Section 1.0 - Parts List

UNCONTROLLED-11/11/14 EXPIRES ONE (1) WEEK FROM SAID DATE
RSP - 1000 PAGE 1 OF 13

DATE:
REPRESENTATIVE SUGGESTED
8/4/10 PRACTICE 1000
REVISION:
A DISASSEMBLY, MAINTENANCE, REPAIR,
8/4/10 INSPECTION & RE-ASSEMBLY FOR LOW
APPROVED:
WRITTEN BY:
TORQUE PLUG VALVES - 1", 2", & 3"
SECTION 1.0 - PARTS LIST 5
3
TOP END
7
8
2 6
18
9
BOTTOM END
17
10
PLUG VALVE SIZES 1" 2" 3" 15
ITEM DESCRIPTION QTY.

16 11
1 LT PLUG VALVE BODY 1 1 1 12
2 FLOW INDICATOR - 1 1 11
3 PLUG VALVE BAR NUT 1 1 1

4 WASHER 2 2 2
5 HEX HEAD BOLT 2 2 2
6 INDICATOR STOP BOLT 1 1 1
7 HAMMER-LUG NUT 1 1 1 12
8 SEGMENTED RING 1 1 1 15
13
9 RETAINING RING 1 1 1
10 ROLL PIN 2 2 4
11 INSERT O-RINGS 2 2 2
12 PLUG VALVE INSERTS 2 2 2 14
13 CAP O-RING 1 1 1
4
14 PLUG VALVE CAP 1 1 1
15 PACKING RING 2 2 2 5
16 PLUG VALVE PLUG 1 1 1

NOTE: ON 1" PLUG VALVES THE BAR NUT
17 GREASE FITTING 1 1 1 AND INDICATOR PLATE ARE THE SAME
18 UNION SEAL RING 1 1 1 (SEE VIEW A-A) VIEW A-A
RSP - 1000 PAGE 2 OF 13
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This document should be referenced only as a guideline for normal repair and safe operations for
specific Kemper flow-line products. As "suggested" practice, this information is no intended to
replace any existing end user's Company Safety Policies or Practices, which should take
precedence and be strictly adhered to. Safety glasses and foot protection are recommended.
SECTION 2.0 - DISASSEMBLY PROCEDURE
Note: If the Bar Nut (3) or the Cap (14) appears to be stuck or locked, pressure may be trapped in the
valve. This is also known as " Pressure Locking." DO NOT ATTEMPT TO DISASSEMBLE A "PRESSURE
LOCKED" VALVE. See Section 4.1 Disassembly Tips for pressure relieving procedures.
• With the valve top end up remove the Bar Nut (3) and Flow Indicator (2). Turn valve over so
that the bottom end is facing up. Leaving the bottom Bolt (5) in place, screw out ( turning
counter-clockwise ) the Cap (14). This will allow the entire internal assembly ( Cap (14),
Plug (16), and Inserts (12 ) to be removed from the valve pocket at once.
• Remove the Bolt (5) & Washer (4) from Sub-Assembly of Plug (16), Cap (14), & Inserts (12).
• Remove the Inserts (12) from around the Plug (16); next remove the Plug (16) from the
Cap (14).
• Remove the Insert O-Rings (11), Cap O-Ring (13) and Packing Rings (15).
• Clean all of the old lubricant and debris from the parts and valve body internal
profile.
SECTION 3.0 - MAINTENANCE

Valves should be greased as part of a regular maintenance program. Regular greasing will increase the
service life of the internal valve parts. Routine disassembly and cleaning as part of a maintenance
program can prevent unnecessary damage to the valve body. Kemper Valve & Fittings Corp. recommends
that valves be greased ideally every actuation; no more than 5 actuations without being greased.
Valves should be greased according to the severity of use. Each operating company should establish
guidelines for a greasing and/or disassembly program. These guidelines should be based on the operating
conditions. Special consideration should be given for conditions in which the following would be involved:
• Abrasive in the fluid stream

• High flow rates
• Caustic or Acidic fluid streams
• High temperature
• Fluid streams that would act as solvents such as condensate
• High number of valve actuations
Valves should not be greased while under pressure unless a Grease Fitting is being used. In addition,
valves should not be disassembled for repair while part of an operating arrangment such as a manifold.
This should not be attempted even though the valve may be isolated from the fluid stream by other valves.
DO NOT ATTEMPT TO DISASSEMBLE A "PRESSURE LOCKED" VALVE. See Section 4.1

