KLINGER SCHÖNEBERG RK-Chemoball Series User manual

Operating instruction ball valves
RK-Chemoball, RK-Proball, RK-Ecoball page 1 of 7 Valid from 12 2013
Operating instructions for
KLINGER SCHÖNEBERG ball al es
type RK-Chemoball, type RK-Proball and type RK-Ecoball
Contents
1
Validity................................................................................
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2
Authorised use and maximum loading...........................................
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3
Type models.........................................................
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4
Safety.............................................................................................
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4.1
Safety instructions..........................................................................
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4.2
Work on the valve...........................................................................
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4.3
Personnel.......................................................................................
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4.4
Instructions for the operator.........
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3
5
Installation......................................................................................
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5.1
General...........................................................................................
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5.1.1
Ball valves with flange connection.....................................
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4
5.1.2
Ball valve with threaded ends..............................................
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4
5.1.3
Ball valves with butt weld ends.............................
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5.2
Valves with actuators.....................................................................
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5
5.2.1
General instructions..........
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5
5.2.2
Functional testing................................................................
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5
6
Operation........................................................................................
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7
Storage and transport.....................................................................
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8
Maintenance...................................................................................
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6
9
Putting out of action and dis
assembly of ball valves......................
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9.1
General...........................................................................................
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7
9.2
Actuators........................................................................................
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7
10
Inspection........................................................................
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7

Operating instruction ball valves
RK-Chemoball, RK-Proball, RK-Ecoball page 2 of 7 Valid from 12 2013
1
Validity
These operating instructions are applicable to the valves given below:
RK
-
Chemoball KH2F
, KH3WF
RK
-
Proball KH
1T
M,
KH 1T W,
KH
2T
M,
KH 2T E, KH
2T K, KH 2T K
-
HP,
KH
2T
F,
KH 3T M, KH 3T S, KH 3T SV, KH 3T F, KH 3W M,
RK
-
Ecoball KHe
1T
M, KHe
2T
M,
KHe 2T E, KHe 2T K, KHe 2T F,
KH
e
3T
M, KHe
3T
S
2
Authorised use and maximum loading
Ball valves are valves with an “open
-
closed” function.
They must be used only for approved media
under approved pressure and temperature conditions.
If the permissible technical parameters, such as pressure or temperature, are not observed, or
if media are used which are not suitable for the valve material, a guarantee of safety is no
longer possible. The valves must not be used at pressures
and temperatures higher than the limit values given in the relevant technical data sheet. This causes
overloading of the valves which they cannot withstand. In this case the manufacturer accepts no
responsibility for the consequences.
Possibly occurring pressure surges (water impact) should not exceed the maximum permissible
pressure. Suitable protective measures must be taken to prevent this.
With driven val
ves it is absolutely essential that the specified connected loads are observed
-
also the
installation and maintenance instructions, as well as the operating instructions for the drive.
3
Type models
Actuation:
The ball valves are actuated by a hand
lever, a gear or by means of a pneumatic or electrical
actuator.
Connection:
The ball valves are connected by a flange, thread or butt weld ends (see respective data
sheet).
Special models:
Use a suitable special model if there is danger of an e
lectrical discharge, in
contact with oxygen, if leakage monitoring is required, if there is danger of frost or fire or at
high temperatures.
4
Safety
4.1
Safety instructions
•
If these safety instructions are not followed all claims for damages a
re forfeited.
•
In addition to the safety instructions given in these operating instructions the existing
national regulations for prevention of accidents, as well as the occupational, operating and
safety instructions of the operating firm, must also be observed.
•
When using the valves acknowledged technical rules must be observed, e.g. standard
specifications, leaflets and work sheets, VDI – VDE (Association of German Engineers,
Association of German Electrical Engineers) directives etc. With plants requiring
monitoring the important relevant laws, directives and technical rules must be observed.

