Axel Larsson 74-KS User manual

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MANUAL
BALL SECTORVALVE AL 74-KS / KSP
VALVE ACCEPTANCE INSPECTION
Make sure that the valve has not been damaged during transport and
that it is complying to your order.Valve body is marked with type,
pressure class PN, size DN, ow arrow, material code and, where
appropriate, CE-label with category and module according to PED
STORING
Valve shall be stored in a clean and dry area preventing corrosion and
fouling. It shall be operated to fully open position. Protection plates
shall not be removed until the valve shall be mounted.
INSTALLATION
This product shall only be inspected, installed and used by a person
who has relevant training or experience. If any questions or hesita-
tion, contact Axel Larsson AB. If the valve shall be equipped with ac-
tuator this shall be done before installation in the pipe line. Separate
instruction is supplied on request. Before installation of the valve,
check that the valve data is in conformity with actual type of service
with reference to media, pressure and temperature. If the valve shall
be used as shut-off valve against atmosphere at the end of the pipe,
where possible leakage can cause person injury or property damage,
there are special limits for max working pressure and, if necessary,
demands on blocking the actuator. Contact your valve supplier. Piping
shall be thoroughly cleaned. Check that the pipe anges are parallel
and that the piping system can not be subject to uncontrolled forces
caused by pressure peaks, or pipe forces caused by variations in
temperature.
IMPORTANT!
Install the valve in such position that injury on person, or damage on
property, is avoided in case of leakage from sealing or ange joints.
Also, make sure that, in case of leakage, inammable media do not
come in contact with electrical components or hot surfaces which
can cause re or damage on property.
The valve shall be operated into fully open position after installation
and the pipe system be properly ushed before put into service.
WARNING!
Risk for serious injury when valve with actuator is bench tested.
Avoid handling the valve with hands or ngers inside the valve! Be
very careful when handling a valve which has been in abrasive service.
Worn valve can have sharp edges on ball sector and seat.
GENERAL
AL 74-KS type KS and KSP are developed and used for controlling
gases, uids, pulp suspensions and slurry.Through its construction
the valve can also be used as a bi-directional shut-off valve.Valve can
be supplied in different material combinations depending on type of
media and service, see table page 4.Valve can be used for temperatu-
res from -400C to +2000C (+2500C).The exact temperature range is
depending on pressure, media and sealing material. Contact your valve
supplier if any uncertainty. See page 5 for tables with pressure and
temperature limits.
FUNCTION
AL 74-KS is made from a half ball, a ball sector, which is journalled in
a valve body via two shafts. One part of the ball sector sphere is used
for shut-off.The other part of the sphere has a hole with a diameter
which is about 80% of the nominal valve size.The ball sector is turned
900 from fully open to fully close. Some smaller valve sizes have a
more reduced orice and operation angle as follows; DN40/32 (700),
DN40/25 (600), DN25/15 (650), DN25/5 (600),
DN25/A-K (720).
ATTENTION!
Operating angle is max 90° and shall not be exceeded as it may cause
damage to the seat ring. If done so by mistake, the pressure on the
seat ring must be reduced! This is done by loosen the screws (item
11) on seat holding ring (item 2). Restore the ball sector to the right
position. Retighten the screws on the seat holding ring.
IDENTIFICATION
Valve size and material combination can be identied by marking code
on the valve body according to the following example:
PN 16 = Pressure class PN
g = Standard ow direction
KS = Type
DN 100 = Valve size DN
1 = Material combination
SS 2343 = Material in body
CHECK OFVALVE SIZE
The valve size can be checked by measuring the outlet port diameter
which is the same as the valve size.The inlet ow bore diameter is
always reduced to about 80% of the outlet port diameter. Sizes DN25
and 40 may be further reduced.

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MANUAL
BALL SECTORVALVE AL 74-KS / KSP
FLOW DIRECTION
The valve’s performance is equal regardless of ow direction.Alt-
hough it is recommended that the valve is mounted according to the
ow direction arrow.