DISASSEMBLY TIPS for pressure relieving procedures.
RSP - 1000 PAGE 3 OF 13
DATE:
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SECTION 4.0 - REPAIR AND INSPECTION

When repairing a Kemper plug valve, the following basic guidelines can help you ensure a good
hydrostatic test of the reassembled valve.
Disassemble the valve completely. See section 2.0 DISASSEMBLY PROCEDURES for detailed
instructions on valve disassembly. Remove old grease and debris from valve pocket with a solvent and
inspect for wear or damage such as:
• Valve Body (1) - Cap seal bore of the pocket: Scratches could be caused by previous
installation of a damaged Cap. Dings can also occur during assembly. Pitting is usually caused
by failure to disassemble and clean valves after they are in service. Use you fingers to feel for
any surface defects which may either fail to seal against the o-ring or may even damage the
o-ring during assembly. ( See Pg.4 Picture 4.11 )
• Cap (14) - O-ring groove area: Check for scratches, dings, or pitting. Dings and scratches here
are usually caused by careless use of sharp metal objects when trying to remove old o-rings.
Feel for any raised edges that might scratch the internal seal bore of the valve body and sand
or file as necessary. ( See Pg.4 Picture 4.12 )
• Valve Body (1) - Pocket walls: Scratches, dings, or pitting, especially in the area immediately
surrounding the valve bore. Use your fingers to feel for any surface defects which may either
fail to seal against the o-ring or may even damage the o-ring during assembly. Check for any
sharp edges around the valve bore that can cut the insert o-rings. These can be caused by
using a bar when swabbing excess grease or using a bar to carry the valve.
( See Pg.4 Picture 4.11 )
• Valve Body (1) & Cap (14) - Threads: Check for damaged threads, especially the lead thread.
Use you fingers to check for any raised edges and carefully sand as needed. Severely
damaged threads must be repaired at the factory. ( See Pg.4 Picture 4.11 & 4.12 )
• Valve Body (1) & Cap (14) - Packing Ring bore: Check for scratches, dings, or pitting. Dings
and scratches here are usually caused by careless use of sharp metal objects when trying to
remove old seals. ( See Pg.4 Picture 4.11 & 4.12 )
• Plug (16) outside diameter & Insert (12) inside diameter: Hold part in a well illuminated area
and inspect for slight scratches. If scratches are visible, use a 600 grit sandpaper to remove
them. ( See Pg.4 Picture 4.13 & 4.14 )
• Plug (16) & Insert (12): If the flow bore is washed and eroded larger than when the bore I.D.
was new, the plug and segment set can only be used when the wear conforms to the
guidelines detailed below. Since thebore will no longer be a perfect circle, you must measure
the largest gap from one side of the bore to the other. If the bore tapers in either direction,
measure the largest dimension. Compare the measurement to the following maximum
acceptable dimensions:
• 1" Plugs and Inserts - 1.090" max

See section 4.2 SANDING TIPS for sanding procedures

RSP - 1000 PAGE 4 OF 13
DATE:
REVISION:
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WRITTEN BY:
SECTION 4.0 - REPAIR AND INSPECTION con't Packing

PICTURE 4.11 VALVE BODY Ring bore
O-ring
groove area
Cap seal bore
of the pocket Threads
Threads
PICTURE 4.12 CAP

Packing Pocket walls
Ring bore
Inside
diameter
Outside
diameter
PICTURE 4.13 PLUG PICTURE 4.13 INSERT
Based on the guidelines stated above, if the Plug (16) & Inserts (12) don't meet this criteria they
must be scrapped. Due to increased turbulance and thin walls they will not be able to support the
working pressure of the valve anymore.
SECTION 4.1 - DISASSEMBLY TIPS
NOTE: If the BAR NUT (3) or CAP (14) appears to be stuck or locked, pressure may be trapped
in the valve. This is also known as "Pressure Locking." DO NOT ATTEMPT TO DISASSEMBLE
A "PRESSURE LOCKED" VALVE.
Release Pressure Lock
• The grease fitting allows for the safe relief of trapped pressure within a
valve. Extreme caution must be followed when attempting to relieve a pressure
locking situation. Slowly turn the grease fitting 1/4 CCW turn to relieve the
pressure.
• Actuate the valve to ensure all pressure has been relieved.

