ITT Industries KNR Series User manual

ITT RICHTER CHEMIE-TECHNIK
The Answer to Corrosion Series KNR
Operating Manual
for Control Ball Valves
with One-piece V-Control Ball/Stem and
Richter ENVIPACK Universal Packing Box
Contents
1 General
2 Safety
3 Transport and storage
4 Product description
5 Installation
6 Operation
7 Maintenance
8 Malfunctions
9 Tables, diagrams,drawings
Total No. of pages 8
Local agent:
See order
Reprinting is generally permitted,
indicating the source.
However, our prior written consent must
be obtained in all cases.
Note:
Before transport, installation operation, etc. TM 2795 en Edition 4/96
read these instructions carefully!. TIE/Wi/Wm Version 1.1
ITT Richter Chemie-Technik GmbH
Otto-Schott-Strasse 2
D-47906 Kempen/Ndrh.
Telephone [phone]
Fax [phone]

2 Edition 4/96
Technical Memorandum: TM 2795 en Version 1.1
1 General
The German version of these operating instructions is autho-
ritative.
RICHTER ball valves comply with the general delivery conditions
for valves as per DIN 3230 resp. MSS SP-72.
Enclosed operating instructions for accessories are also to be
carefully read and observed.
1.1 Use
The universal corrosion-resistant fluoroplastic lining of the valve
makes it ideally suited for aggressive media.
When the valve is to be employed using alternative operational
data, the operating company has to carefully consider whether the
valve and accessories are suitable for the new application.
1.2 Product data
Type code
KNR : Control ball valve with lever
or with actuator
Nominal diameters : 25, 40, 50, 80, 100, 150, 200
2 Safety
The safety precautions in these operating
instructions are specially marked with the standard
symbol for danger when non-observance could
endanger personnel.
The non-observance of these safety precautions
can affect the valve and impair its operation.
2.1 Qualifications and training of personnel
The personnel responsible for installation, operation and
maintenance must hold the appropriate qualifications.
The operating company must precisely define the responsibilities,
competence and supervision of the personnel. If the personnel
lack the necessary knowledge, they are to be trained and
instructed.
If required, this can be carried out by the manufacturer/ supplier of
the valve at the request of the operating company.
Furthermore, the operating company is to ensure that the contents
of the operating instructions have been fully understood by the
personnel.
2.2 Dangers through non-observance of the
safety precautions
The non-observance of the safety precautions can lead to the loss
of all claims for damages.
Non-observance may - for example - result in the following:
- failure of important functions of the valve / plant.
- endangering of personnel by electrical, mechanical and
chemical influences.
- endangering the environment through leakage of dangerous
media.
2.3 Safety awareness at work
Attention is to be paid to the following:
- The safety precautions in these operating instructions.
- The national regulations concerning accident prevention.
- The working, operating and safety regulations of the operating
company.
2.4 Safety precautions for the operator/user
- If hot or cold components of the valve are a source of danger,
the operating company has to secure these components
against contact.
- Contact guard for moving parts must not be removed when
valve is in operation.
2.5 Safety precautions for maintenance
Work on remotely actuated valves is only to be carried out when
they are at a standstill.
Valves delivering harmful media which are a health hazard must
be decontaminated.
On completion of work, all safety and protective equipment must
immediately be refitted resp. reactivated.
Before reoperation, attention has to be paid to the instructions in
the section "Initial start-up".
2.6 Unauthorized reconstruction and
manufacture of spare parts
Reconstruction or alterations to the valve are only permissible with
the agreement of the manufacturer.
Original spare parts and accessories authorized by the
manufacturer serve to maintain safety.
The use of unauthorized parts can annul all liability of the
manufacturer for the consequences.
2.7 Improper operation
The operational reliability of the valve supplied is only guaranteed
when used as designated, as laid down in Section 1 of these
operating instructions.
The application limits given on the identification plate must not be
exceeded under any circumstances.
3 Transport and storage
The universally recognized rules of technique and
the regulations regarding accident prevention have
to be observed at all times during transport
handling.
3.1 Transport
The goods have to be handled with care in order to avoid damage.
The flange caps provide protection during transport and may not
be removed.
CAUTION !

