SERIES WB

TRUNNION MOUNTED BALL VALVE

INSTALLATION, OPERATION & MAINTENANCE MANUAL

KF SERIES WB

FULLY WELDED BODY BALL VALVE

Installation, Operation and Maintenance Manual

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Document Name:
IOM-WB
Revision:
15333
Release Date: 06/12/2015

SERIES WB
TRUNNION MOUNTED BALL VALVE

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Release Date: 06/12/2015

CONTENTS
BILL OF MATERIALS ------------------------------------------------------------------------------------------------------------------------------------------------- 3
1)

SCOPE-------------------------------------------------------------------------------------------------------------------------------------------------------------- 4

2)

INSTALLATION ------------------------------------------------------------------------------------------------------------------------------------------------ 4

3)

OPERATION ----------------------------------------------------------------------------------------------------------------------------------------------------- 5

4)

MAINTENANCE ------------------------------------------------------------------------------------------------------------------------------------------------- 5

5)

IN LINE RPEPAIR ---------------------------------------------------------------------------------------------------------------------------------------------- 6

6)

VALVE SERVICING INTERVALS -------------------------------------------------------------------------------------------------------------------------- 7

7)

VALVE MAINTENANCE GUIDE LINES ------------------------------------------------------------------------------------------------------------------ 7

7.1) Routine maintenance ---------------------------------------------------------------------------------------------------------------------------------------- 7
7.2) Valve flush ------------------------------------------------------------------------------------------------------------------------------------------------------ 7
7.3) Valve cleaning ------------------------------------------------------------------------------------------------------------------------------------------------- 7
7.4) Emergency Repair -------------------------------------------------------------------------------------------------------------------------------------------- 8

8)

QUICK REFERENCE ------------------------------------------------------------------------------------------------------------------------------------------- 8

8.1) New installation Start-Up-------------------------------------------------------------------------------------------------------------------------------- 8
8.2) Proper Valve Testing----------------------------------------------------------------------------------------------------------------------------------------- 8
8.3) Shell Testing ---------------------------------------------------------------------------------------------------------------------------------------------------- 8
8.4) Hydrostatic Seat Testing ------------------------------------------------------------------------------------------------------------------------------------ 8
8.5) Supplemental Air Seat Test -------------------------------------------------------------------------------------------------------------------------------- 9
8.6) Double Block and Bleed (DBB) valves------------------------------------------------------------------------------------------------------------------- 9

9)

GEAR OPERATOR FIELD ADJUSTMENT ---------------------------------------------------------------------------------------------------------- 9

10)

VALVE MAINTENANCE OVERVIEW ---------------------------------------------------------------------------------------------------------------- 9

11)

LUBRICATION EQUIPMENT--------------------------------------------------------------------------------------------------------------------------- 9

12)

PROPER VALVE STORAGE ----------------------------------------------------------------------------------------------------------------------------- 9

13)

TROUBLE SHOOTING---------------------------------------------------------------------------------------------------------------------------------- 10

Installation, Operation and Maintenance Manual

SERIES WB
TRUNNION MOUNTED BALL VALVE

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Document Name:
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BILL OF MATERIALS

Installation, Operation and Maintenance Manual

Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
18
19
20
22
23
24
26
28
29
30
31
34
42
43
46
50

Description
Body
Adapter
Bonnet
Ball
Stem
Trunnion Block
Seat Ring
Internal Stop Plate
Seat Spring
Thrust Bearing
Trunnion Bearing
Bonnet Protection O-Ring
Fire safe Packing
Stem O-Ring
Stem Protection O-Ring
Sub Seal Primary O-Ring
Sub Seal Secondary O-Ring
Feet (Optional)
Lifting Lug
Cap screw, Stop Plate
Stem Thrust Bearing
Bleed Fitting
Lube/Sealant Fitting
Internal Check
Key
Antistatic Pin
Antistatic Spring
Trunnion Block Pin
Relief Valve

53
58
72
73

Cap screw, Key

Pin, Stop Plate
Seat Retainer
Seat Primary Seal O-Ring

82
*

Gland Ring
Seat Assembly

SERIES WB
TRUNNION MOUNTED BALL VALVE

1) SCOPE
The following instructions are very important
for the maintenance, disassembling and
assembling of series WB ball valve. The
instruction refers also to grease emergency seal
valves with back-up rings for high pressure
services.

