Kitz 150 SCTBZ Series Operation Manual

Two peace type steel ball valves

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Document No.：KE-1027-00

150/300SCTBZ,UTBZ

（Flanged

Ｔwo Peace Type Steel Ball Valves

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.

Operation Manual

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ends）

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Page 1 Document No.：KE-1027-00 Operation Manual For Ｔwo Peace Type Steel Ball Valves 150/300SCTBZ,UTBZ （Flanged ends） 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. ...
Page 2 CAUTION AND WARNING To ensure safe and trouble-free function and performance of the product, please read all items of this manual before handling, transportation, mounting and operation of valves. Keep this manual in a convenient place for your valve operations’ easy access. The signal words “WARNING” and “CAUTION” are defined as follows: Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. 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-1027-00 C O N T E N T S Sheet Ⅰ Construction and Design Features ･･････････････････ 1 Ⅱ Valve Operation Device ･････････････････････････････ 4 Ⅲ Shipping, Handling and Storage of Valves ･･･････････ 7 Ⅳ Valve Installation ...
Page 4 Document No.：KE-1027-00 Sheet:1/29 CHAPTER Ⅰ Construction and Design Features ...
Page 5: Ⅰ Construction And Design Features
Document No.：KE-1027-00 Sheet:2/29 Ⅰ Construction and Design Features 1. Construction and Design Features 1.1 The typical valve design is as illustrated below. 1.2 Range of operation from full opening to full closing is 90°. 1.3 The ball is supported by both ball seats. When the valve is pressurized, the ball moves against the downstream seat to complete the seal, shutting off flow of the line fluid. 1.4 This ball valve design may be used on applications where a bi-directional flow is needed. This illustration represents a typical construction. ...
Page 6 Document No.：KE-1027-00 Sheet:3/29 Ⅰ Construction and Design Features 2. Design Features 2.1 Split Body, Side Entry Design The valve is Split Body, Side Entry Design with the coupling flanges fastened by bolts and nuts. 2.2 Fire safe provision KITZ ball valves can be optionally provided with graphite packing and body to body-cap 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 The 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 uniformity 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 bush, stem-to-body and gland-to-stuffing box are precision controlled on machining and assembly for low emission service. ...
Page 7 Document No.：KE-1027-00 Sheet:4/29 CHAPTER Ⅱ Valve Operation Device ...
Page 8: Ⅱ Valve Operation Device
Document No.：KE-1027-00 Sheet:5/29 Ⅱ Valve Operation Device 1. Lever Type Operator 1.1 Levers are mounted directly on the valve stem. 1.2 Rotating the lever clockwise by 90 ° will close the ball, and moving the lever counterclockwise by 90°opens it. ...
Page 9 Document No.：KE-1027-00 Sheet:6/29 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-1027-00 Sheet:7/29 CHAPTER Ⅲ Shipping, Handling and Storage of Valves ...
Page 11: Ⅲ Shipping, Handling And Storage Of Valves
Document No.：KE-1027-00 Sheet:8/29 Ⅲ Shipping, Handling and Storage of Valves 1. Shipping and Handling Valves 1.1 Care for Shipping and Handling Valves (1) Keep off the valve lifting area to prevent personal injury caused by unsecured valves. (1) Take care not to damage coated surface of valves during shipment. This may cause rust or other types of corrosion to form on valves. Any damaged surface should be adequately treated before installation. (2) Take care the handling and storage of carton packed. The high humidity may damage the cartons, which may lead to damaging valves. 1.2 Shipping and Handling Valves 1.2.1 Maintain original packing condition during shipment. 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-1027-00 Sheet:9/29 Ⅲ Shipping, Handling and Storage of Valves 2. Storage 2.1 Care for Valve Storage (1) DO NOT storage valves in the corrosive environment, which may cause corrosion on threaded portions of valves. (2) DO NOT remove protective covers until installation. As they will prevent the intrusion of any foreign object, the removal of covers could cause damage to the closure elements such as ball and seats. (3) DO NOT fall, drop, give mechanical impact or place any other objects on valves, and DO NOT step on them, which 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. And storing the valves in the fully closed position may damage the ball, when the flange protections 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 places is recommended. 2.2.2 Storage of valves directly on the ground or concrete floor is not recommended. Place packed valves on the racks for storage. 2.2.3 Take appropriate measures to prevent valves from direct exposure to dust, rain and sunlight, if valves should be stored outdoors. ...
Page 13 Document No.：KE-1027-00 Sheet:10/29 CHAPTER Ⅳ Valve Installation ...
Page 14: Ⅳ Valve Installation
