Kitz 150TAZM Series Operation Manual

One piece floating type ball valves

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Document No.：KE-1075-01

Operation Manual

One Piece Floating Type Ball Valves

（ Conform to ISO5211, Flanged Ends）

《For US》

【150/300TAZM 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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Summary of Contents for Kitz 150TAZM Series

Page 1 《For US》【150/300TAZM 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’ ...
Page 2 Indicating potentially hazardous conditions, which may result in injury to personnel or only property damage, if such conditions shall be ignored. Indicates prohibition of an action. Indicates mandatory implementation of an action. NOTES TO USERS This manual covers the normal usage of the product. Technical data and instructions for operation, maintenance and inspection of the product are prepared in consideration of safety. However, they are good only to cover typical applications as a general guideline to users. If technical assistance beyond the scope of this manual is required, contact KITZ Corporation or its distributors. The illustrations given in this manual do not introduce all details. If more detailed data are needed, refer to our relevant valve assembly drawings. ※ Any information provided in this operation manual is subject to revision at any time without notice. This edition cancels all previous issues.
Page 3: Table Of Contents
Document No.：KE-1075-01 C O N T E N T S Sheet Ⅰ Construction and Design Features ･･････････････････ 1 Ⅱ Valve Operation Device ･････････････････････････････ 4 Ⅲ Transportation and Storage ････････････････････････ 7 Ⅳ Valve Installation ...
Page 4 Document No.：KE-1075-01 Sheet:1/31 CHAPTER Ⅰ Construction and Design Features ...
Page 5: Ⅰ Construction And Design Features
Document No.：KE-1075-01 Sheet:2/31 Ⅰ Construction and Design Features 1. Construction and Design Features 1.1 The typical valve design is as illustrated below. 1.2 The rotation of the stem by 90°fully opens or closes of the valve. 1.3 Valves are serviceable only in fully open or closed position. 1.4 The ball is supported by two ball seats placed in the valve body and insert. The upstream pressure pushes the ball, which compresses the down stream side ball seat to completely shut off the fluid flow. 1.5 Fluid can flow through valve port in both directions. ...
Page 6 Document No.：KE-1075-01 Sheet:3/31 Ⅰ Construction and Design Features 2. Design Features 2.1 Uni-body, End entry design The valve is uni-body and end entry floating ball valves with one-piece body, which completely eliminates concern of fugitive emission through valve body joints. 2.2 Firesafe provision KITZ ball valves can be optionally provided with graphite packing and body to insert flange gaskets for use in the areas of production facilities where external leakage may be caused by plant fires. These graphite components will contain the line media where PTFE or other lesser materials may burn away, feeding fuel increasing the magnitude of the fire. KITZ ball valves provided with graphite sealing components are identified as the SUPER-FIRESAFE version in our product catalogs. The integral, secondary seats on the body and body-cap minimize internal leakage, when resilient ball seats are deteriorated in case of a plant fire. 2.3 Anti-static provision Anti-static devices are provided to ensure electrical continuity between ball, stem and body. 2.4 Valve application This ball valve may be used on application where a bi-directional flow is needed. 2.5 Actuator Mounting Pads ISO 5211 actuator mounting pad is integrally provided for uniformly simplified mounting of any actuators provided with valve mounting flanges designed to ISO 5211 dimensional requirement. 2.6 Low Fugitive Emission Feature The surface of stem and stuffing box, and interface clearance of stem-to-gland bushing, stem-to-body and gland-to-stuffing box are precision controlled on machining and assembly for low emission service. ...
Page 7 Document No.：KE-1075-01 Sheet:4/31 CHAPTER Ⅱ Valve Operation Device ...
Page 8: Ⅱ Valve Operation Device
Document No.：KE-1075-01 Sheet:5/31 Ⅱ Valve Operation Device 1. Lever Handle 1.1 The lever handle is directly mounted on the valve stem. 1.2 Rotation of the lever handle by 90°fully opens and fully closes the valve. Turning the lever clockwise closes the valve, and turning the lever counterclockwise opens the valve. ...
