Kitz T60S/SF Series User manual

Document No.：KE-1081-02
Operation Manual
For
API 6D, 3 piece, Trunnion Mounted Ball Valve
Soft and Metal seated
T60S/SF, UF3TCS Series
T60M/SF, UF3TC6H Series
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.

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This manual applies to manual operation of KITZ flanged ends manual operated soft and
metal seated API 6D, 3 piece, trunnion mounted ball valve series.
CAUTION AND WARNING
To ensure safe and trouble-free function and performance, please read all the contents of
this manual before handling, transportation, mounting and operation of the valves. Keep this
manual to the place accessible to the operator.
The signal words “WARNING” and “CAUTION” are defined as follows:
Indicating potentially hazardous conditions, which may result in
serious injury to personnel, if such warnings shall be ignored.
Indicating potentially hazardous conditions, which may result in
injury to personnel or only property damage, if such cautions shall
be ignored.
Indicates prohibition of an action.
Indicates mandatory implementation of an action.
NOTES TO USERS
This manual covers normal usage of our products. The technical data for operation, maintenance
and inspection of the products 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 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-1081-02
Index
Page
Ⅰ. Construction and Design features ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1
Ⅱ. Shipping, Handling and Storage ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 7
Ⅲ. Valve installation ・・・・・・・・・・・・・・・・・・・・・・・・・・ 10
Ⅳ. Valve operation ・・・・・・・・・・・・・・・・・・・・・・・・・ 15
Ⅴ Periodic inspection ・・・・・・・・・・・・・・・・・・・・・・・・・・ 21
Ⅵ Disassembly and Reassembly Soft seat ・・・・・・・・・・・・・・・・・・・・・・・・・・ 26
Ⅶ. Disassembly and Reassembly Metal seat ・・・・・・・・・・・・・・・・・・・・・・・・・・ 51
Ⅷ. Trouble shooting ・・・・・・・・・・・・・・・・・・・・・・・・・ 75

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Ⅰ. Construction and Design feature

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Ⅰ． Construction and Design features
1. Construction and Design features
1.1 Construction and parts names are as illustrated next page.
1.2 The valve can be operated by rotating the stem by 90 degrees to open or shut.
1.3 The valve is designed for use in the full open or full closed position only.
1.4 The valve for size up to NPS4 for full bore and up to NPS6 for reduced bore have two
stems, at the top and bottom, supporting the ball, the design of which gives the valve
less impact on operation torque.
1.5 The valve for size NPS6 and larger for full bore and size NPS8 and larger for reduced
bore have two trunnion plates, at the top and bottom of the ball, supporting the ball,
the design of which gives the valve less impact on operation torque.
1.6 The valve is a bi-directional valve.

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Ⅰ． Construction and Design features
1.7 Typical construction for Soft seated valve.
This illustration shows typical construction for size up to NPS4.
This illustration shows typical construction for size NPS6 and larger.
Stem
Packing (Graphite)
O-ring with back up ring
Gasket (Graphite)
Gasket (Graphite)
Packing (Graphite)
O-ring with back up ring
Seat spring
Ball
Ball seat
Seat retainer
Gasket (Graphite)
End plate
Stem
Packing (Graphite)
O-ring with back up ring
Gasket (Graphite)
Gasket (Graphite)
Packing (Graphite)
O-ring with back up ring
Seat spring
Trunnion plate
Ball
Ball seat
Seat retainer

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Ⅰ． Construction and Design features
1.8 Typical construction for Metal seated valve.
This illustration shows typical construction for size up to NPS4.
This illustration shows typical construction for size NPS6 and larger.
Stem
Coned disc spring
Packing (Graphite)
Gasket (Graphite)
Packing (Graphite)
Seat spring
Ball
Ball seat
Retainer gland
Gasket (Graphite)
Stem
Coned disc spring
Packing (Graphite)
Gasket (Graphite)
Packing (Graphite)
Seat spring
Ball
Ball seat
Retainer Gland
Gasket (Graphite)
End plate

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Ⅰ． Construction and Design features
2. Design features
2.1 Double block and bleed function.
The ball seat is provided on the upstream and downstream, which independently
function to seal the media. Consequently the valve bore and the body cavity are
isolated from each other when the valve is fully opened or shut so that the residue
within the body cavity may be disposed through the drain port.
Soft seated design features Metal seated design features
2.2 Excessive cavity pressure relief mechanism
Seal is made on the upstream side by the seat retainer whose seat spring pushes
the ball seat against the ball at fully shut position. In case the line fluid trapped in
the body cavity evaporates and causes excessive rise in the cavity pressure for
some reasons, especially when the cavity pressure exceeds the line pressure, the
ball seat will move slightly away from the ball surface to relieve the excessive cavity
pressure into the valve bore.
Soft seated Metal seated
Cavity pressure
Ball seat
Li
Cavity pressure
Seat retainer
Ball seat
Body
Ball Line pressure
Ball seat Packing
O-Ring
Seat spring
Cap
Seat retainer Ball
Seat spring
Body
Packing
Cap
Ball seat
Retainer gland
Line pressure

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Body
Bleeder
Plug
Ⅰ． Construction and Design features
2.3 Fire safe design
When the ball seats are decomposed or deteriorated by a fire, the edge of the metal
seat retainer preloaded by the seat spring comes into contact with the ball to shut
off the fluid to minimize internal leakage through the valve bore.
And also, metal seated design is composed of noninflammable materials, which is
suitable for fire safe design.
2.4 Drain or vent port
The valve has the block and bleed structure that allows a valve
or other types of connection to be installed at the drain or vent
port though which the fluid in the cavity can be discharged.
Gasket (Graphite)
Packing (Graphite)
Before After
Internal leakage prevention
External leakage prevention
Packing
(Graphite)
O-Ring
Gasket
(Graphite)
AfterBefore