START-UP
The valve shall be operated and controlled that closing- and opening
functions are correct before start-up. Check that the valve operates
within its max- and minpositions. Limit-switches, positioner, feed-back
signal and torque switches shall be checked for correct function.
Start-up shall be done gradually and under careful attention. If water
hammer, leakage, cavitations or noise occurs in the system they have
to be eliminated before they cause any harm.
DISMOUNTING FROM PIPELINE
Before the valve is dismounted from the pipe, all wiring in form of po-
wer supply and control signals as well as supply air has to be discon-
nected. If the valve is equipped with spring closing/opening actuator
thoroughly check that the valve has taken its fully closed or opened
position
VALVE POSITION INDICATION
The actual position of the ball sector can be dened on the lower
shaft end, opposite to the actuator:
Seat holding ring (item 2)
with seat (item 10)
Shaft (item 5) with
indication groove
Valve body (item 1)
OPEN CLOSE
DN 25-250
No Part
1 Body
1A Flange
1B Grub screw
2 Seat holding ring
3 Ball sector
4 Bearing sleeve
4A Split ring
8 Woodruff key
9 Bearing
10 Seat ring
11 Screw
12 Nut
13 O-ring
13A Sliding ring
14 O-ring
15 O-ring
16 O-ring
PARTS
DN 25-250
Attention!
Check that the pipe is depressurized and drained. Great caution must
be taken when there is a risk for toxic or corrosive media is captured
in the valve!

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MANUAL
BALL SECTORVALVE AL 74-KS / KSP
DN 300
No Part
1 Body
2 Seat holding ring
3 Ball sector
4 Bearing sleeve
4A Saftety ring
5 Shaft
6 Shaft
7 Seat support ring
8Key
9 Bearing
10 Seat ring
12 Grub screw
13 O-ring
13A Sliding ring
14 O-ring
15 O-ring
16 O-ring
19 Clamp ring
20 Screw
21 Nut
DN 300

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MANUAL
BALL SECTORVALVE AL 74-KS / KSP
DN 300 (12")
a) Loosen nuts (21), remove bolts (20) and clamping rings (19)
b) Remove inlet cover ring (2)
c) Lift out seat support ring (7).
d) Lift out seat ring (10) carefully from its groove using a pointed tool
and the O-rings (15 and 16).
e) Loosen screws (12) enough to loosen the bearing sleeves (4).
f) Pull the bearing (4) out from the shafts and out of the body or/and
knock on the shaft (6) and eventually on the bearing.
g) Push out the shaft (5) and eventually the bearing by means of a rod
inserted through the shaft hole.
h) Remove O-rings (13 and 14). Be careful not to damage sliding ring
(13A). See ”Reassembly”.
REASSEMBLY
Proceed in reverse order. O-rings (13, 14 15 and 16) shall be lubrica-
ted with suitable grease before reassembling. Please note ”Important
when assembling ” below. If the o-rings show sign of wear or other
damage, check if the most appropriate o-ring material has been used.
Check the sliding ring (13A) replace if necessary.The sliding ring is
not necessary for the valve function but will increase the efciency
and life of the shaft seal. Proper mounting of the sliding ring may be
done only with the appropriate tool as shown in g 2.
Important when reassembling:
DN 25 (1")
a) Check carefully that the groove for the o-rings (13 and 14) is clean
and free from damage.Also check the conical entrance on the
bearing sleeve and lower shaft hole on the body.
b) Apply silicon grease generously on the O-rings before assembling.
Mount the sliding rings (13A), and the ball sector (3) with tool
shown in g 2.
c) Mount o-ring (13) on the drive shaft but not on the lower shaft.