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KF offers an optional gear operator with hand

wheel which can be field mounted. Depending
on size, some valves have gear operators
mounted with exposed bolting. Installation of a
gear operator on these valves simply requires
placing the operator over the stem, onto the
top cover or bonnet and securing it with bolts.
IMPORTANT! Lubricate all threads, gears and
fasteners with recommended lubricants or equal
prior to installation. Tighten all mating flange
fasteners in a diagonal pattern and check
bolting torques and retighten as necessary
after installation. Do not over torque in fully
open or closed position to avoid thermal
binding.
WELDING:
Instruction and precautions
Keep the ball in open position prior to
installation/welding of KF series WB ball
valve.
Place the valve in position by aligning
weld ends to the pipe. Prior to welding
it is imperative that all welding surface
be clean from contamination such as dirt,
dust and grease which may affect weld
performance.

NAME PLATE INFORMATION

2) INSTALLATION
Install valve in system using proper size and type
mating flanges and appropriate gaskets (for RF)
or seal rings (for RTJ). Valve design allows for line
flow in either direction.
KF Series WB Ball Valves are provided with keyed
stem and large flanges with mounting holes on a
machined top cover or bonnet surface for
convenient actuator or gear operator mounting.
Consult factory for location and dimensions of
these holes.

Caution: During the welding process, valve

body temperatures should be monitored
around the circumference at a location in
line with the sealant injection fittings. The
temperatures at this plane should be
checked with temperature stick or other
reliable temperature indicator and not
allowed to exceed 300F. This precaution is
necessary to assure that non-metallic seals
do not suffer heat damage.
Tack weld valve in positions and check for

proper alignment.
Finish weld following proper weld procedure
for material grade and condition, and the
above caution.

Installation, Operation and Maintenance Manual

SERIES WB
TRUNNION MOUNTED BALL VALVE

3) OPERATION
Initial Start-up / commissioning
Once the valve has been installed on the line it
shall be left either in fully open or fully closed
position depending on start-up / commissioning
operation
IMPORTANT! Do not leave the valve in half /
partially open position for a long period of
time. Ensure that the pipeline is free of any
debris such as sand, tool, welding slag or
weld splatter and rod ends. This will damage
the valve ball and seat during startup/commissioning operations.
NORMAL OPERATING ACTIVITY
The valves are recommended for on-off service
only. Pressure temperature limits are stated on
the valve tag. Throttling (partial opening) may
cause excessive and non-uniform wear on the
seats, preventing tight shut-off. Kindly refrain
from using the valve neither for controlling flow
in partially open position nor for throttling
service unless this requirement was clearly
stated on the purchase order for the concerned
valve. The valve can be operated from the fully
open to fully closed position by acting on the
hand wheel/lever (clockwise to close). Exact
closed and open position is determined by the
radial location of the stem flats or keyway with
respect to the fluid bore centerline of the body.
For actuator operated valves refer to actuator
operating instructions.
Double Block and Bleed Operation:
KF Series WB Ball Valves are well suited for
sealing fluids, concurrently, at both ends. The
relief valve provides a safe and convenient
method for checking closed valve seat sealing
effectiveness as required for Double Block and
Bleed valves.
Caution: Replace relief valve with pipe plug
during hydrostatic shell testing to avoid
damage. Reinstall relief valve after test
completion.

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BODY CAVITY RELIEVING SYSTEMS

Trunnion mounted ball valves do have a body
cavity where pressure can be trapped into a
closed volume. Under this circumstance any
increase of the contained fluid temperature or
any degradation of the contained fluid can result
in an uncontrolled pressure increase of the
trapped fluid to figures that are above the
design pressures of the pressure equipment.
To avoid the above scenario, KF Series WB
trunnion mounted ball valves are provided with
body cavity relieving systems.
Safety Relief Valve: When both the seats are not
self-relieving type (i.e. both the seats are of the
Double Piston Effect type) the body cavity must
be protected from overpressure by means of a
Pressure Relieving Valve (PRV) set to relieve
exceeds pressure.
The standard PRV provided by KF does relieve
body cavity overpressure to the atmosphere
once it reach a value between 1.1 and 1.33 times
the design pressure of the pressure equipment it
is assembled.

