D1-live.emerson.com
KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Before installation these instructions must be fully read and understood TABLE OF CONTENTS 2 RECEIPT, HANDLING AND STORAGE FIGURE 1 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. Troubleshooting 8 10. Ordering spares 8 11. Disassembly and re-assembly (EL and UL series) 9 12. Body cavity relief operation 15 13. Gland packing assembly procedure 15 14. Recommended tightening torques for fasteners and plugs 16 15. Service of valves with API monogram 17 16. Information for PED 2014/68/EU compliant valve 17 17. Warranty 18 18. Factory address for correspondence 18 · 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. Typical box and lifting position Top support Bottom support Forklift lifting forks near bottom support FIGURE 2 Lift Lift 1 SCOPE This manual is provided to ensure proper installation, operation and maintenance for KTM Virgo series Top Entry Trunnion Ball valve, manufactured and supplied by Emerson (Applicable to Soft / Metal seated, Cast, EL, UL subseries.) Swing WARNING Always use Personal Protective Equipment (PPE) when carrying out above activities. Emerson.com/FinalControl © 2021 Emerson. All Rights Reserved. VCIOM-16362-EN 21/05 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE 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. · 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) FIGURE 3 Lifting straps FIGURE 4 WARNING Do not lift from the top flange of stem extension Provide proper support from here to prevent toppling Always use lifting hooks for lifting of stem extension FIGURE 5 Body marking Size matl heat no. Name plate 2 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE 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, weldslag 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. · If mounting stand or support stand of valve is provided on end flange they shall be removed before installation on the pipeline (refer Figure 6). · 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. · To reinstall the mounting/support stand on 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 6. · Examples of valve support configurations are shown in Figure 7. · 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 8. FIGURE 6 Mounting stand attached to body flange FIGURE 7 Support from overhead Foot support (ground support) REMOVE Remove while installing the valve FIGURE 8 WARNING Do not mount in this position 3 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Installation of valve in vertical pipeline or horizontal stem · Installation of valve in vertical pipeline: - This design does not permit the valve installation in vertical pipeline. · Installation of valve with horizontal stem: - T his design does not permit the valve installation with stem in horizontal or inclined position. Only vertical position is allowed. 4 OPERATION · 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. · 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 counterclockwise 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 counterclockwise 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. 4 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 5 GEAR OPERATOR INSTRUCTIONS 5.3 Procedure for gear operator setting FIGURE 9 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. 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 11 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 12 below illustrates the two possible orientations for a gear operator when assembled together with the series EL and UL - Top entry Soft / Metal Seated Trunnion Ball Valve Assembly with bracket and coupling Position indicator Gear operator Coupling key Handwheel Coupling Bracket Stem key Stem FIGURE 10 Assembly without bracket and coupling Handwheel Position indicator Gear operator Stem key FIGURE 11 Gear operator setting Adjust right bolt for open position Adjust left bolt for close position Lock nut / check nut Open position Close position FIGURE 12 Orientation 1 Pipe line axis Orientation 2 Pipe line axis 5 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE 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 13 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 13 Sealant injection fitting - Type A (standard supply) Check valve Sealant fitting End cap Giant buttonhead coupler Body / bonnet / housing Slot for sealant gun adapter Type A (marking) 6 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE 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. 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. 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 8 POSSIBLE MISUSE OF BALL VALVE Sr. no. Possible misuse Actions to prevent misuse 1 Exceeding the pressure and / or temperature limits of Do not exceed pressure and / or temperature limits mentioned on name plate affixed to the valve. the valve. 