Operating instruction ball valves
RK-Chemoball, RK-Proball, RK-Ecoball page 3 of 7 Valid from 12 2013
•
Actuation of the ball valves should be uniform and not too fast, since movements which
are too fast or jerky can cause overloading of the system through medium surges (water
impacts).
•
Heating or cooling should not be too fast in order to prevent overloading of the material
through ununiform temperature distribution
•
If pneumatic or electro
-
mechanical drives are used safety of the operating or maintenance
personnel should be ensured since with these drives there is a danger of pinching or
squeezing. If necessary guards should be fitted.
4.2
Work on the al e
•
Work on the valve should be carried out only in a depressurized and cooled state. At the
same time the temperature of the medium should be below the evaporation temperature
in all areas coming into contact with the medium.
•
Work on (driven) valves should be carried out only with the system at a standstill. It is
absolutely essential that the procedure for shutting down described in the operating
instructions is followed. Valves which come into contact with media which are detrimental
to health must be decontaminated.
•
Immediately after completion of the work all safety devices and guards must be r
efitted or
put back into operation.
4.3
Personnel
The valves should be used only by expertly trained personnel.
KLINGER SCHÖNEBERG
ball valves
have been manufactured according to the current state of the art, and are reliable and safe to operate.
However, these valves can be dangerous if they are used by untrained personnel or are used
improperly, since they are comparable with pressure vessels. The following points must therefore be
observed.
•
Personnel must be expertly trained.
•
The operating fi
rm must ensure that the contents of the operating instructions have been
completely understood by personnel.
•
Personnel responsible for operation, servicing and installation must understand the
interactions between the valve and plant.
•
Faulty operation
of a valve can lead to serious consequences, e.g.:
•
Leakage of medium
•
Standstill of the plant machine
•
Impairment (reduction increase of the effect function) of the plant machine
•
Failure of important functions of the valve plant
•
Fail
ure of specified methods for maintenance and repair
•
Endangering of persons through thermal, electrical, mechanical or chemical effects
•
Endangering of the environment through leakage of dangerous materials
Improper handling can cause danger to pers
ons, property and the environment through
leaking medium. Therefore, in addition to observing these operating instructions, all relevant
accident prevention regulations and technical rules must also be followed.
4.4
Instructions for the operator
•
If
hot or cold valve components cause danger (e.g. housing components or hand lever)
these components must be guarded to prevent contact touching by the operator
(customer’s obligation)

Operating instruction ball valves
RK-Chemoball, RK-Proball, RK-Ecoball page 4 of 7 Valid from 12 2013
•
Leakage (e.g. spindle sealing material) of dangerous conveyed materia
l (e.g. explosive,
toxic, hot) must be removed in such a way that there is no danger to persons and the
environment. Legal regulations must also be observed.
•
Danger from electrical energy must be eliminated (for details see, for example, the
regulations of the VDE and local power supply companies).
KLINGER SCHÖNEBERG
GmbH accepts no liability for damage or faults
occurring
during operation
which are caused through improper handling or non-observance of these operating instructions, as
well as for any changes made to the valves without agreement with the manufacturer.
5
Installation
5.1
General
The ball valves can be installed at any required position using normal pipe installation methods. Care
should be taken that the ball valves are easily accessible for operation.
Any direction of flow can be installed (with the exception of types with pressure relief drill holes). The
ball valves can also be installed where there is a change in the direction of flow. Ball valves with a
specified direction of flow are marked accordingly by means of an arrow.
Valves and pipes which are operated at high (> 50°C) or low (< 0°C) temperatures must be protected
against contact by insulation, or an appropriate sign indicating the danger on contact must be provided.
If condensation water is formed or there is danger of icing up in air
-
conditioning units, cooling or
refrigeration plants, suitable diffusion-resistant insulation of the complete valve is necessary, possibly
also including the hand lever. If ice is formed there is a risk that the actuating function of the valve will
be blocked. In such cases please enquire about “low temperature version” special types.
If a ball valve is installed in a pipe as the terminal valve this should be secured against
unauthorised or accidental opening using suitable measures. This will avoid damage to persons
or property since there is a danger of injury on closing the valve.
During installation no static or dynamic forces should act on the ball valve. The ball valve
s should not
be used as a fixed point on the pipe. Damaging tensile, pressure or bending forces must be kept away
from the valves, in order to avoid seal leakage and fracture of the housing. The plastic caps should not
be removed until shortly before installation of the ball valve. The pipe must be rinsed to remove dirt,
scale, burr, zinc and welding residues etc, since otherwise this can cause damage to the ball or seals.
5.1.1.
Ball al es with flange connection
During installation it is partic
ularly important to ensure parallelism of the pipe flange and
perfect close fitting. Only suitable screws, nuts and seals should be used. If necessary the
relevant installation instructions for fitting the seals, as well as media and temperature
compatibility, are to be observed. The seals must be properly centred. The screws must be
tightened crosswise using the specified torque.
5.1.2.
Ball al es with threaded ends
Connection according to
EN 10226
-
1
:
The valve is connected to the pipe with a interna
l screw thread,
according to EN 10226-1. This is a system in which the pipe thread seals into the connecting thread.
Fittings or pipes with a tapered outside thread and a suitable sealant are to be used as counterpart.