4) MAINTENANCE
Routine maintenance of KF series WB ball valves
consists of periodic grease injections through the
lube fittings provided on the adapter (closure)
flange. General purpose grease, such as Valtex
2000 (or equivalent), is recommended for this
service. The use of thick, very viscous grease may
hamper designed sealing action and make seat
removal during any required disassembly more
difficult. To extend the life of valve, it shall be
lubricated and maintained on regular basis. If
the valve is not ROUTINELY MAINTAINED, the
general thumb rule is to inject one ounce of
grease per inch of bore size into each seat.
Example: 20 bore valve will require 20 x 1 = 20
ounce of grease per seat.

Installation, Operation and Maintenance Manual

SERIES WB
TRUNNION MOUNTED BALL VALVE

The best results are achieved by injecting while

the valve is fully open or fully closed position.
When attempting to seal the valve, if leakage is
persisting check the valve stops to ensure the
valve is fully closed. Always consult service
manual or factory before attempting any service
procedure. The stem journals are permanently
lubricated at the factory and require no routine
maintenance.
Note: The bonnet fittings are for sealant
injection provides temporary sealing in the
event of a stem seal failure (Seal weld Ball
Valve Sealant No.5050, available from
Sealweld Corp., Houston, TX or Calgary,
Alberta-Canada). Also, in the event of
internal seat/ball interface leakage, sealant
may be injected through the two body lube
fittings to provide temporary sealing, Do not
inject Grease into Bonnet fittings as the
stem requires no routine maintenance.
Injection of Grease in this fitting may result
in premature failure.

proceed with sealant injection

Check for leak. If sealing is not adequate,
stroke the valve and repeat sealant injection.

5) IN LINE RPEPAIR
STEM LEAKAGE
Stem leakage can be temporarily stopped by
injecting sealing grease into the stem grease
fitting (30). It is also possible to replace the
upper stem O-ring without disassembling the
bonnet (3).
For replacement operate as follows:
a) Mark in a lasting way, the operation
device (actuator or gearbox), the internal
stop plate (8) and the gland ring (12) in
order to reassemble the component in
the same position.
b) Close the valve and discharge the residual
pressure left inside the body through the
drain valve.
c) Remove the gear box or the actuator.
IMPORTANT: If the valve is operated
by an actuator, after removing the
studs or the cap screws connected
with the valve, lift the actuator on a
straight line until it is completely
disconnected from the stem(5) being
careful not to damage either on the
stem or on the key (34).

LUBRICATION PROCEDURE GENERAL

All KF series WB valves are pre-lubricated prior to
shipment and are provided with seats and/or
stem emergency seal grease injectors. Emergency
grease injectors may be used to stop/reduce
leakage across the seats and/or through the stem
seals.
STEM AND SEATS LEAKAGE
(STOP OR REDUCTION)
Sealant grease must be injected only when
leakage occurs. Prior to injecting grease
we suggest in flushing the seats with a flushing
fluid. Grease/flushing fluid injection pressure
shall never be more than 1000 psig above the
line pressure.
Proceed as follows:
Inject flushing fluid and meanwhile stroke
the valve a few times.
Check for leak reduction
Repeat flushing as above and check again
If leak do not disappear, close the valve and

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d) Remove the key cap screw (53) and the

key (34).
e) Remove the internal stop plate screw (26)
and the internal stop plate (8).
f) Remove the gland ring (12) and replace
the upper stem O-ring (18) and FS packing
(13) whenever provided.
IMPORTANT: During the reassembling
care must be taken to put the O-ring and
the FS packing in the correct location.
SEAT LEAKAGE
Seat leakage can be temporarily eliminated or,
at least, considerably reduced injecting sealing

Installation, Operation and Maintenance Manual

SERIES WB
TRUNNION MOUNTED BALL VALVE

grease when the valve is in closed position. Seat

grease fittings (30) are located either in the
adapter for above ground valves or on top of
the stem extension, for buried valves.