3 Edition 4/96
Technical Memorandum: TM 2795 en Version 1.1
3.2 Unpacking
Immediately after unpacking, the shipment is to be checked in
respect of entirety and possible transport damage.
3.3 Storage
If the valve is not to be installed immediately on delivery, it must
be properly stored.
Storage should be in a dry room at a temperature as constant as
possible.
Storage over a longer period may necessitate individual moisture-
proof packaging. This is dependent on the local conditions.
3.4 Return shipment
Operators of valves used for aggressive or toxic
media have to ensure that the valves have been
well flushed and cleaned before being handed to
the maintenance personnel.
This is of particular importance when returning to
the manufacturer.
3.4.1 Certificate of safety
A certificate of safety in accordance with EUROPUMP relating to
the application has to be enclosed with the return shipment.
If necessary, safety and decontamination measures are to be
included.
Forms can be obtained from Richter.
4 Description of product
Control ball valves of the series KNR with V-control ball/stem are
suitable for shutting off and controlling media in pipelines.
The drawings in Section 9 show the construction.
4.1 Housing
The housing of the valve consists of a body and an end piece.
As per DIN EN 19 and MSS SP-25, the body carries the following
data:
- nominal diameter
- nominal pressure
- body material
- lining material
- manufacturer's mark
- foundry sign
- cast charge number
4.2 V-control ball/stem
The main advantage of a one-piece V-control ball/stem is the
transmission of force free of play. This is of particular importance
for plastic-lined components.
The end surface of the stem respectively the pivot are marked
with:
- direction of flow
- flow rate Kvs resp. Cv
- lining material
The closing occurs clockwise, seen from the top of the valve.
4.3 Richter ENVIPACK universal packing
The packing insert is permanently connected to the thrust ring.
The spring gland follower exerts a relatively even pre-loading.
4.4 Valve actuation
The ball/stem has a pivot to attach a lever resp. a coupling.
Lever resp. pivot parallel to the axis of the pipeline:
Valve open
Lever resp. pivot at right angles to the axis of the pipeline:
Valve closed
---------------------------------------------------------------------------------------
In the case of a coupling, a red mark indicates the position of the
ball.
Mark parallel to the axis of the pipeline:
Valve open
Mark at right angle to the axis of the pipeline:
Valve closed
The transmission of torque is made free of play:
- by a sleeve nut
- by a setscrew
4.4.1 Actuated by lever
The lever is attached to the pivot of the stem and fixed with a bolt.
A lever stop limits the rotation.
4.4.2 Actuated by worm gear
Richter ball valves can be operated with all commercially available
worm gears which are equipped with an
F-connection as per ISO 5211.
Couplings and brackets are part of Richter’s range of products.
4.4.3 Remotely actuated
Richter ball valves can be remotely actuated by means of
pneumatic, hydraulic or electric quarter-turn actuators with an F-
connection as per ISO 5211.
Couplings and brackets are part of Richter’s range of products.
4.4.4 Required breakaway torque
The breakaway torque of the actuator must be
at least as high as the breakaway torque of the
valve, about 20% higher being better however.
Media of higher viscosity and/or those with solids may require an
increased factor of safety when calculating the size of the actuator.
This is particularly true for non-Newtonian liquids such as high
polymer substances, suspensions, pastes, lubricants, resins,
lacquers etc.
Admissible factors of safety lie in the range of 20 - 50% of the
breakaway torque.
To prevent damage to the valve, particular attention must be paid
to the maximum admissible breakaway torque in
Section 9.
CAUTION !