Page 9 Document No.：KE-1075-01 Sheet:6/31 Ⅱ Valve Operating Device 2. Worm Gear Operator 2.1 The worm gear operator is mounted on the valve. 2.2 According to the arrow or letter on the handwheel, turning the handwheel clockwise closes the valve, and turning the handwheel counterclockwise opens the valve. 2.3 Handwheel operating torque depends on the size and opening position. 2.4 Worm gear operator is to transmit a large torque to valve stems, converting a torque from drive shaft by means of reduction gearing unit using worm gears. . ...
Page 10 Document No.：KE-1075-01 Sheet:7/31 CHAPTER Ⅲ Transportation and Storage ...
Page 11: Ⅲ Transportation And Storage
Document No.：KE-1075-01 Sheet:8/31 Ⅲ Transportation and Storage 1. Transportation 1.1 Cautions for Safety Keep off the valve lifting area to prevent personal injury caused by unsecured valves. (1) Take care not to damage the painted surfaces of the valve during transporting. This may result in corrosion and rust. If the paint is chipped damaged are should be repainted. (2) Take care when handling and storing packed cartons. High humidity may damage the cartons. 1.2 Transportation 1.2.1 Keep packages as they are delivered just before installation. If the protective covers are found missing during transportation, provide appropriate type of protective covers. 1.2.2 Handle valves carefully so that they may not fall or drop on the ground. Any extraordinary mechanical impact should be avoided. ...
Page 12 Document No.：KE-1075-01 Sheet:9/31 Ⅲ Transportation and Storage 2. Storage 2.1 Cautions for Safety (1) DO NOT store valves in a corrosive environment, which may cause corrosion on threaded portions of valves. (2) DO NOT remove protective covers until installation. This will prevent the intrusion of any foreign object which could cause damage to the closure elements such as ball and seats. (3) DO NOT place any other objects on valves, and DO NOT step on them. Overloading may damage valves. (4) DO NOT carelessly pile up products to avoid risk of product damage and personal injury caused by unstable piling. (5) Keep the valves in the open position during storage. Storing the valves in halfway position may deform the ball seats, leading to the internal leakage. 2.2 Storage 2.2.1 Storage valves at a dust-free, least humid and well ventilated places. Indoor storage is recommended. 2.2.2 ...
Page 13 Document No.：KE-1075-01 Sheet:10/31 CHAPTER Ⅳ Valve Installation ...
Page 14: Ⅳ Valve Installation
Document No.：KE-1075-01 Sheet:11/31 Ⅳ Valve Installation 1. Flange Type 1.1 Cautions for Safety (1) The sealing materials determine the characteristics of service fluid and service range of pressure and temperature. Check the valve specifications with the catalogs and/or the attached nameplate. Services beyond the valve specifications may cause fluid leakage and valve malfunctions. (2) DO NOT install valves in dead end service, which may result in external leakage. In such a case use a blind flange to prevent the leakage. (1) Keep a secure footing for valve installation and operation. (2) Sufficient lighting should be prepared for valve operation. (3) Piping should be properly supported, if needed. 1.1.1 Allow sufficient room for safe and easy operation, installation and subsequent maintenance of valves. 1.1.2 For smooth operation, inspection and maintenance, take appropriate measures for valves which are forced to be installed in small places. ...
Page 15 Document No.：KE-1075-01 Sheet:12/31 Ⅳ Valve Installation 1.2 Cautions for Safety Keep off the valve lifting area to prevent personal injury caused by unsecured valves. (1) Take care not to catch fingers in flanges during mounting work. (2) Take care not to damage flanges, ball and ball seats surfaces. (3) Pipes should be properly supported, if needed. (4) Retighten the gland bolts before operation. Packing compression may become less due to the stress relaxation which may take place during transportation and storage, leading to the occurrence of leakage through the gland area. (5) Be sure to insert new gaskets for valve mounting. ...