6) VALVE SERVICING INTERVALS

Valve shall be inspected regularly during
operation and subjected to scheduled
maintenance. The operator is responsible for
servicing the valve at regular intervals. The
service intervals are determined by media in line,
temperature, pressure and number of cycles
during the operations. High pressure accelerates
the loss of lubricants.
LUBRICATION MAINTENANCE CAPACITIES:
The insufficient lubricants and build-up of
decomposed grease residue leads to
lubrication/sealant determination, Every time
the valve is cycled, a small amount of lubricant
is lost downstream. The following table shows
the lubrication capacities for Ser. WB valves.
Bore Size

Amount per
Seat (In Ounce)

Amount per Valve

(In Ounce)

8
10
12
14
16
18
20
24
30
36
42

3
3
3
4
4
4
6
8
12
16
20

6
6
6
8
8
8
12
16
24
32
40

LUBRICATION MAINTENANCE CAPACITIES

EXTERNAL SEALANT LINES
Inside Diameter of
Riser

Ounce / Foot of Riser

1/4"
3/8
1/2"
3/4"

1/2 OZ
1.3 OZ
2 OZ
4 OZ

7) VALVE MAINTENANCE GUIDE LINES

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during the operation and subject to scheduled

maintenance. All maintenance work shall be
done by qualified personnel. Follow the grease
gun or pump manufactures equipments
guidelines for proper use. Local regulations shall
be strictly followed for the safety and health of
persons involved.
7.1) Routine maintenance
The valve lubricants are designed for routine
valve maintenance. It consists of injecting
lubricant/sealant though the groove or
channel inside the valve leading to seal points
around the ball thus topping off the
lubricant/sealant. The Top Off quantity can
vary greatly due to frequency of valve
operation and service conditions. The lubricant
is available in stick or liquid from and should
be free from heavy agent such as PTFE, clay
and wax. The most widely used lubricant by
manufacturers and users is HYDROCARBON
GREASE.
7.2) Valve flush
Valve flush is a blend of synthetic oils. It works
through penetration by pressure and often
successful in softening hardened deposits of
lubricants and sealants. It forms protective
coating on the metal surface and impenetrable
barrier which will withstand high pressure and
friction in server service demands.
7.3) Valve cleaning
When the valve does not seal properly and
hard to turn, the valve cleaning is required.
Valve cleaners are the product that contains
detergent, sealant and oils. It clears
channel/passage where old grease may have
been hardened, Inject cleaner through the
lubrication channels, leaves it for three-to-four
hours. If possible, cycle the valve to evenly
distribute the cleaner in the ball-seat contact
area. This procedure is often successful in
freeing seized or hard to turn valve.

In order to guarantee efficient valve operation,

the valve shall be inspected on regular basis

Installation, Operation and Maintenance Manual

SERIES WB
TRUNNION MOUNTED BALL VALVE

5. Valves are to be substantially

relieved of air or gas when tested
with liquid.
6. Seat closure tests are to be
conducted after acceptable shell
test.

Note: Always displace the valve cleaner

with equal quantities of Lubricant/Sealant
after cleaning.
7.4) Emergency Repair
A severe seat or ball damage may cause the
valve to leak. The valve sealants are designed
to stop a leaking valve. The sealant contains
heavier agent such as PTFE and clay in a grease
base. The temporary seal can be achieved by
injecting a heavy sealant. Displace a heavy
sealant after use of a lighter lubricant/sealant
to avoid complications. The valve which
requires continuous heavy sealant injections
shall be either replaced or repaired
immediately.

8) QUICK REFERENCE
8.1) New installation Start-Up
Valves are frequently damaged by debris
during hydro testing or start-up of a New
Installation. It is very important that the
valve be in full open position during this
process.
If the valve is closed or partially open,
debris can damage the ball and find its
way into seat pockets
This can cause the valve to leak soon
after start-up
8.2) Proper Valve Testing
1. Each valve is to be operated before
and after testing for any unusual
torque requirements.
2. Test pressure measuring devices are
to be either currently calibrated
pressure
gages
or
pressure
transducers.
3. Tests are to be made with ball and
seat free of any sealant.
4. Fluid for shell and seat tests is to be
water with a corrosion inhibitor.