• After the removal of all trapped pressure, you may remove all components.
RSP - 1000 PAGE 5 OF 13
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REVISION:
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WRITTEN BY:
SECTION 4.2 - SANDING TIPS
Sanding is necessary to repair blemishes from the sealing surfaces of parts.
• Sanding of scratches, dings, and pitting should always be done with 600 grit
sanding cloth that is well lubricated with water or solvent. When sanding sealing
surfaces, it is VERY important to avoid sanding in one spot continuously; sand
evenly across the entire sealing surface. Sand scratches by moving the sandpaper
around the plug, not up and down, along the length of the plug. If scratches cannot
be removed utilizing this technique, replace the parts. If raised edges or dings in
non-sealing areas are too large to be sanded effectively, you may use a rotary
flapper-type sanding wheel. It is very important that you do not remove any material
other than the actual raised edge. Do not remove any of the base material or you
may permanently damage the valve and render it unsafe for use.
SECTION 4.3 - ASSEMBLY TIPS
When rebuilding / recertifying a Plug Valve out in service, you will encounter the issue of mixing old and
new parts together as you swap out parts deemed unusable for new ones. When doing this you need to
make sure that the parts being reused are free of any defects. After the valve is rebuilt it will be pressure
tested and any defects could cause leakage or damage to the valve or any internal components.
Refer to the sections below for detailed information.
See section 4.0 REPAIR AND INSPECTION for detailed repair and inspection instructions.
See section 4.2 SANDING TIPS for detailed sanding instructions.
See section 5.0 ASSEMBLY PROCEDURES for detailed assembly instructions.

RSP - 1000 PAGE 6 OF 13
DATE:
REVISION:
APPROVED:
WRITTEN BY:
SECTION 5.0 - ASSEMBLY PROCEDURE

TOOLS NEEDED:
1) 1" 1ft Breaker Bar 9) Rags 17) 600 Grit Sandpaper
2) 1" 3ft Breaker Bar 10) Socket Wrench 18) Emery Cloth
3) Hammer; 3-5 lb 11) 7/8" Socket
4) 1 11/16" Box Wrench 12) Flashlight
5) Screw Driver - flat head 6" 13) Degreaser
6) Rubber Gloves - surgical 14) Torque Wrench
7) Plug Valve Grease 15) Anti-Seize compound
8) Paper Towels 16) Male & Female end protectors
NOTE: It is imperative that the workstation being used to assemble the valve be clean and free of
anything that could possibly contaminate the grease such as metal shavings, dirt, rust, old paint,
etc. Do not sand or deburr near the workstation.
1. All Parts to be clean, free of chips, dirt and all foreign material ( SEE PG.11 PICTURE 1 )
• All Parts ( except nuts, washer, and o-rings ) must be washed, dried and free of both oil and
Rust preventative before being brought to assembly.
• Check surfaces around the valve bore inside the valve pocket for sharp edges that could cause
cutting of the insert o-rings.
• Then screw the clean CAP (14) all the way into the valve body to make sure the threads are
not damaged.
2. Install Valve Body (1) onto Fixtured table. Use a lift do not pick up without assistance.
( SEE PG.11 PICTURE 2 )
3. Install Retaining Ring, Wing Nut, and Segmented Rings
• Place Retaining Ring (9) on Male end / neck.
• Then place Wing Nut (7) on male end and install the Segmented Ring (8).
• Secure the Segmented Ring (8) with the Retaining Ring (9)
4. Apply Anti-Seize
• CAP (14) - Place the CAP (14) with the threaded end facing upwards. Apply a thin coat of
Anti-Seize to the first 1/4" of threads; 360 degrees around. Applying too much will result in
the Anti-Seize to have over flown and causing a mess that needs to be cleaned up before
paint. Place cap a side with threads facing up. ( SEE PG.11 PICTURE 3 )
• BOLTS (5) - Apply a thin coat of Anti-Seize to the first 1/3 of the length of the thread for
approximately 270 degrees around. 360 degree application is not necessary because too
much application will again result in overflow that will need to be cleaned before paint.
• GREASE FITTING (17) - Same as Bolts. ( SEE PG.11 PICTURE 4 )