Insert the drive shaft into the big inlet hole in the body and then
into the big shaft hole so that the ball sector now is in the body.
d) Mount O-ring (14) on bearing sleeve (4) and roll up the bearing (9)
on its place in the bearing sleeve. Carefully mount the bearing
sleeve on the drive shaft taking notice that the bearing (9) and O-
ring (13) not is damaged.
e) Mount the split ring (4A) in its groove on the bearing sleeve(4)
then push the bearing sleeve out from the body until the split ring
meets the valve body. Hold the bearing sleeve in this position and
push the lower shaft through its hole in the body as much as it
needs to mount the O-ring (13) from the outside of the valve body.
Apply lubricant generously.
f) With greatest care, push the shaft and O-ring into its place in
the valve body using a proper tool, f. ex. the sliding ring tool, see g
2. Use the tool to push the O-ring, alternately pull the shaft, until
the O-ring reaches its sealing position.This position is reached
when the ball sector sphere are in the middle of the body.
g) Mount O-ring (15) and seat (10) in the holding ring (2) and O-ring
(16).Turn the ball sector clockwise into closed position.
h) Mount the seat holding ring with screws (11). Check that the seat
holding ring is in full contact with body. Eventually the holding ring
can be pressed to the body with help of a jaw vice with soft grips.
i) Turn the bearing sleeve so that the hole for the stop screw (1B)
pointing in right direction, then push the ange (1A) into position.
Mount stop screw (1B) carefully checking that it goes fully into the
hole in the bearing sleeve.
MAINTENANCE
Ramén Ball Sector valve requires no lubrication and a minimum of
maintenance. If any part of the valve should become damaged it can
be replaced by a spare part. Spare parts are obtained from the valve
distributor.Any spare parts order must indicate valve type (KS), size
(DN), material combination and item number according to the spare
parts list.
Design change
Valves type KS, DN40-300, which from the year 1997 are delivered
with a number 2 stamped before or after the type (2KS or KS2) are
supplied with a locking ring , pos 4A on the inside en of the shaft
(DN40-50) or on the bearing sleeve (DN80-300).
DISASSEMBLY
DN 25 (1")
a) Loosen and remove screws (11) and inlet cover ring (2).
b) Lift out seat ring (10) carefully from its groove using a pointed tool.
and the O-rings (15 and 16).
c) Loosen the nut (12) and pull out fastening ange (1A).
d) Push bearing sleeve (4) into the valve and remove split ring (4A).
e) Pull bearing sleeve (4) out from the valve body (1), and shaft with
ball sector (3) out from the bearing sleeve (4).
f) Remove Rulon bearing (9) from the shaft (3).
DN 40-50 (1 1/2" - 2")
a) Loosen screws (11) and inlet cover ring (2)
b) Lift out seat ring (10) carefully from its groove using a pointed tool.
and the O-rings (15 och 16).
c) Lift out seat support ring (7).
d) Loosen locking rings (18) and washer (17) at both trunnion shaft
ends.
e) Push the ball sector slightly so that the locking ring, 4A, can be
removed using a small screw driver. Pull out trunnion shaft (6) by
fastening it in a jaw vice and then knocking on the actuator ange
on the valve body.
f) Push out trunnion shaft (5) by means of a rod inserted through the
shaft hole.
g) Remove Rulon bearing (9) from the shafts.
h) Remove O-rings (13 and 14). Be careful not to damage sliding ring
(13A). See ”Reassembly”
DN 80-250 (3" - 10")
a) Loosen screws (11) and inlet cover ring (2)
b) Lift out seat ring (10) carefully from its groove using a pointed tool
and the O-rings (15 and 16).
c) Lift out seat support ring (7).
d) Loosen locking rings (12) enough to loosen the bearing sleeves
(4). Push the ball sector slightly so that the locking ring, 4A, can be
removed using a small screw driver.
e) Pull out the bearing sleeves (4) from the shafts and out of the valve
body, and/or trunnion shaft (6) by fastening it in a jaw vice and then
knocking on the actuator ange on the valve body.