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8.3) Shell Testing

Prior to painting or other external coatings,
Valves is to be subjected to a hydrostatic
shell test. There is to be no leakage under
the test pressure when both ends are
blanked and ball is partially open. Testing
pressure is 1.5 times MOP. Test duration
are 2 min for 4 and under valves, 5 min for
6 to 10 valves, 15 min for 12 to 18
valves and 30 min for 20 and larger.
1. Fit the vent valve and set it in open
position.
2. Operate the valve to the half-open
position.
3. Fill in the valve with the fluid (Venting
the air through the vent valve)
4. Close the vent valve and apply pressure
in accordance with max operating
pressure of the pipeline.
5. Visually check the outside of the ball
valve for possible deformations or
leakage.
6. Depressurize the valve.
8.4) Hydrostatic Seat Testing
Valves are to be subjected to a hydrostatic
seat test. There is to be no leakage under
test pressure. Test pressure is to be applied
successively to both sides of closed valve
with other side open to atmosphere.
Testing pressure is 1.1 times MOP. Test
durations are 2 min for 4 and under valves,
5 min for 6 and larger valves.
1. Operate the valve to the fully close
position and open the vent valve.
2. Pressurize one side in accordance with
max operating pressure of the pipeline.

Installation, Operation and Maintenance Manual

SERIES WB
TRUNNION MOUNTED BALL VALVE

3. From the body vent, check for possible

seat leakage.
4. Repeat same operations as per points 2
& 3 on opposite side of the valve.
5. Depressurize the valve.

media continues to escape thru bleed

fitting, leakage is confirmed.
6. If leakage continues to be observed at
bleed fitting, turn gear operator hand
wheel clockwise (right) to further close the
ball valve. As hand wheel is turned,
observe for change in amount of flow out
bleed fitting. The objective is to find a
position where flow no longer comes from
bleed fitting. At each check position, it is
necessary to allow some time to see if the
flow changes. If a position is not found to
stop leakage in the CW direction, turn hand
wheel CCW to see if the valve may have
been over-closing.
7. If a position is found where leakage stops,
turn the stop-screw CW until it hits snugly
then tighten the lock nut.
8. If a position is not found where leakage
stops, it can be concluded that the seat
insert is damaged and repair is necessary.

Note: For valve without a body vent or drain

connection, it is necessary to install on the pipeline
a control system to measure pressure upstream
and downstream the valve.

8.5) Supplemental Air Seat Test

Valves subjected to an 80psi air seat test
shall show no signs of visible leakage.
8.6) Double Block and Bleed (DBB) valves
If the valve has DBB, the test shall be
performed as follows:
1. With the valve in half-open position, the
valve shall be completely filled
2. The valve shall than be closed and the
valve vent opened to allow excess fluid to
overflow from the cavity connection
3. Apply pressure on both the seats
simultaneously
4. Seat tightness shall be monitored from
the cavity connection
5. Depressurize the valve.

9) GEAR
OPERATOR
ADJUSTMENT

10) VALVE MAINTENANCE OVERVIEW

Establish a valve Maintenance group.

Have a set valve servicing schedule
Service schedule is dependent on the
media and the number of times the valve
is cycled.
Valves should be lubricated at least one
time every six months.

FIELD

1. Locate closed stop adjustment screw on

gear operator. It is the screw on back of
gear case on same side of operator as the
hand wheel.
2. Operate ball valve to full closed, feel the
valve hit the stop.
3. With pressure on closed ball valve, loosen
the lock nut on closed stop adjustment
screw then back out screw [CCW] 3 or 4
turns.
4. Open bleed fitting on side (center) of ball
valve.
5. Line media will escape from bleed fitting
while evacuating ball cavity. Allow a minute
or two for body cavity to bleed down. If

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11) LUBRICATION EQUIPMENT

Hydraulic hand guns are efficient for 4

Bore and smaller.
Hand guns require 50 Strokes to
move 1oz of product
Air operated guns are the most efficient for
6 bore and larger.

12) PROPER VALVE STORAGE

Inside Storage
Ball valves should be in the full open
position.
End connection protectors should be tight
to prevent ingress of moisture and debris.

Installation, Operation and Maintenance Manual

SERIES WB
TRUNNION MOUNTED BALL VALVE

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Valves should be left in original shipping

container (If possible).

13) TROUBLESHOOTING

Verify leakage (Block & Bleed)

Cycle the valve 3-6 Times
Wipes the ball and often allows trapped
debris to travel downstream
Can free-up a stubborn seat
Adjust Gear Operator/Actuator Stops
Occasionally, a stop set on a gear
operator may loosen causing the valve to
over or under level.

REVISION HISTORY
REV

PREPARED BY

BHARATH D K

DESCRIPTION

Initial Release

Installation, Operation and Maintenance Manual

DATE

APPROVED BY

06/12/2015

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