RSP - 1000 PAGE 7 OF 13
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WRITTEN BY:
SECTION 5.0 - ASSEMBLY PROCEDURE con't

5. Apply Grease
• CAP (14) - (Still with threads facing upwards) - First, hand pack grease into the circular cavity.
Pack grease in a circular ring pattern allowing air to escape and thus making it easier for the
grease to flow and fill the void. Second, Thoroughly hand pack seal bore and the thru hole.
Finally, hand wipe grease into the o-ring groove of the cap. Fill groove approximately 1/2 full for
the entire 360 degrees. Too much will cause a mess that will have time consuming cleaning
process. ( SEE PG.11 PICTURE 5 )
• PACKING RING (15) - Work entire seal thru greased fingers. Make sure that the grease sticks
to the metal ring and fills the groove. Place greased PACKING RING (15), brass end facing
down into the seal bore of the CAP (14). Gently press the seal fully into the bottom of the bore.
• CAP O-RING (13) - Work entire o-ring thru greased fingers approximately 2-3 times. Install
o-ring into the o-ring groove of the CAP (14). Re-smooth grease around the o-ring with your
finger. Note: May need to add additional grease. Make sure grease entirely fills groove.
Important: Must be sure that o-ring is completely in groove or o-ring will be sheared off
during CAP (14) installation. Firmly press o-ring into groove and visually inspect. Smooth
grease such that grease coverage is uniform and all voids in groove are filled. Additional grease
may be needed. At this time, clear the insert groove of grease by using a flat screwdriver and
running it around the groove. The groove needs to have some grease in it in order to allow the
inserts to slide into place but the groove should not be completely filled for it will impede the
inserts from easily moving into place. At this time set the CAP (14) aside. Be sure that the
threads are still facing up. ( SEE PG.11 PICTURE 5 & PG.12 PICTURE 7 )
• INSERTS (12) - Thoroughly hand wipe grease on the inside of the curved surface of the
INSERTS (12). Make sure that there is an even layer approximately 3/16" thick. A little thicker
near the thru hole is desired. Remove excess build up of grease from undercut groove by taking
a regular screwdriver and score a grease groove. Do not completely remove grease from the
groove. Next hand wipe grease on the outside curved surfaces of the INSERTS (12). Be sure
that the o-ring groove is completely filled. Place the INSERTS (12) on the work surface with
lipped edge. ( SEE PG.12 PICTURE 8 )
• INSERT O-RINGS (11) - Work entire o-ring thru greased fingers approximately 2-3 times. Install
INSERT O-RING (11) into the o-ring groove of the insert by placing ring into groove and
pushing the o-ring hard with both thumbs starting at the 6 o'clock position and working around
the groove. Inspect o-ring to be sure it is fully in the groove. O-ring can be damaged during
valve assembly if the o-ring is not properly seated into the groove. Due to handling during
installation, it is necessary to re-distribute the grease that has already been applied to both the
inner and outer insert surfaces. At this time, run you finger into the grease of the role pin hole in
order to identify where the groove is located during installation. ( SEE PG.12 PICTURE 7 & 8 )
• VALVE BODY (1) - IMPORTANT: First, inspect body cross holes for sharp edges. Sharp
edges will cut o-rings and cause valve to leak requiring disassembly and repair. If sharp
edges exist, rub with emery cloth followed by scotch bright and wipe clean. Now its OK
to grease. By hand/thumb, coming from the bottom side of the VALVE BODY (1), generously
apply grease into the bottom 1/8 of the VALVE BODY (1): in the plug shaft bore, seal bore, and
up the plug bore. Make sure to thoroughly coat the bottom edge of the thru hole, even such that
grease is slightly into the hole. ( SEE PG.12 PICTURE 9 )
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• PACKING RING (15) - Grease as previous PACKING RING (15). Install PACKING RING (15),
brass ring face down, into the seal bore of the VALVE BODY (1). Make sure seal does not flip
during installation. Gently press seal fully into the bottom of the bore. At this time, re-distribute
grease evenly back on top of the seal and thru the shaft bore are.
• VALVE BODY (1) - Finish applying grease throughout the entire inside of the body, except for
the threaded area. Thickness should be approximately 1/4" thick, especially in the are of 3.5"
diameter around the thru hole. Longitudinal uniform strokes are best. A 3/16" thickness or
slightly thinner in the cap o-ring bore area works well. Thicker causes a mess when the
CAP (14) is installed and will have to be cleaned before painting. Be sure that the o-ring bore
is completely covered so the o-ring will slide into place and not be damaged during installation.
Take the ROLL PIN (10), dip one end in grease and insert, by hand, the greased end into the
hole in the VALVE BODY (1). Gently tap ROLL PIN (10) until it bottoms out in the hole. If
needed to, re-work grease for uniform coverage. After all pins are installed, make a grease
mark on the topside of the body indicating where the pins are located. This will be
helpful during assembly. ( SEE PG.12 PICTURE 10 )
• PLUG (16) - Visually inspect again for cleanliness and scratches. Must be free of both and
including preventative coatings or the grease may not stick causing leakage. Thoroughly hand
wipe grease on all exterior surfaces of the plug EXCEPT for the hex area. A 3/16" thickness on