Document No.：KE-1027-00 Sheet:11/29 Ⅳ Valve Installation 1 Care for choice of location for Valve installation (1) Check the valve specifications with the identification plate or tag and the relevant catalog, 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. Incorrect application of a specific valve could be hazardous. (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 Allow sufficient room for operation, installation 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 such outer forces as vibrations. 1.4 It is recommended to install valves in horizontal piping with the stem in upright position. ...
Page 15 Document No.：KE-1027-00 Sheet:12/29 Ⅳ Valve Installation 2 Care for Valve inspection (1) Keep off the valve lifting area to prevent personal injury caused by unsecured valves. (2) Take care not to catch fingers in flanges during mounting work. (3) Take care not to damage flanges, ball and ball seats surfaces. (4) Pipes should be properly supported, if needed. (5) Pressure applied to the gland packing may be lowered due to the stress relaxation taking place during transportation or storage, which may cause leakage. Retighten gland packing before operation (6) Be sure to insert new gaskets for valve mounting. ...
Page 16 Document No.：KE-1027-00 Sheet:13/29 Ⅳ Valve Installation 2.2 Check the following items before installation for safe operation of valves. 2.2.1 The service conditions should be within the range of the relevant valve specification. 2.2.2 Valve flanges should correspond with pipe flanges. 2.2.3 Gasket contact surfaces of pipes and valve flanges must be thoroughly inspected. No scratch or other indications of flaw should be found. 2.2.4 The appropriate space should be kept between pipe flanges for the valve face-to-face dimensions including the gasket thickness. 2.2.5 Pipes and valves should be accurately aligned. 2.2.6 Pipe flanges should face parallel to each other. The bolt holes of flanges should be symmetrically lined up against the center line of flanges. 2.3 Before installation, the connecting pipes should be cleaned to remove any foreign object such as sand, dust or welding spatters. 2.4 Handle valves carefully so that they may not fall or drop on the ground. Any extraordinary mechanical impact should be avoided. 2.5 Remove flange covers from valves just before installation. 2.6 Check all threaded areas after installation and retighten them, if needed. 2.7 Piping should be flushed before test operation with the valve fully open, to assure removal of any foreign object that could damage valves. Do not operate the valve during flusing. ...
Page 17 Document No.：KE-1027-00 Sheet:14/29 Ⅳ Valve Installation 3 Installation Procedures 3.1 Make sure that pipes should be aligned accurately. 3.2 The appropriate space 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. 3.4 Insert gaskets between the valve and pipe flanges. It is recommended to evenly apply a little 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 flange and lightly tighten them. 3.7 Evenly tighten the bolts alternately in a star pattern as shown below. Once the bolting is ...
Page 18 Document No.：KE-1027-00 Sheet:15/29 CHAPTER Ⅴ Valve Operation ...
Page 19: Ⅴ Valve Operation
Document No.：KE-1027-00 Sheet:16/29 Ⅴ Valve Operation 1. Care for valve operation. (1) DO NOT apply too excessive force to operate the valves by such methods as using a pipe or any other device. (2) Never loosen bolts or nuts used in the gland, cap flanges and end threads of pressurized valves. (3) DO NOT use valves in an intermediate position. Such use may damage ball seats and cause internal through-bore leakage. (4) Retighten the gland bolts and nuts before operation of valves. Check a handle torque while retightening the bolts and nuts so that the operation won’t become too difficult due to over-tightening. Gland bolts should be alternately tightened with an even force. (5) Valve should be kept fully open during the line test or pressure test. Fully closing valves during the test may deform the ball seats, leading to the occurrence of internal through-bore leakage. (6) In case service temperature fluctuates, retighten gland bolts and nuts after the temperature is stabilized due to the occurrence of stress relaxation of the gland packing. (7) Gradually open valves to prevent damage of pipes, when high temperature fluids such as steam are handled. (8) Take some appropriate measures to prevent freezing, as needed. 2. Operation 2.1 Lever handle ...
Page 20 Document No.：KE-1027-00 Sheet:17/29 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 Retighten gland bolts. Gland Area with soap Replace the gland packing as solution needed Visual Check Retighten flange bolts. Flange Areas with soap Replace gaskets as needed. solution External Visual Check Retighten each threaded areas. Leakage Threaded Portions with soap Replace valve components as ...
Page 21 Document No.：KE-1027-00 Sheet:18/29 Ⅴ Valve Operation 4. Corrective measures (1) Wear the 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. 4.1 Leakage from the gland area Retighten the gland bolts or nuts, if 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. ...
Page 22 Document No.：KE-1027-00 Sheet:19/29 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. Foreign objects may have choked Flush the built-up objects by the up the valve body cavity and media with the ball slightly open and Excessive valve torque stock around the ball seats. disassemble and inspect the valve. Loosen the gland bolts once and The gland bolts may have been adequately retighten them so that overly tightened.. the leakage through the gland does ...
