B8M
M6 12 12 9911 5
M8 29 29 22 21 26 12
M10 52 52 40 37 47 21
M12 87 87 67 62 79 36
M14 133 133 102 95 121 54
M18 256 256 197 183 233 105
M20 359 359 276 256 326 147
Note: To prevent seizing and to reduce the torque needed, all studs and nuts
described in this table must be lubricated before tightening.

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14A NPS ½”-6” Page 12 of 13
Fig. 3 BREAK TORQUE TABLE
Values in Nm
DIFFERENTIAL PRESSURE
bar
NPS Port Ø 20 50 100
½” 14 5810
¾” 19 6810
1” 25 810 15
1-1/2” 38 20 25 30
2” 51 25 35 40
3” 76 60 90 120(2)
4” 102 120 175 250(2)
6” 152 250 350 -----
1Nm = 0.1 da Nm = 0.1 m Kg. = 0.723 ft.lbs = 8.68 In.lbs
Note 1: Maximum break torque values for clean water, ambient temperature and
standard seat material.
Note 2: Values according to the pressure limitations of seats. Please ask KCE for
further information.

ENGINEERING
KITZ CORPORATION OF
EUROPE, S.A.
DEPARTMENT Date: 1999-01-25
Doc.NºIM/F14A/E
OPERATION, MAINTENANCE AND
INSTALLATION INSTRUCTIONS
FIG. F-14ANPS ½”-6”
Page 13 of 13
PORT
RB FB mm Water Air
- 1/4" 9.5 30 (22) 76 (55) 150
(110)
207
(152)
15 (11) 24 (18) 38 (28) 60 (44) 96 (70) 105 (77) 150
(110)
1/2" 3/8" 9.5
3/4" 1/2" 14
1" 3/4" 19 15 15
1 1/4" 1" 25
1 1/2" 1 1/4" 32
(110)
2" 1 1/2" 38
2 1/2" 2" 51
3" - 58
3" 2 1/2" 65 (77) (77)
4" 3" 76 60 60
5" 4" 102
6" 5" 111
8" 150 144
- 6" 152
1.- Test temperature: Ambient
2.- Pneumatic seat test shall be performed at 6 bar for both seats.
3.- For Gas Service it shall be performed a pneumatic seat test at 0.3 bar
4.- Values in brackets ( ) correspond to the hydraulic seat test; this test will only be performed if it's strictly necessary.
5.- Reference Standards: ANSI B16.34, API 598, BS 66755 p.1, DIN 3230 p.3
KITZ CORPORATION
OF EUROPE S.A. PRESSURE TEST TABLE ACCORDING RATING
HIDROSTATIC PRESSURE FOR BODY AND SEATS
PN-70 PN-100C-800
N.D.
PN-40 PN-63
TIME
(seconds)
A-600 PN-10A-150 A-300 PN-16 PN-25