the largest diameter with a little more around the perimeter of the thru hole, some in the thru
hole edge works best. Vertical uniform hand strokes throughout the length of the large diameter.
Place PLUG (16) aside with the hex end down for stability. ( SEE PG.12 PICTURE 11 )
6. SUB-ASSEMBLY; CAP (14), PLUG (16) & INSERTS (12)
• Place CAP (14) on work surface such that greased end is up and cross holes are down
towards the work surface.
• PLUG (16) into CAP (14) - Grasp the PLUG (16), with the HEX END UP, by holding the plug in
the thru hole area while being careful not to touch the greased surfaced. Use the hex end for
balance if needed. Insert the PLUG (16), NON HEX END, into the CAP (14) and press firmly
down until the PLUG (16) mates tightly with the CAP (14). PLUG (16) may need slight back and
forth rotation in order to get it into the CAP (14). Inspect PLUG (16) to make sure grease has
not been disturbed. If need to, re-work grease for uniform coverage. Note: that at the hex end
of the plug, there is a milled notch with arrows that align with the thru hole. Remember
this for future reference. ( SEE PG.12 PICTURE 12 )
• INSERTS (12) onto PLUG (16) - Grasp one half of the INSERTS (12), lipped edge facing down,
by holding on the edges and thru hole while not touching the inside or outside greased surfaces.
Slide the INSERT (12) on top of the CAP (14) until it touches the plug. Make sure that the thru
hole of the INSERT (12) lines up with the thru hole of the PLUG (16). Lipped edge of the
INSERT (12) must be trapped by the groove in the CAP (14). Be careful not to disturb the
greased surfaces of the PLUG (16) and the INSERT (12). Grab the remaining INSERT (12) and
install on the opposite side in a similar fashion as the first one installed. Press both
INSERTS (12) tightly against the PLUG (16). Inspect greased surfaces and re-work if needed.
Observe where the roll pin slots are located and re-mark if needed. Do not confuse the role pin
slots with the two gaps between the two INSERTS (12). Note the orientation of the milled slot
arrows on the PLUG (16). ( SEE PG.13 PICTURE 13 )
RSP - 1000 PAGE 9 OF 13
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7. ASSEMBLY; SUB-ASSEMBLY & VALVE BODY (1)
• Rotate SUB-ASSEMBLY PLUG (16) such that the CAP (14) is upright and the hex end of the
PLUG (16) is faced down towards the work surface. Be careful not to disturb the grease. Insert
a 1" diameter breaker bar into the CAP (14) cross holes.
• Lift SUB-ASSEMBLY PLUG (16) and position over the VALVE BODY (1) opening. Need to
align the following: Role pin grooves in the INSERT (12) with the ROLE PINS (10) in the body.
Remember the grease marks on the VALVE BODY (1) and the grease line on the
INSERTS (12) that were previously made. It is critical that these align. Damage may occur to
parts if the assembly process is continued with misaligned parts. Slowly lower the
SUB-ASSEMBLY into the VALVE BODY (1), checking alignment all the way. Gently push
assembly further into the VALVE BODY (1) until there is thread engagement with the CAP (14)
and VALVE BODY (1). Some gentile turning back and forth, less than 1/4 turn, of the CAP (14)
may be needed to help seat the thread engagement. Once engaged, place 1" diameter breaker
bar into the male end of the body so that it goes all the way thru the PLUG (16) and
INSERT (12) thru hole. This is to make sure that the plug & inserts do not rotate during
installation. ( SEE PG.13 PICTURE 14 )
• With either a 3ft or 1ft breaker bar, slowly screw in the CAP (14) into the VALVE BODY (1).
Turn 1 rotation at a time with a slight pause in between each rotation. This will allow air to
escape and grease to flow where it needs to. A 1ft bar may be desired to use at the start and
the replaced with a longer bar. As turning occurs you may hear popping (air) and grease will
flow out of the grease fitting hole. This is expected. Continue to screw the CAP (14) into the
VALVE BODY (1) until the INSERT (12) thru hole lines up with body thru hole. Use a regular
screwdriver to scrap along the body thru hole and feel the step created by the INSERT (12) thru
hole. Continue to screw the CAP (14) until the step disappears. Suggest to also use a flashlight
to get a visual indication of insert movement. Do not allow the PLUG (16) to turn/rotate while
the CAP (14) is being screwed down. The 1" diameter breaker bar should stop this from
occurring. When the step is no longer present the CAP (14) threads should be almost flush with
the top of the VALVE BODY (1), this is just a visual guideline and is not an exact fit. Step
removal using a screwdriver is the determining factor. When the INSERT (12) is close to
position, several 1/4 turns may be needed to get the proper position. DO NOT go pass the
flush position. ( SEE PG.13 PICTURE 15 )
8. FINISH ASSEMBLY
• Remove any grease from the top of the Plug / Cap area where the threaded hole is located.
Install the WASHER (4) and BOLT (5), and torque down the BOLT (5) with a ratchet to
approximately 65 ft-lbs for 2"-3" valves; 55 ft-lbs for 1" valves. Clean any grease and Anti-Seize
from the Cap and Body area using degreaser and break cleaner.
• Rotate the Valve such that the CAP (14) is facing the floor and the hex portion of the PLUG (16)
is up by loosening the table fixture then retighten the fixture. Remove all grease from the Body
and Plug by using degreaser and break cleaner. ( SEE PG.13 PICTURE 16 )
• Adjust the PLUG (16) so that the thru hole is wide open by aligning the milled slot of the
PLUG (16) with the inlet and outlet of the VALVE BODY (1).