Operating instruction ball valves
RK-Chemoball, RK-Proball, RK-Ecoball page 5 of 7 Valid from 12 2013
Connection according to
E
N ISO 228
-
1
:
The screw connections have a internal screw thread
according to EN ISO 228-1. This is a system in which the pipe thread does not seal into the connecting
thread. Fittings or pipes with a cylindrical outside thread and a seal are required, for example, as
counterpart. The seal should be inserted between the supporting surface of the flange sleeve and the
flat front surface of the counterpart and then compacted. The sealing surfaces must be metallically
clean and dry. Suitable seals should be used (pay attention to temperature and medium resistance), and
the relevant applicable installation instructions are to be observed.
The housing of the ball valves has an attached hexagon on both sides. This enables the the ball
valve to be held in the required installation position by means of a suitable tool when screwing
in the counterpart, and the screwing forces can be countered.
5.1.3
Ball al es with welded connection
These ball valves are suitable for use with the gas and arc welding processes. Pro
per sealing can be
guaranteed only if welding has been carried out expertly.
Extended butt weld ends
The construction length is selected in such a way that, with correct execution of the weld the
complete valve can be welded in. The following points must be observed here:
•
Tack weld the ball valve in the pipe with at least 3 welding spots (offset at 120°)
•
Weld together
–
colour
-
change crayons are recommended for checking the temperature.
The temperature during preheating and welding should not exceed 200°C in the area at
the edge of the housing. Cooling during the welding operation is advisable.
•
After the weld seam has cooled down the housing screw connections are tightened with
the specified torque (see technical data sheet).
•
Carry out a func
tional check.
Butt weld ends
•
Tack weld the ball valve in the pipe with at least 3 welding spots (offset at 120°) per
connection.
•
Dismount the ball valve and mount a spacer in its place.
•
Weld the connections completely and allow to cool.
•
Remove
the spacer and mount the ball valve. In doing so observe the specified torques for
the housing connecting screws (see technical data sheet).
•
Carry out a functional check.
5.2
Val es with actuators
5.2.1
General instructions
Electrical lines
must be connected only by competent persons. The VDE 0100 and VDE 0165
(Explosion Protection) regulations are to be observed. All electrical devices, such as servo
drives, switch boxes, solenoid valves, limit switches etc must be installed in dry areas
protected from flooding. The voltage and frequency must correspond to the data given on the
name plate. If the user fits a self-automation system the mechanical stops must be removed.
5.2.2
Functional testing
The shutting off function should be tested
by operating several times. For valves with electrical and
pneumatic drives the regulating distances forces must be limited. For this the operating instructions of
the drive manufacturer must be followed.

