1. Storage
When storing the valves prior to installation, the following conditions shall be met:

1.1 In a covered area free from dust.
1.2 The valves shall be stored in the open position
1.3 The valves shall either be stored in their original packaging or stood on shelves, or in clean boxes free of any contamination, which could damage the lining. The flange protectors should be left in place at all time when in storage.
1.4 When the original packing is used for storage, care should be taken to avoid excessive stacking of the boxes.

The packing cases should be handled by means of trucks, pallet trucks belts or chains. The use of hooks, which may pierce the packing and damage the valve linings, should be avoided.

2. Installation and Start-up Conditions.

2.1 Before installing the valves in the pipeline, drain and clean the mating flanges to avoid damaging the valve by swarf, grit, weld splatter etc.

2.2 Ensure that the valve is in the open position.
a) Remove the plastic flange protectors.
b) Check that the valve internals appear clean and free from obvious contamination.
c) Clean, and if necessary blow-dry with clean air, the inside of the valve.
d) Clean the mating faces of the valve and the pipe with appropriate solvents.
e) Rotate the valve manually to check the correct seating of the valve in the open and closed position.

2.3 Actuated Valves
Before installing the valves, check the air pressure of the actuators.
Carry out a bench function test of the valve / actuator assembly, including any accessories such as positioners, pressure reducers & switches.

For actuated assemblies which are fail closed (spring to close) install the valve in the lined in the closed position.
Note: The valve should be opened and closed up to the stops, to ensure that
Complete opening and closure is achieved.

3. Maintenance & Repair.
The KLBC ball check valves do not require any routine maintenance. If after a period of use leakage occurs down the line, this is generally owing to wear to the PTFE ball
This leakage can be eliminated by replacing the ball following the procedure described below.
Important: decontamination.
Because KLBC ball check valves are likely to be handling corrosive or hazardous liquids, it is important that the valve is fully decontaminated prior to dismantling, and that it is free from any residual vapour.
Do not use steam to decontaminate the valves.

3. Maintenance & Repair.

Owing to their design, KLB ball valves do not require any routine maintenance. If after a period of use leakage occurs down the line, this is generally owing to wear to the ball or PTFE seats of the valve.
This leakage can be eliminated by replacing the seats and ball following the procedure described below.
Important: decontamination.
Because KLB ball valves are likely to be handling corrosive or hazardous liquids, it is important that the valve is fully decontaminated prior to dismantling, and that it is free from any residual vapour.
The valve should be decontaminated in the half-open position, following procedures documented by the utility in question.
Do not use steam to decontaminate the valves.

3.1. Maintenance Area.
Maintenance of the KLB ball valves should be carried out on a clean working surface, free of dust, swarf, or other particles, which could damage the PFA lining of the valve parts.
It should be maintained in a clean state.

3.2. Tooling.
No special tools are required for the maintenance of KLB ball valves. Operators will require a set of spanners and hexagon type keys for dismantling the valves and a torque wrench to set the body bolts at the correct torque on re-assembly

4. Dismantling The Valve.

a) Place the valve on a clean surface.
b) Remove the lever (9), lever stop pin (10) and anti-static device (13).
c) Remove the gland follower (6).
d) Remove the PTFE gland packing (4). It is recommended by Kenway that the packing be removed using compressed air. Using a blank flange fitted to an end flange and another flange fitted with an air fitting to the other end flange. With the valve in the half open position increase the compressed air pressure slowly to remove the gland packing safely from the valve. This method of removal eliminates any mechanical damage to the PFA lined parts and PTFE gland packing rings.
e) Loosen body bolts (15) and remove adaptor(2) from body (1).
f) Carefully remove from ball/stem (3) from the body (1).
g) Remove the PTFE seats (5) from the body (1) and adaptor (2).

 

5. Assembly of The Valve.

a) Place all the valve parts on a clean surface.
b) Insert for seats (5) into the seat cavities in the body (1) and adaptor (2).
c) Carefully insert the ball/stem (3) into the body (1).
d) Locate the adaptor (2) into the body (1).
e) Insert the body bolts (15) and finger tighten.
f) Insert the gland packing (as shown in the diagram below)
g) Insert the gland follower (6) and manually compress the packing.
h) Insert the gland follower set screws and tighten until follower is clear of flats on the stem.
i) Tighten body bolts (15) in an even cross tightening sequence with a torque wrench (as shown in table 1.)
j) Fit the anti-static advice (13) over the stem (3).
k) Fit the lever (9) and lever stop pin (12).

Table 1.  Type KLB Body Bolt Tightening Torques
Size Dimensions Torques Nm
0.5" & 0.75" 4 x M10 40
1" 4 x M10 40
1.5" 4 x M12 40
2" 4 x M12 40
3" 6 x M12 60
4" 6 x M12 60
 

6. Seat Testing.
Following maintenance an air seat test should be carried out for all the valves.
Recommended test pressures:
3 minutes at 2 bar, 3 minutes at 6 bar and 3 minutes at 10 bar

7. Valve Protection.
Following seat test fit the plastic flange protectors to protect the lining. Flange protectors should be fitted at all times in storage and should be removed only when the valve is installed into the pipeline.

8. Condition of Spare Parts.
When overhauling Kenway type KLB ball valves, only parts in good condition should be used. Any parts showing evidence of cuts, scratches, abrasions or deformation, which may be detrimental to the smooth operation or tightness of the valve, should be rejected.

9. Guarantee.
As described above, the overhaul of the Kenway type KLB ball valve is a simple process. However, it should be carried out by skilled personnel experienced in such operations. Site maintenance shall be carried out under the sole control of the site personnel, and shall not be the responsibility of Kenway (Valves) UK Ltd.

10. Contacts.
For original replacement parts or if you have any technical questions, please contact our sales staff on.
Tel: 01509 508131       Fax: 01509 505485      Email: sales@kenwayvalves.co.uk