Page 16 Document No.：KE-1075-01 Sheet:13/31 Ⅳ Valve Installation 1.2.1 Check the following items before valve mounting: (1) Service conditions should be within the valve specifications. (2) Valve flanges should correspond with piping flanges. (3) Gasket contact surfaces of pipes and valve flanges must be thoroughly inspected to make sure no scratch or any other indication of flaw is found. (4) The appropriate length should be kept between pipe flanges for the valve face-to-face dimensions including gasket thickness. (5) The valve and pipe center should be aligned accurately. (6) Bolt holes of flanges should be arranged symmetrically lined up against the center line of flanges. 1.2.2 Before installation, the connecting pipes should be cleaned to remove any foreign object such as sand, dust and welding spatters from the connecting pipe interior. 1.2.3 Handle valves carefully so that they may not fall or drop on the ground. Any extraordinary mechanical impact should be avoided. 1.2.4 Remove flange covers from valves just before installation. 1.2.5 Check all threaded areas after installation and retighten them, if needed. ...
Page 17 Document No.：KE-1075-01 Sheet:14/31 Ⅳ Valve Installation 1.3 Installation Procedures 1.3.1 Make sure that pipes should be aligned accurately. 1.3.2 The length between piping flanges should correspond with the valve face-to-face dimensions including gasket thickness. 1.3.3 Insert the valve between pipe flanges. Thread bolts through bottom bolt holes and tighten bolts lightly. 1.3.4 Insert gaskets between valve and pipe flanges. It is recommended to apply the gasket paste to gasket faces. 1.3.5 Make sure the correct alignment of gaskets, which are held by bottom bolts between valve and pipe flanges. 1.3.6 Thread bolts through the other bolt holes and tighten them lightly. 1.3.7 Tighten bolts evenly, gradually and alternately in a star pattern as shown below. The ends of all tightened bolts should protrude equally beyond the nuts. ...
Page 18 Document No.：KE-1075-01 Sheet:15/31 CHAPTER Ⅴ Valve Operation ...
Page 19: Ⅴ Valve Operation
Document No.：KE-1075-01 Sheet:16/31 Ⅴ Valve Operation 1. Cautions for Safety (1) DO NOT apply excessive torque by using a pipe or any other device to operate the valve. (2) DO NOT loosen bolts and nuts of gland and flange area of pressurized valves. (3) Avoid the services in intermediate position for long period, which may damage ball seats and cause seat leakage. (4) Retighten the gland bolts and nuts before operation of the valve. Check a handle torque while retightening the bolts and nuts so that the operation won’t become too difficult due to over-tightening. The gland bolts should be alternately tightened with an even force. (5) Valve should be kept fully open during the line test or pressure test. The ball seats may be deformed, if the valve is fully closed during test. Possible internal though-bore leakage may occur under such conditions. (6) When service temperature fluctuates, retighten the gland bolts and nuts after the temperature is stabilized in preparation for the occurrence of stress relaxation of the gland packing. (7) Open the valve gradually to prevent damages of pipes, when the valve handles high temperature fluid such as steam. (8) Take appropriate measures to prevent freezing, as needed. 2. Operation 2.1 Lever handle ...
Page 20 Document No.：KE-1075-01 Sheet:17/31 Ⅴ Valve Operation 3. Daily Inspection In order to operate your valves safely and satisfactorily, the daily inspection is very important. Here are the inspection items. Inspection Areas to be Inspection Remedial Measure items inspected Method Visual Check with Retighten gland bolts. Gland area soap solution Replace the gland packing Visual Check with Retighten flange bolts. Flange areas soap solution Replace gaskets. External leakage Visual Check with Retighten each threaded areas. Threaded portions soap solution Replace the parts as needed. Visual Check with Body surface Replace the valve. soap solution Auditory check Valve body ...