4 Edition 4/96
Technical Memorandum: TM 2795 en Version 1.1
4.5 Identification plate
An identification plate permanently fitted onto the shell contains
the following information:
- valve series, nominal pressure, lining material
- admissible operating pressures at admissible temperatures
- Richter serial-no.
- possibly, customer details
Example of serial-no.: 96 4875/2/1
In case of queries please state the serial-no. of the valve.
An additional plate points out: - direction of flow
- control characteristic
- flow rate Kvs resp. Cv
5 Installation
Contamination or damage of the sealing surfaces can best be
avoided by leaving the flange caps on the flanges until just before
installation.
To prevent the sealing surfaces being damaged by the mating
flanges, we recommend the installation of gaskets.
When there is a considerable danger of damage to the plastic
sealing surfaces, e.g. with mating flanges of metal or enamel,
PTFE-lined seals with a metal inlay should be used.
5.1 Location and direction of flow
Any fitting position can be chosen, but the installation is dependent
of the direction of flow.
5.2 Earthing of the valve
The earthing is effected via the pipeline bolts.
The V-control ball/stem is earthed via a grounding spring washer.
6 Operation
6.1 Initial start-up
Normally the valves have been tested for
tightness with water and air. Unless other
arrangements have been agreed to, there may still be a residual
quantity of water in the flow section of the valve. This is to be
taken into account due to a possible reaction with the operating
medium.
Following the initial loading of the valve with operating pressure
and operating temperature, the torques of all connecting bolts
must be checked. For table of torques see Section 9.
6.2 Shut-down
Before loosening the flange bolts:
- ensure plant to be free of pressure
- flush out medium
- observe safety regulations
Having dismounted the valve, immediately protect the flanges
against mechanical damage by means of flange caps.
6.2.1 Additional information for KNR with
actuator
Ensure that a remotely actuated actuator cannot
be accidentally switched on.
6.3 Inadmissible modes of operation and their
consequences
•Crystallisation must be prevented (e.g. by means of heating
the valve). Damage to the seat rings or the V-control
ball/stem would otherwise be unavoidable.
•In extreme cases, the ball can be blocked.
•Accelerated wear is the result of operation with solids.
•Operation during cavitation leads to increased wear.
•Non-observance of the pressure-temperature diagram can
lead to damage.
7 Maintenance
7.1 Tightness
Sporadic check in accordance with the plant requirements on the
following pieces:
•Packing
•Flange connections body / end piece
•Flange connections to pipelines
7.2 Screwed connections
Sporadically check the torques of the following pieces in
accordance with the plant requirements:
•Packing nuts
•Housing bolts
•Pipeline bolts
For torques, see Section 9.
7.3 Cleaning
Before beginning maintenance, the valve is to be
thoroughly cleaned.
The V-control ball/stem must be set into "semi-
open" position. Even with proper cleaning and
flushing of the valve, a residual quantity of medium
may remain in the valve, e.g. between the sealing surfaces.
The plastic components may have also absorbed medium which
gradually seeps out of the material following cleaning.
For this reason, regulation safety clothing is to be worn. See also
Section 3.4.
CAUTION !

5 Edition 4/96
Technical Memorandum: TM 2795 en Version 1.1
7.4 Dismantling
7.4.1 KNR with lever
- Remove lever.
- Dismount packing gland follower resp. spring gland follower.
- Dismount thrust ring together with packing insert and
grounding spring washer.
- Remove end piece.
- Pay attention when dismounting the ball/stem not to damage
the body lining.
- Remove seat rings.
7.4.2 KNR with actuator
- Loosen the sleeve nut at the coupling approx 2
rotations.Before doing so, notice the drawing in Section 9.
- Loosen the setscrew in the coupling 1 rotation.
- Remove actuator and coupling.
- Dismount packing gland follower and spring gland follower.
- Remove bracket.
The remaining disassembly is carried out as described in Section
7.4.1.
7.5 Assembly
- Position seat rings in the body and in the end piece.
- Pay attention when mounting the V-control ball/stem not to
damage the body lining. Notice the direction of flow.
- See also drawing in Section 9.
- Mount the end piece. Tighten the greased nuts only handtight.
housing
- Adjust V-control ball/stem.
- Press in packing insert together with thrust ring.
- Press in grounding spring washer.
- Tighten housing nuts crosswise with a torque according to
Section 9.
7.5.1 KNR with lever
- Mount lever stop. In doing so, notice direction of rotation of V-
control ball/stem. See drawing in Section 9.
- Mount spring gland follower and packing gland follower. In
doing so, notice central position. Observe torques in
Section 9.
- Close tapped holes still open with sealing caps.
- Mount lever.
7.5.2 KNR with actuator
- Mount the bracket with the opening at right angle to the
direction of flow.
- Mount spring gland follower and packing gland follower. In doing
so, notice central position. Observe torques in Section 9.
- Mount coupling and actuator. In doing so, notice direction of
rotation of V-control ball/stem. See drawing in Section 9.
- Position of the actuator in accordance with the operating
instructions of the actuator.
- Tighten the setsrew in the coupling.
- Tighten the sleeve nut at the coupling firmly. Before doing so,
notice the drawing in Section 9.
7.6 Conversion from lever to actuator
- Remove lever.
- Remove spring gland follower, packing gland follower, lever
stop and sealing caps.
- Check the fits of coupling, bracket and actuator.
The further assembly occurs as in Section 7.5.2 described.
7.7 Tests
Following the assembly, the valve has to be tested.
•Measurement of the breakaway torque
The breakaway torque required for opening and closing the
valve is to be ascertained. The maximum torque must not
exceed the values given in Section 9.
•Tightness
The tightness of the packing and the seat rings must be
tested.
Tightness is verified according to DIN 3230 part 3, BF and BO,
leak rate 1 respectively MSS SP-72.
Test medium: air
Test pressure: 6 bar
Test temperature: 15 to 35oC
Test period: to DN 40 15 seconds
DN 50 to DN 150 60 seconds
DN 200 120 seconds
8 Malfunctions; causes and their elimination
•Flange connection valve/pipeline leaking
Tighten screw connections with torque according to Section 9.
Should this not produce the required tightness, the
recommended torque may be exceeded by 10%.
If this fails to stop the leakage, dismount and inspect the valve.
•Flange connection body/end piece leaking
Tighten housing nuts. Same procedure as above.
•Packing leaking
Tighten packing nuts according to details in Section 9.
•Valve does not switch
Is the actuator supplied with power ?
Has a directional control valve been correctly connected ?
Is there foreign matter in the ball valve ?
•The ball fails to fully close
Is the stem deformed ?
Is the coupling worn ?
For worm gears or actuators check whether the limit stops can
be adjusted. Refer to the operating instructions issued by the
manufacturer of the worm gear or actuator for details.
Never actuate valve by force or by adding
pipe extension to lever.
1. Try to get the valve running by carefully switching
on and off.
2. Remove the lever stop and try to actuate the valve
against the normal direction of rotation.
3. If an actuation with the maximum admissible torque
as given in Section 9 does not prove possible, the
valve is to be dismounted and individual
components are to be checked.
CAUTION !