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• Install the INDICATOR STOP BOLT (6) and FLOW INDICATOR (2). Note the position of the
FLOW INDICATOR (2) such that it is in the open position. Clean all grease.
• Place BAR NUT (3) on plug hex, with "KEMPER" at the 3 o'clock position. This is just for
consistency. Secure the BAR NUT (3) down with the WASHER (4) and BOLT (5).
• Remove grease from grease fitting hole and install the GREASE FITTING (17). Torque to
85 ft-lbs. Place black plastic cap back onto the fitting.
After complete assembly of the Plug Valve, it must be Hydrostatic Pressure Tested to the RATED cold
working pressure (CWP).
SECTION 6.0 - ASSEMBLY CONVERSION CHART
SIZES / CAN CONVERT INTO

STYLES
1" 2" 3"
GEAR OP
BAR OP NO CONVERSION NO CONVERSION HYDRAULIC
GEAR OP
HYDRAULIC AIR ACTUATED AIR ACTUATED BAR OP
HYDRAULIC
GEAR OP DOES NOT EXIST NO CONVERSION BAR OP
AIR ACTUATED HYDRAULIC HYDRAULIC DOES NOT EXIST

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PICTURE 1 PICTURE 2
PICTURE 3 PICTURE 4
PICTURE 5 PICTURE 6
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PICTURE 7 PICTURE 8
PICTURE 9 PICTURE 10
RSP - 1000 PAGE 13 OF 13
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PICTURE13 PICTURE 14
PICTURE15 PICTURE 16

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UNCONTROLLED-11/11/14 EXPIRES ONE (1) WEEK FROM SAID DATE

RSP - 1000 PAGE 1 OF 13