Emerson KTM VIRGO N Series Manual

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

Swing

Forklift lifting forks

near bottom support

FIGURE 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)

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.

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

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.

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

Position indicator

Gear operator

Coupling 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

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

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.

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.

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.

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

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