Page 21 Document No.：KE-1075-01 Sheet:18/31 Ⅴ Valve Operation 4. Remedial Measures (1) Wear protective items such as goggle, gloves and working boots. (2) Take safety measures against the toxic, flammable or corrosive fluid. (3) Reduce the line pressure to the atmospheric level before retightening gland and flange bolts and nuts. (4) Operators should take protective measures to prevent direct exposure to the fluid, when the fluid spouts out from flange areas. (5) Reduce the line pressure to the atmospheric level, when the packing and gaskets are replaced or bolts and nuts are loosened. Operator should take protective measures to prevent direct exposure to the fluid, when the fluid spouts out from valves. (6) DO NOT apply any grease or lubricant to the pipe or valves that handle oxygen. 4.1 Leakage from the gland area Retighten the gland bolts or nuts if the leakage from this area is detected . Evenly tighten the bolts or nuts alternately as shown below. Adequate torque should be applied when retightening the bolts or nuts so that the valve operation won’t become difficult. If it does not stop the leakage, the packing rings should be replaced. 4.2 ...
Page 22 Document No.：KE-1075-01 Sheet:19/31 Ⅴ Valve Operation 5. Trouble Shooting Defect Possible causes Remedial measure Foreign objects may have choked Disassemble and inspect the valve Disturbed up the valve body cavity and components. valve operation stock around the ball seats. Foreign objects may have stuck Remove the foreign objects and to the stem. check the valve. Flush the valve bore with the fluid Foreign objects may have choked with the valve slightly open to up the valve body cavity and remove the built-up objects or Excessive valve torque stock around the ball seats. disassemble and inspect the valve. Once loosen the gland bolts and The gland bolts may have been adequately retighten them to an overly tightened.. ...
Page 23 Document No.：KE-1075-01 Sheet:20/31 CHAPTER Ⅵ Periodic Inspection ...
Page 24: Ⅵ Periodic Inspection
Document No.：KE-1075-01 Sheet:21/31 Ⅵ Periodic Inspection 1. Periodic Inspection 1.1 Carry out the periodic inspection on the valve in use at least once a year. 1.2 Examine the valve to ensure the smooth operation and sufficient function. 1.3 See Chapter Ⅴ “Valve Operation” for inspection items and inspection methods. 1.4 Where valves and adjoining piping are not daily inspected or not operated for a long period of time, a periodic inspection is also recommended. (A periodic inspection should be carried out on all valves.) 1.5 It is particularly important to thoroughly check valves used for the following service : a) Where performance failure of valves could result in a major shutdown of an entire plant unit. b) Where the clogging of pipes with the fluids is likely to occur. c) Where corrosion or/and wear by the fluids is expected. 1.6 It is recommended to replace the gland packing at the time of periodic inspection. 2. Inspection and Maintenance ...
Page 25 Document No.：KE-1075-01 Sheet:22/31 Ⅵ Periodic Inspection 2.1 Care for removal of the valves from pipelines or installation of the valves on pipelines. (1) Discharge the fluid from the pipes and reduce the line pressure to the atmospheric level when disassembling valves. Trapped pressure or fluid is very dangerous and can cause accidents resulting in personal injury. In the case of dead end service, the fluid might enclose between the valve and the blank flange. Open the valve and discharge the fluid from the pipe before the blank flange removal. (2) Discharge the fluid and pressure trapped within the valve body with the valve intermediate position before disassembling.. (3) In case fluid is toxic, inflammable or corrosive, remove the fluid completely from pipes and internal valves. (4) Take protective measures to prevent direct exposure to the fluid and catching fire. (5) Keep off the working area to prevent personal injury if valves are installed at higher places. (1) Wear protective items such as goggle, gloves and working boots. (2) Keep a secure footing for valve dismantle or installation. (3) Piping and valves should be properly supported, if needed. ...
Page 26 Document No.：KE-1075-01 Sheet:23/31 Ⅵ Periodic Inspection 2.3 Test and Inspection Refer to the following procedure for test and inspection. 2.3.1 Operation Test (1) Check smooth operation of valves without galling or sticking of internal valve components. (2) Check that the stem is firmly assembled with the ball. (3) Ensure that there should be no offset of the ball port and ball seats in the fully open position. The ball should not protrude into the valve port other than the rounded surface of the ball port edges. 2.3.2 Shell Test and Seat Leakage Test (1) Care for shell test and seat leakage test (1) Wear protective items such as goggle, gloves and working boots. (2) Before shell test and seat leakage test begin, take some precautions for ...