2 Valve 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. 3 Use for control application. These ball valves are designed for on/off application and should not be used for control / throttling. 4 Mounting of valve upside down. Follow `Installation' section of this document. 5 Wrong installation in case of uni-directional valve. Verify flow direction on valve body or on additional plate affixed to valve. 6 Use of improper actuator when customer automates Contact factory for correct sizing of actuator. valve on site. 7 Opening/closing of valve by using inappropriate Operate valve only with levers, gear operator, hand wheel or actuator provided / recommended extensions like pipes/bars etc. by Emerson. 8 Any modification by customer in valve e.g. drilling, Unauthorized modifications are not allowed. Modification voids warranty. tapping, change of valve ends etc. Contact factory if any such case arises. 9 Testing 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. 7 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 9 TROUBLESHOOTING Problem Leakage across closed valve Valve too hard to operate / valve torque too high / stick-slip operation Leakage through stem Leakage through body to bonnet joint; bonnet to housing joint Leakage through drain, vent and sealant fittings. Possible cause 1. Damaged ball surface. 2. Damaged seats / seat seals. 3. Ball not closed fully. 4. Seat not moving freelyresulting in inadequate contact between ball and seat. 1. Damaged seats / seat seals / ball. 2. Seat not moving freely due to accumulation of dirt, debris, corrosion between seat and body or seat and ball. 3. Operator not sized properly, damaged operator parts. 4. Actuator not sized properly, damaged actuator parts, insufficient input air/gas pressure to actuator, restriction/clogging of actuator vent. 1. Loose gland fasteners. 2. Damaged stem, stem sealing surface. 3. Damaged stem seal. 4. Accumulation of dirt, debris, corrosion between stem and housing. 1. Damaged seal/gasket. 2. Relaxation of joint fasteners. 3. Accumulation of dirt, debris, corrosion between body and bonnet. 1. Loosening of fittings. Remedy 1. Refurbish or replace the ball. 2. Refurbish or replace seats. Replace seat seals. 3. Check and reset ball. Open/close settings. 4. Open valve, check for accumulation of dirt, debris, corrosion between seat and body, clean and re-assemble. 1. Refurbish or replace the seats / seat seals / ball. 2. Open valve, clean and reassemble. 3. Select correct operator and replace. 4. Select correct actuator and replace. Check input air supply, clean actuator vent. 1. Tighten the fasteners. 2. Refurbish or replace the stem. 3. Replace the stem seal. 4. Open valve, clean and reassemble. 1. Replace seal/gasket. 2. Retighten the fasteners evenly in criss-cross manner. 3. Open valve, clean and reassemble. 1. Retighten. If leakage persists may require fresh thread sealant or replacement of fitting. WARNING: Do not remove fittings when valve / body cavity is under pressure. 10 ORDERING SPARES When ordering spares, please furnish the following information. Size Class Batch number / serial number Manufacturing date Part number Part name Purchase order number Available on name plate or body of the valve Available on name plate or body of the valve Available on name plate or body of the valve Available on name plate or body of the valve Available on general arrangement drawing Available on general arrangement drawing Available on general arrangement drawing 8 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11 DISASSEMBLY AND RE-ASSEMBLY Sections 11.1 Warnings 11.2 Notes 11.3 Series EL and UL Top entry Soft / Metal Seated Trunnion Ball Valve Construction: One-Piece Type: Integral trunnion 11.3.1 Disassembly procedure 11.3.2 Re-assembly procedure 11.3.3 General arrangement view 11.3.4 Assembly tool 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. · Ball valves can retain pressure and process fluid in cavity 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 sideto-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. 9 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE 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 bonnet, bonnet and housing, gear operator or actuator and ISO pad or housing to ensure same orientation during re-assembly. · Before disassembly, 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 as shown in Figure 14. · 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 14 10 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11.3 Series EL and UL - top entry soft / metal seated trunnion ball valve Construction: One-piece Type: Integral trunnion Refer Section 11.3.3 for general arrangement view and location of parts. 