f) Push out trunnion shaft (5) and eventually the sleeve (4) by means
of a rod inserted through the shaft hole.
g) Remove Rulon bearing (9) from the shafts.
h) Remove O-rings (13 and 14). Be careful not to damage sliding ring
(13A). See ”Reassembly”

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MANUAL
BALL SECTORVALVE AL 74-KS / KSP
j) Mount the nut (12) slightly with ngers. Fasten the ange (1A) into
a vice and tighten nut (12) hard with a box-spanner.
k) Turn ball sector between open and closed a few times to ensure
that the necessary torque is normal, approx 5 Nm, during the hole
stroke.
DN 40-50 (1½"-2")
(reassembly is done in reverse order)
Sliding ring (13A) can only be mounted with the tool shown in g 2.
When O-ring (13) has been placed in its groove on the shaft (5) and
drive shaft (6) and then pushed into the body great care must be
taken not to damage the o-ring. Fig. 3 shows a suitable method and
dimensions on a tool that will protect the O-ring (13) and Rulon
bearing (9) when assembling.
Check that the locking ring (4A) is undamaged and kept in some
tension in its groove after reassembly. Change ring if necessary.
DN 80 - 300 (3"-12")
(reassembly is done in reverse order)
Sliding ring (13A) can only be mounted with the tool shown in g 2.
Carefully push the bearing sleeve (4) with the O-ring (14).When the
O-ring passes the drilled hole for the stop screw (12) it might be
pressed into the hole with risk for damage. Check that the hole is
free from sharp edges or burrs.When the O-ring passes the hole it
can be pushed back from out side with a blunt end pin.
Check that the locking ring (4A) is undamaged and kept in some
tension in its groove after reassembly. Change ring if necessary.
After reassembly
Pressure test the valve with air from the valves outlet side and with
the valve closed.The valve immersed in water or with leakage spray
shall be bubble tight over shaft seals and seat. I small bubbles can be
detected around the shafts it can be enough to actuate the valve a
few times allowing the O-rings to nd its correct position. If the valve
still leaks the o-ring has been damaged and must be changed.Valves
with PTFE-seat shall be bubble tight in both directions.Valves with
stellited seat will never be bubble tight.These valves can be tested
with water. Max leakage for a new valve is 0,01% of the valves Cv/
Kvs-value.
Mounting actuator on the
valve - IMPORTANT!
a) Avoid to axially move the ball sector in the valve body. Never ham
mer on the drive shaft end when mounting the actuator.
b) The ball sector must not be turned more than 900 necessary to
operate the valve from closed to open position. If the ball sector
accidentally has been turned out of the range, the screws on the
inlet cover must be loosened and the contact pressure between
ball sector and seat ring reduced to zero before the ball sector is
returned to right position.
c) When the actuator is properly mounted and adjusted it shall turn
the ball sector 900 between open and closed. Closed position of
the ball sector sealing surface shall for optimum tightness be such
that the seat ring is located in the middle of the sealing surface as
indicated in g. 4.
Fig. 2 - Tool for mounting gliding ring and O-ring.
DN Dy Dj L1 L2 L3
150-200 32 26 100 40 36
250 38 32 110 45 42
300 50 40 130 60 55

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MANUAL
BALL SECTORVALVE AL 74-KS / KSP
Fig. 4 - Ball sector position when valve is closed.
Fig. 3 - Tool for mounting shaft and drive shaft.
Sliding ring (13A)
Bearing (9)
O-ring (13A)
Ball sector (3)
Seat ring (10)
Telephone [phone] •[email protected] •www.axel-larsson.se
STOCKHOLM GÖTEBORG MOTALA KARLSTAD FALUN SKELLEFTEÅ
Design and specications subject to change without prior notice.
Head Ofce: Truckvägen 12, P.O. Box 805, SE-194 28 Upplands Väsby (Stockholm), Sweden.