6 Edition 4/96
Technical Memorandum: TM 2795 en Version 1.1
9 Tables, diagrams, drawings
9.1 Connecting dimensions
- Face to face : See order
- Flange bores : See order
- Actuator : ISO 5211 F05 for DN 25
F07 for DN 40 and DN 50
F10 for DN 80 and DN 100
F12 for DN 150 and DN 200
9.2 Weights (with lever)
DN Kg
25 6
40 14
50 16
80 35
100 55
150 105
200 120
9.3 Flow rates Kvs in m3/h
3 different flow rates available for each DN
DN Kvs1
m3/h
Kvs2
m3/h
Kvs3
m3/h
25 8 14 20
40 16 25 40
50 25 40 60
80 80 120 160
100 100 160 250
150 160 250 400
200 160 250
9.4 Flow rates Kvin %
angle of Kv
opening
%%
10 5,5 Characteristic : equal percentage
20 7,6 Rangeability : 1:25
30 10,5
40 14,5 Best control range:
50 20,0 20-90% of the angle of opening
60 27,6
70 38,1
80 52,5
90 72,5
100 100,0
9.5 z - values
for the different V-control ball/stem
according to the Kvs-values in Section 9.3.
at Kv/ Kvs = 75 %
DN z1 z2 z3
25 0,60 0,58 0,43
40 0,53 0,50 0,35
50 0,47 0,39 0,32
80 0,31 0,29 0,22
100 0,27 0,24 0,16
150 0,15 0,13 0,08
200 0,15 0,13 0,08
XF≤z : non-critical conditions
XF≤1,4 x z : tolerable cavitation
XF>1,4 xz : unacceptable cavitation
9.6 Breakaway torques
DN ∆p in bar
3 6 10 16 max.perm.
Nm Nm Nm Nm Nm
25 12 12 12 12 28
40 20 20 20 25 80
50 25 25 25 30 100
80 60 60 65 80 250
100 80 80 90 170 350
150 200 250 350 ./. 1200
200 200 250 350 ./. 1200
Testmedium: Water 20 °C. For other media, higher
breakaway torques can occur.
9.7 Torques
Bolts greased, tighten crosswise
Packing nuts: See Section 9.9
Housing nuts Pipeline bolts
DN number and size Nm number and size Nm
25 4 x M12 35 4 x M12 12
40 4 x M16 45 4 x M16 22
50 4 x M16 45 4 x M16 30
80 8 x M16 50 8 x M16 25
100 8 x M16 60 8 x M16 30
150 8 x M20 150 8 x M20 55
200 8 x M20 150 8 x M20 75
9.8 Pressure-Temperature-Diagram
XF=differential pressure ratio of the plant
∆p=differential pressure inlet/outlet
p1=absolute pressure at the inlet
pv=vapour pressure at operating temperature
XF=
∆p
p1- pv

7 Edition 4/96
Technical Memorandum: TM 2795 en Version 1.1
9.9 Sectional drawings

8 Edition 4/96
Technical Memorandum: TM 2795 en Version 1.1