11.3.1 Disassembly procedure 1. Position the valve with ball in closed position as shown in Figure 15. 2. Slowly remove the vent / drain plug (20) to relieve any residual pressure from the body cavity. 3. Remove the stem key (9) from the stem (5). 4. Remove cap-screws (14a). 5. Remove ISO pad (8). 6. Unscrew and remove body nuts (13) from body studs (12). 7. Screw an eyebolt inside the tapping provided on the top surface of the bonnet and lift the bonnet-housing sub-assembly. Ensure that stem will not fall while lifting bonnethousing assembly. 8. If it is necessary to replace the stem gasket, follow instructions 9 to 11 below. Otherwise donot disassemble the stem-bonnet subassembly and go to instruction no. 12. 9. Push the stem (5) out of its housing on the bonnet (2). 10. Remove stem o-rings (10c) and backup rings (if provided) from bonnet and then remove graphite stem gasket (11a). 11. Remove stem thrust washer (22) from the stem. 12. Insert the two hydraulic pistons inside body cavity and clamp the external profile of the spring holder ring (3a) (Refer assembly tool view 11.3.4 and Figure 15. 13. Close the hydraulic pistons together to pull the seat spring holder rings towards center of the valve. 14. Remove spacer (3b) from both spring holder rings. (Refer Figure 16). 15. Use the hydraulic pistons to push spring holder ring (3a) back inside body recess. 16. Remove hydraulic pistons from body cavity. 17. Rotate the ball (4) to fully open position using two eye bolts screwed on ball. 18. Remove the ball from the body (1) using eye bolts. 19. Remove seat assembly (3, 3a, 3b) from body. 20. Remove the Bearing Retainer (7), ball bushing (21) and ball thrust washer (23) from the body if provided. 21. Remove seat (3) from the seat spring holder ring (3a). 22. Remove o-rings (10a, 10b) and its back-up ring (if present) from seat and seat spring holder ring. 23. Remove all the springs (15) from the seat spring holder ring. FIGURE 15 FIGURE 16 11 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11.3.2 Re-assembly procedure 1. Install all the springs (15) in spring holder ring (3a) then put spacer (3b) on spring holder ring and move till the end of spring holder ring. 2. Assemble the spring holder ring over the seat (3). 3. Install seat o-ring (10a) and retainer o-ring (10b) with backup ring (if provided) on seat (3). 4. Insert seat assemblies inside the body (1) and push them till the end of the pocket in the body. 5. Install bearing retainer (if not integral with body) (7), ball bushing (21) and ball thrust washer (23) inside body. 6. Insert ball (4) inside body using eye bolt screwed on ball, such that ball is in the open position. 7. Rotate the ball to fully closed position. Remove eye bolts. 8. Insert anti-static spring (15a) in the central hole of the ball. 9. Using hydraulic pistons, pull the two seat assemblies towards the ball. 10. Move spacer (3b) in the groove provided on spring holder ring (3a). 11. Remove hydraulic pistons from body. 12. If the stem was disassembled from housing, follow instructions from 13 to 16 otherwise go to Section 17. 13. Insert stem thrust washer (22) over the stem (5). 14. Insert stem o-rings (10c) along with backup rings (10c) (if provided) inside the housing (6). 15. Install o-ring (10d) and graphite gasket (11b) between housing (6) and bonnet (2). Now fasten the housing to bonnet using fasteners (14). 16. Insert stem inside the bonnet and housing with respect to ball in the closed position. While inserting stem inside the housing, the edges of keyway slot may damage the o-rings. Hence take suitable protection like wrapping stem keyway side with common adhesive tape. 17. Install o-ring (10) and graphite gasket (11) between bonnet and body and fasten the assembly using fasteners (12 / 13). 18. Install stem gasket (11a) inside housing and then assemble the ISO pad (8) using cap screw (14a) and pins (24). Install stem key (9). 19. Install the drain plug and vent plug and injection fittings as applicable. 12 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11.3.3 General arrangement view E and U series top entry ball valve Construction: One-piece Type: Integral trunnion 1 13 12 27 8 14 14a 9 5 24 16a 16 11 10 2 19 A C C B 11a 6 10c 11b 10d 21a 22 21 15a Stem detail A 15 3b 3a 10a 3 10b 23 4 20 7 Position Nr. 19 Vent bleeder detail Position Nr. 20 Drain plug detail PARTS LIST Item No. Part name 1 Body 2 Bonnet 3 Seat ring 3a Spring holder ring 3b Retainer ring 4 Ball 5 Stem 6 Housing 7 Bearing retainer 8 ISO pad 9 Stem key 10 Body o-ring 10a Seat o-ring 10b Grease retaining o-ring 10c Stem o-ring 10d Housing o-ring 11 Body gasket 11a Stem gasket 11b Housing gasket Item No. 12 13 14 14a 15 15a 16 16a 17 18 19 20 21 21a 22 23 24 Part name Body studs Body nuts Housing