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Ⅱ. Shipping, Handling and Storage

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Ⅱ. Shipping, Handling and Storage
1. Shipping and Handling Valves
1.1 Care for Shipping and Handling Valves.
● Keep off the valve lifting area to prevent injuries caused by the unsecured valves.
Unstable stacking may also result in personal injuries.
● Pay attention not to damage painted surfaces during transportation,
which may subsequently cause corrosion to the valve.
Repair is required if the surface is damaged.
● Pay attention to handling and storage of carton packed products.
The high humidity may damage the cartons.
1.2 Shipment
1.2.1 Maintain original packing condition during shipment. Provide appropriate
protection covers if they are found damaged during transportation.
1.2.2 Handle valves carefully so that they may not fall or drop on the ground. Any
extraordinary mechanical impact should be avoided for the valve protection.
1.2.3 When hang the products using the eyebolts, please use it within the load
capacity range of the eyebolts. The hanging angle has to be 45 degrees or
less and hang with two slings.
1.2.4 When hold the products using the support legs, please ground it so as not to
shock the products while keeping it level on the hard plane.

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Ⅱ. Shipping, Handling and Storage
2. Storage
2.1 Care for Valve storage
● DO NOT store valves in the corrosive environment, which may cause corrosion
from the valve threaded areas.
● DO NOT remove protection covers until installation. They prevent any foreign
objects from intruding valves.
● DO NOT place any objects on valves, and DO NOT step on them. Overloading
may cause damage to valves.
● DO NOT pile up products carelessly to avoid damage to the products and
personal injury caused by unstable piling.
● Keep the valves in the opened position during storage. Storing the valves in
halfway position may deform the ball seats, leading to cause of the seat leakage.
And storing the valves in fully shut position may damage seal surface of the ball
by foreign objects intrusion affect, when the flange protectors 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 place is
recommended.
2.2.2 Storage of valves directly on the ground or concrete floor is not recommended.
Place packed valves on the pallets or the racks for storage.
2.2.3 Take some appropriate measures to protect valves into the directly exposure to
dust, rain or sunlight if valves are temporarily stored outdoors.

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Ⅲ. Valve installation

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Ⅲ. Valve installation
1. Care for Valve installation.
● Check the valve specifications with the identification plate or tag and the
relevant Catalogue, 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 and ball seat
materials. Incorrect application of valves could be hazardous.
● DO NOT install for pipe end service, which may cause the external leakage.
In such a case, use the blank flange to prevent the leakage.
● Keep a secure footing for valve installation and operation.
● Sufficient lighting should be prepared for valve operation.
● Piping should be properly supported, if needed.
1.1 Allow sufficient room for operation, installation, removal 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
outer forces such as vibrations.
1.4 It is recommended to install valves to horizontal pipes in upright positions.
1.5 When hang the products using the eyebolts, please use it within the load capacity
range of the eyebolts. The hanging angle has to be 45 degrees or less and hang
with two slings.

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Ⅲ. Valve installation
2. Care for Piping.
● Keep off the valve lifting area to prevent injuries caused by the unsecured
valves.
● Care should be taken to keep hands clear of valves while placing them
between pipe flanges.
● Pay attention not to damage flange surfaces and gaskets.
● Piping should be properly supported to align pipes on both sides.
● For valves with the gland packing structure, retighten gland packing before
operation. Pressure applied to the gland packing may be owered due to the
stress relaxation taking place during transportation or storage, which may
cause leakage.
● Use new gaskets when installing valves into pipelines.

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Ⅲ. Valve installation
2.1 Check the following items before installation of the valves.
2.1.1 The service conditions should be within the range of the relevant valve
specification.
2.1.2 Valve flanges should correspond with pipe flanges.
2.1.3 Gasket contact surfaces of pipe and valve flanges must be free from scratches
or any other damages.
2.1.4 The appropriate length should be kept between pipe flanges for the valve
face-to-face dimensions including the gasket thickness.
2.1.5 Pipes and valves should be accurately aligned.
2.1.6 Pipe flanges should face parallel to each other. The bolt holes of flanges should
be symmetrically lined up against the center line of flanges.
2.2 Before installation of the valves, the connecting pipes should be cleaned to remove
any foreign objects such as sand, dust and welding spatters.
2.3 Do not give extraordinary shock to valves by throwing, dropping, dragging or toppling
them down.
2.4 Remove flange covers from valves just before installation.
2.5 Check all threaded areas after installation and retighten them, if needed.
2.6 Flush the inside of the valves and pipes, after installation to remove foreign objects.
During be flushed, the valves should open. Do not operate the valves during flushing.

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Ⅲ. Valve installation
3. Valve installation procedure
3.1 Pipes and valves should be accurately aligned.
3.2 The appropriate length 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. Support the valve during the remaining steps of installation.
3.4 Insert gaskets between the valve and pipe flanges.
It is recommended to apply lubricant (gasket 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 flanges 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 the test run. Retighten valve
bolting, if needed.

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Ⅳ. Valve operation

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Ⅳ. Valve operation
1. Lever type operator
1.1 The lever handle is directly mounted on the valve stem.
1.2 Rotate the lever handle clockwise by 90° to shut the valve and counterclockwise by
90° to open the valve.
<SHUT>

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Ⅳ. Valve operation
2. Gear operator
2.1 The gear operator shall be mounted on the valve.
2.2 There should be an arrow or letter to the gearbox surface for indicate the wheel
rotation direction to open or shut the valves.
2.3 Hand wheel operation forces differ in the valve opening position, fluid pressure value
and /or fluid temperature value.
2.4 Gear operator is the device to convey force from the operator to the valve stem
through reduction gear.
OPEN SHUT