Operating instruction ball valves
RK-Chemoball, RK-Proball, RK-Ecoball page 6 of 7 Valid from 12 2013
6
Operation
The ball valve is opened and
closed by turning the hand lever or the control shaft through 90°. The
valve closes when turned to the right (clockwise). The ball valve is opened when the hand lever is
positioned parallel to the pipe. If the hand lever is removed the position is indicated by the dihedron
(valve open when dihedron is parallel to the pipe). Ball valves are not suitable for regulating the flow.
The hand lever should be operated slowly.
If a medium with extremely high expansion through temperature change is used pressur
e
relief must be provided. For this please follow the relevant operating instructions. If pressure
is relieved by drilling a hole the ball valve can be operated only in one direction of flow.
If the ball valve is used for a purpose other than that for
which it was intended, e.g. continuous use in
the throttling position, this will cause increased wear. If the hand lever is used improperly, for example
by using a lever extension, or if it is used as a climbing aid, correct functioning will be impaired. If the
valve is not operated for a long period the actuating moment may have to be increased. To remedy
this we recommend regular functional checks. If the surface is damaged through impact or friction this
can cause corrosion, and can therefore lead to a reduction in the service life.
7
Storage and transport
Ball valves should be stored in a dry place, protected from contamination. When loading and unloading,
as well as during transport of the valves, care should be taken that the ball valves are not thrown or
knocked, in order to avoid damage. Covers which may have fallen off should be cleaned and replaced.
The ball valves have been protected against corrosion before leaving the works.
The ball valves must be stored in the opened position. The
plastic caps should not be
removed. The ball valves should be protected against environmental influences, such as
moisture, wetness, rain, dust, dirt, sand, mud, salty air or drizzle and salt water.
During storage temperatures should not drop below or exc
eed the values
–
20°C to + 50°C. Rapid
changes in temperature should be avoided as far as possible (development of condensation water).
Lubrication is recommended following long storage (caution
–
not with the oxygen model). The ball
valves should subsequently be opened and closed at least twice.
For valves with single
-
acting actuators (e.g. pneumatic actuators with spring closed or similar system),
in which the “closed” position is required as final position in a pressureless state of the control circuit,
it is permissible to supply the valve in the closed position. If necessary the valve should be cleaned
before installation.
Specially actuated valves with mounted solenoid valves and limit switches must be treated
extremely carefully. The packing should be removed preferably shortly before installing. Do
not knock heavy valves on hand levers or mounted components.
8
Maintenance
If used properly
KLINGER SCHÖNEBERG
ball valves are maintenance
-
free. Correct functioning and
sealing should be checked at regular intervals. If maintenance is required please observe the following
points:
Maintenance work should be carried out only by trained specialists. If maintenance is carried
out while the valves are in operation, there must be no residual pressure in the line and in the
ball valve. The ball valve should be opened and closed at least once in order to ensure that the
dead volume is also no longer under pressure.

Operating instruction ball valves
RK-Chemoball, RK-Proball, RK-Ecoball page 7 of 7 Valid from 12 2013
In case of leakage correct fitting of all screws should be checked. Further
more it should be checked
whether the ball valve is 100% closed. If this is not the cause of leakage the ball valve must be
dismantled (for this see repair instructions).
9
Putting out of action and disassembly of ball al es
9.1
General
During
long standstill periods liquids which change their state through changes in the concentration,
polymerisation, crystallizing out, solidification or similar processes must be drained off from the pipe
system. If necessary the pipe system, including the valves, must be rinsed.
Before dismantling the complete valve from the pipe, or before repairs and maintenance work
on the valve itself, the complete valve must be depressurized and cooled down to such an
extent that the temperature drops below the evaporation temperature of the medium in all
regions coming into contact with the medium. In this way the danger of scalding is eliminated.
Disassembling of al es under pressure is dangerous to life !
If media have been conveyed which are toxic, easily
inflammable, or have residues which cause
corrosion danger with atmospheric moisture, the valve must be drained off, rinsed and or ventilated.
Residual liquid which may have been left in the valves owing to the installation position should be
collected and disposed off as waste.
If necessary wear a mask and protective clothing.
The valves should be carefully rinsed and drained off before transporting. If the ball valves are returned
to the manufacturer they must be delivered in a state free of contamination.
9.2
Actuators
If drives which are fed by an outside power supply (electric or pneumatic) are dismantled from the
valves, or are themselves dismounted, the outside power should be switched off before beginning this
work and the instructions relating to the drive should be followed.
10
Inspection
Since the seal can become damaged through abrasion, the ball valve should be regularly checked for
proper sealing.
If the ball valve is dismantled it is essential that the relevant
KLINGER SCHÖNEBERG
repair
instructions are observed.
In the interest of technical progress, designs and dimensions are subject to modification.
KLINGER SCHÖNEBERG GmbH | Heidelberger Straße 3 | DE-76676 Graben-Neudorf
Fon [phone] | Fax [phone] | www.klinger-schoeneberg.de | [e-mail]