capscrew ISO pad capscrew Springs Antistatic spring Stem grease fitting Nipple Seat grease fitting Check valve Vent bleeder valve Drain plug Ball bushing Stem bushing Stem thrust washer Ball thrust washer Pin Stem detail B SECTION C-C 18 17 13 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11.3.4 Assembly tool view Quantity Nr: 2 For maintenance 1 valve Hydraulic quick coupling female " Close Open Seat holder connection Seat holder connection Hydraulic piston double effect 14 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 12 BODY CAVITY RELIEF OPERATION 13 GLAND PACKING ASSEMBLY PROCEDURE Single piston effect seat - self relieving seat When seats are under pressure in pipeline, upstream and downstream both, the resultant thrust from pressure pushes the seat rings towards the ball. At the same time, pressure in the body cavity creates a thrust that pushes the seat rings away from the ball. The single piston effect (SPE) permits the automatic release of overpressure in the body cavity when the valve is in the fully open or closed position. In single piston effect design, seat rings are thus "self-relieving". Double piston effect seat (DEP) - non relieving type of seats When seats are under pressure in pipeline, upstream and downstream both, the resultant thrust from pressure pushes the seat rings towards the ball. Also, pressure in the body cavity creates a thrust that pushes the seat rings towards the ball. 1. In case of packing contain braided graphite, it shall be placed at bottom and top. Position of packing arrangement such that the oblique cut of these braided graphite is 180° apart. Refer Figure below for appropriate arrangement for die molded and for VEE type packing. 2. Place the gland into the housing and disk spring (for VEE type packing) and the cap screw / hex bolt. 3. Hand tighten cap screw / hex bolt in crisscross pattern. 4. Tighten gland cap screws / hex bolt in crisscross pattern by using 25% torque as specified in Section 14 against mentioned fasteners material. 5. Ensure no bottoming up of gland or otherwise one ring needs to be added in packing set. 6. Verify that the gland top surface is at equal depth from top face of housing. NOTE Full tightening of screws shall be done during performance testing depending on leakage observed. When the valve is designed with double piston effect (DPE), self-relieving does not occur and hence PR (pressure relief) valve is mandatory with pre-setting to avoid over pressure building in the cavity. FIGURE 18 Square/rectangular type stem packing arrangement FIGURE 19 VEE type stem packing arrangement Stem Gland Braided gaskets Gland bolt Disk springs Gland Stem Braided gaskets One packing set Die molded gaskets One packing set VEE type packing set 15 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 14 RECOMMENDED TIGHTENING TORQUES FOR FASTENERS AND PLUGS NOTES 1. Ensure that all the nuts/bolts are tightened to the torque values as specified in below tables. 2. Torque values for carbon and low alloy steel material are for dry and non-lubricated fasteners. 3. Torque values for austenitic stainless steel material are with anti-seize lubricant. 4. Apply pipe thread sealant to the threads of the drain and vent plugs. 5. 1 Nm = 0.737 ft·lb FOR METRIC SERIES (Nm) Non-coated bolts / nuts Low resistance bolt / High resistance bolt / stud material stud material Thread size B8M B8M (Metric) Pitch L7M, B7M Class 1 Class 2 L7, B7 Gr 660 M8 1.25 15 6 18 20 16 M10 1.50 30 11 36 40 32 M12 1.75 52 19 62 69 55 M14 2.00 83 31 99 108 88 M16 2.00 126 47 150 165 134 M18 2.50 174 65 207 228 185 M20 2.50 243 91 289 318 258 M22 2.50 327 122 327 428 348 M24 3.00 415 155 415 544 441 M27 3.00 601 224 492 787 639 M30 3.50 814 303 511 1066 866 M33 3.50 1097 409 688 1436 1167 M36 4.00 1410 526 884 1845 1500 M39 4.00 1810 675 1135 2370 1925 M42 4.50 2241 835 1406 2934 2384 M45 4.50 2780 1036 1744 3639 2957 M48 5.00 3348 1248 2100 4383 3561 M52 5.00 4298 1602 2696 5626 4572 M56 5.50 5343 1991 3352 6995 5683 M60 5.50 6624 2469 4155 8671 7046 Coated bolts / nuts Low resistance bolt / High resistance bolt / stud material grade stud material B8M B8M L7M, B7M Class 1 Class 2 L7, B7 Gr 660 9 3 11 12 10 18 7 21 24 19 31 12 37 40 33 49 18 58 64 52 74 28 88 97 79 103 38 123 135 110 143 53 143 187 152 191 71 191 250 203 245 91 200 320 261 351 131 287 459 373 477 178 299 625 507 639 238 401 836 680 824 307 517 1078 876 1052 392 660 1377 1119 1306 487 819 1710 1389 1613 601 1012 2112 1716 1948 726 1222 2571 2072 2488 927 1561 3257 2646 3098 1155 1943 4056 3295 3824 1425 2399 5006 4067 16 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS FOR IMPERIAL SERIES (Nm) Non-coated bolts / nuts Low resistance bolt / High resistance bolt / stud material stud material Thread size B8M B8M (Inch) TPI