Page 27 Document No.：KE-1075-01 Sheet:24/31 CHAPTER Ⅶ Disassembly and Reassembly ...
Page 28: Ⅶ Disassembly And Reassembly
Document No.：KE-1075-01 Sheet:25/31 Ⅶ Disassembly and Reassembly 1. Disassembly procedure 1.1 Care for disassembly Operator should take an appropriate caution for not being exposed to the fluid or catching fire. (1) Wear protective items such as goggle, gloves and working boots. (2) Pay attention not to catch fingers during disassembly. (3) When disassembling valves of large sizes, use an appropriate machine to lift up valves. 1.2 Before Disassembly 1.2.1 Place the valve in a dust-free place. 1.2.2 Take care not to damage the flange surfaces, ball and stem. 1.2.3 Give identification marks on edges of the coupled flanges for adequate and easy coupling of the body cap on subsequent reassembly. ...
Page 29 Document No.：KE-1075-01 Sheet:26/31 Ⅶ Disassembly and Reassembly 1.3 Disassembly procedure 1.3.1 Full close the valve. 《Disassembly procedure for lever handle operated valve》 1.3.2 Remove the handle lock plate bolt (123A) and handle lock plate (43), handle (9) or handle head (9B) from the stem (3). In case of the handle head type (9B), Remove the handle bolt (123B) and handle bar (9A) from the handle head (9B). 1.3.3 Remove the snap ring (48) and key lock plate (40) stopper (49) from the stem (3). 1.3.4 Remove the stopper plate bolts (126) and stopper plate (51) from the body (1). 1.3.5 To Common 1.3.9 . 《Disassembly procedure for gear operated valve》 1.3.6 Remove the bolts (99) and gear unit (102) with bracket (93) from the body (1) 1.3.7 Remove the connector (92) from the stem (3) or gear unit (102) . 1.3.8 To Common 1.3.9 . 《Common》 1.3.9 Remove the insert(29). ...
Page 30 Document No.：KE-1075-01 Sheet:27/31 Ⅶ Disassembly and Reassembly 1.3.17 Remove the stem bearing (67) from the stem (3) or body (1). 1.3.18 Remove the grand washer (58), gland packing (8) and packing washer (20) (Up to size 11/2 ) from the body (1). ...
Page 31 Document No.：KE-1075-01 Sheet:28/31 Ⅶ Disassembly and Reassembly 2. Reassembly procedure 2.1 Care for reassembly (1) Wear protective items such as goggle, gloves and working boots. (2) No open flame or smoking should be allowed in the working area. (3) Take care not to catch fingers in flanges during assembly. (4) Replace the gland packing, gasket and O-ring with new ones to ensure satisfactory sealing performance. Reuse of these components may cause leakage. (5) When assembling valves of large size, use appropriate machine to lift up valves. (6) DO NOT apply any grease or lubricant to wetted areas, when the valves handle oxygen. 2.2 Before reassembly 2.2.1 Check all parts before reassembly. If any unsatisfactory function is found, replace the valve. ...
Page 32 Document No.：KE-1075-01 Sheet:29/31 Ⅶ Disassembly and Reassembly 2.3 Reassembly procedure 2.3.1 Assemble the stem bearing (67) to the stem (3). 2.3.2 Insert the stem (3) from inside the body (1). Make sure that the stem collar contacts the body, and set the stem (3) in fully closed position of the valve. 2.3.3 Assemble the coned disc springs (145) to the gland bolts (36). 2.3.4 Assemble the gland bushing (57) to the gland (7). 2.3.5 Mount the packing washer (20) (Up to size 11/4), gland packing (8), grand washer (58) and Gland (7) in the body (1), temporary tightening the gland bolts (36). 2.3.6 Mount the ball seats (30) in the body (1) and insert (29). 2.3.7 Mount the ball (4) in the body (1). 2.3.8 Mount the gasket (19A,19B) on the gasket face of the body (1). 2.3.9 ...
Page 33 Document No.：KE-1075-01 Sheet:30/31 Ⅶ Disassembly and Reassembly 《Assembly procedure for gear operated valve》 2.3.13 Mount the connector (92) to the stem (3). 2.3.14 Mount the gear unit (102) with bracket (93) to the body (1) and fix it with the bolts (99). ◎ All threaded areas should be securely tightened. Retighten them, if found loosened. ...
Page 34 Document No.：KE-1075-01 Sheet:31/31 Ⅶ Disassembly and Reassembly 3. Cross-sectional assembly drawing. This illustration introduce a typical construction for lever handle operated valve. Refer to the approval drawing before disassembly and assembly. This illustration introduce a typical construction for gear operated valve. Refer to the approval drawing before disassembly and assembly.

This manual is also suitable for:

300tazm series