Page 23 Document No.：KE-1027-00 Sheet:20/29 CHAPTER Ⅵ Periodic Inspection and Maintenance of Valves ...
Page 24: Ⅵ Periodic Inspection And Maintenance Of Valves
Document No.：KE-1027-00 Sheet:21/29 Ⅵ Periodic Inspection and Maintenance of Valves 1. Periodic Inspection 1.1 A periodic inspection with valves mounted to pipelines is recommended at least once a year. 1.2 Ensure the smooth operation and safety of valves before inspection. 1.3 Inspection items and methods are same as daily inspection. See Chapter V for the items and methods suggested. 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 the 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 media contain high viscosity and therefore may get stuck and build up inside the valves. c) Where corrosion or/and wear by the media is expected. Remove the valves from the pipelines and disassemble them for inspection, if needed. 1.6 It is recommended to replace the gland packing every time the periodic inspection is conducted. ...
Page 25 Document No.：KE-1027-00 Sheet:22/29 Ⅵ Periodic Inspection and Maintenance of Valves 2. Inspection and maintenance In case pipelines or facilities where valves are installed are shut down for the pipeline inspection, remove the valves from the pipelines and perform the body and seat pressure tests as well as operation tests, if needed. If any defect is found, disassemble the valves for further inspection. The valves must pass required inspections before being sent back to the pipelines or facilities for reinstallation. 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. (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 the protective items such as goggle, gloves and working boots. ...
Page 26 Document No.：KE-1027-00 Sheet:23/29 Ⅵ Periodic Inspection and Maintenance of Valves 2.2 Assembly and disassembly Refer to Chapter VII for assembly and disassembly procedure. 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 the protective items such as goggle, gloves and working boots. ...
Page 27 Document No.：KE-1027-00 Sheet:24/29 CHAPTER Ⅶ Disassembly and Reassembly of Valves ...
Page 28: Ⅶ Disassembly And Reassembly Of Valves
Document No.：KE-1027-00 Sheet:25/29 Ⅶ Disassembly and Reassembly of Valves 1. Disassembly procedure 1.1 Care for disassembly (1) Operator should take an appropriate caution for not being exposed to the fluid or catching fire. (1) Wear the 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 and body cap on subsequent reassembly. ...
Page 29 Document No.：KE-1027-00 Sheet:26/29 Ⅶ Disassembly and Reassembly of Valves 1.3 Disassembly procedure 1.3.1 Full close the valve. 1.3.2 Remove the body-cap(2). 1.3.3 Disassemble the body(1) and body-cap(2). 1.3.4 Remove the ball(4) from the body(1). 1.3.5 Remove the ball seats(30) and gasket(19) from the body(1) and body-cap(2). 1.3.6 Size1/2-1”: Remove the stem nut(10) handle(9) gland nut(34) lock plate(40A) spring(43) gland(7) and gland packing(8) from the body(1). Size11/2-8”: Disassemble the handle(9) snap ring(48) stopper(49) gland bolts(36), gland(7),and gland packing(8) from the body(1). 1.3.7 Push the stem (3) down into the body cavity to remove it from inside the body(1). 1.3.8 Remove the thrust washer (47)or stem bearing(67)from the body(1) or stem(3). ...
Page 30 Document No.：KE-1027-00 Sheet:27/29 Ⅶ Disassembly and Reassembly of Valves 2. Reassembly procedure 2.1 Care for reassembly (1) Wear the 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 reassembly. (4) Replace the gland packing and gasket for 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. 2.2 Before Reassembly 2.2.1 Check all parts before assembly. If any unsatisfactory function is found, replace the valve. 2.2.2 The consumables such as ball, ball seats, seat packing, gland packing, gasket and thrust washer should be prepared beforehand. ...
Page 31 Document No.：KE-1027-00 Sheet:28/29 Ⅶ Disassembly and Reassembly of Valves 2.3 Reassembly procedure 2.3.1 Mount the thrust washer (47) or stem bearing (67) in the stem (3). 2.3.2 Assemble the stem (3) in the body (1) from the body interior. Ensure that the stem collar securely contacts the valve body and that the valve position is fully closed. 2.3.3 Size1/2-1”: Mount the gland packing (8) and gland (7) in the body(1).Assemble the spring(43) lock plate(40A) and grand nut(34) and tightening the gland nut (34). Assemble the handle(9) and handle nut(10) and tightening the handle nut(9). Size11/2-8”: Mount the gland packing (8) and gland (7) in the body (1), tightening the gland bolts (36). Mount the stopper (49) in the stem (3) and fix it with the snap ring (48). 2.3.4 Mount the ball seats(30) in the body (1) and insert (29). 2.3.5 Place the ball (4) into the body (1). 2.3.6 Mount the gasket (19) on the gasket face of the body(1). 2.3.7 Assemble the body-cap(2) in the body (1). Ensure that the ball seats (30) are placed in the correct position and tightening the insert. 2.3.8 All threaded parts should be securely tightened. Retighten them, if founded loosened. ...
Page 32 Document No.：KE-1027-00 Sheet:29/29 Ⅶ Disassembly and Reassembly of Valves 3. Cross-sectional assembly drawing. This drawing introduces a typical construction of the valve. Refer to the approval drawing before disassembly and assembly. ...

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