L7M, B7M Class 1 Class 2 L7, B7 Gr 660 5/16" 18 15 6 18 20 16 " 16 26 10 22 34 28 ½" 13 61 23 73 80 65 " 11 118 44 141 155 126 ¾" 10 206 77 245 270 219 " 9 328 122 328 429 349 1" 8 488 182 488 639 519 1" 8 706 263 578 925 751 1¼" 8 981 366 803 1285 1043 1" 8 1320 492 933 1727 1404 1½" 8 1727 644 1083 2261 1837 1" 8 2211 824 1387 2894 2352 1¾" 8 2777 1035 1742 3636 2954 1" 8 3433 1280 2153 4493 3651 2" 8 4183 1559 2624 5476 4449 2¼" 8 5997 2235 3762 7851 6379 2½" 8 8271 3083 5188 10828 8797 2¾" 8 11117 4144 6973 14591 11824 3" 8 14481 5397 9084 19007 15403 3¼" 8 18462 6881 11581 24232 19637 3½" 8 23114 8615 14499 30336 24585 3¾" 8 28485 10617 17868 37388 30298 Coated bolts / nuts Low resistance bolt / High resistance bolt / stud material grade stud material B8M B8M L7M, B7M Class 1 Class 2 L7, B7 Gr 660 10 4 12 12 11 15 6 18 20 16 37 14 44 47 39 71 26 85 92 76 122 45 145 160 130 194 72 194 255 206 289 108 289 378 307 414 154 339 544 440 571 213 467 750 607 763 284 479 1002 812 994 370 624 1305 1057 1266 472 794 1527 1347 1585 591 994 2080 1686 1952 728 1224 2563 2076 2373 884 1489 3114 2524 3375 1258 2117 4418 3590 4635 1728 2907 6068 4930 6208 2314 3894 8148 6603 8064 3006 5058 10583 8577 10256 3823 6433 13461 10909 12812 4775 8037 16817 13627 15762 5875 9887 20688 16765 FOR NPT PLUG THREADS Plug size " NPT ½" NPT ¾" NPT 1" NPT Thread per inch 18 14 14 11½ 15 SERVICE OF VALVES WITH API MONOGRAM Approx. torque (Nm) 61 68 75 88 NOTES 1. Torque values given for NPT threads are only for reference, it may change depending upon accuracy of thread profile, sealing requirement, nature of the sealant used etc. 2. As a general guideline, after hand-tight engagement, tighten 1-3 full turns so that you get 'leak proof' joint. In case of repair and service of "API monogram" valve, service engineer shall consult Head- QA for any further actions. 16 INFORMATION FOR PED 2014/68/EU COMPLIANT VALVE The year of manufacture Essential maximum / minimum allowable limits The normal size for piping DN Test pressure applied in bar and date Tare mass in kg The fluild group Refer name plate affixed to the valve Refer name plate affixed to the valve Refer name plate affixed to the valve Refer tag plate affixed to the valve Refer tag plate affixed to the valve Refer tag plate affixed to the valve 17 KTM VIRGO SERIES E & U TOP ENTRY TRUNNION BALL VALVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 17 WARRANTY 18 FACTORY ADDRESS FOR CORRESPONDENCE Our liability in respect of any defect in or failure of the goods supplied or for any loss, injury or damage attributable thereto is limited to making good by replacement or repair defects which under proper use appear therein and arise solely from faulty materials and workmanship within a period of 18 calendar months after the original goods shall have been first dispatched or 12 calendar months from the date of commissioning, whichever is earlier provided that such defective parts are returned free to our works for examination. The undertaking shall exclude any and every other obligation. CAUTION Emerson does not assume responsibilities for any liabilities/damages arriving out of wrong application of its valve, or imprudent operations carried out by inexperienced operators, or which does not comply with this manual, or instructions provided by Emerson. The valve shall be appropriately used for the purpose they are built, or applications they are supplied. Use of standard valve for special applications is not recommended unless it has been communicated and agreed to by Emerson. Valve shall be operated and maintained strictly in accordance with the procedures. Operation or maintenance outside these procedures constitutes abuse of the product and voids all warranty and claims. Emerson Process Management (India) Private Limited (Manufacturing Regional Sales Office) 277 / 278 Hinjewadi Phase II, Maan (Mulshi) Pune - 411 057, INDIA Phone: +91 20 6674 4000 Fax: +91 20 6674 4021 www.emerson.com Emerson Process Management (India) Private Limited Plot No. C1 Talegaon Industrial Area Phase 2, Talegaon MIDC, Mindewadi, Taluka - Mawal, Pune - 410 506, INDIA Phone: +91 21 1461 1100 www.emerson.com Emerson Automation Solutions (Regional Sales Office) 10225 Mula Road, Suite 130 Stafford, TX 77477, USA Phone: +1 281 933 3100 Fax: +1 281 933 3110 www.emerson.com VCIOM-16362-EN © 2021 Emerson Electric Co. All rights reserved 05/21. KTM is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective owners. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Emerson Electric Co. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Electric Co. product remains solely with the purchaser. Emerson.com/FinalControl 18MCM Plus Adobe PDF Library 15.0; modified using iTextSharp™ 5.5.10 ©2000-2016 iText Group NV (AGPL-version)