KLINGER BALLOSTAR KHA User manual

wT 2858/02
Page 1
Issued: 08/2017
KLINGER Fluid Control GmbH
Am Kanal 8-10 » 2352 Gumpoldskirchen » Austria
[email protected] » www.klinger.kfc.at » Tel: [phone]

wT 2858/02
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Contents
1Declaration of Conformity ......................................................................................3
2Individual Parts Designation...................................................................................4
3Proper Use ...........................................................................................................5
4Testing of KLINGER Valves....................................................................................5
5Labeling of the Valves............................................................................................5
6Safety Instructions.................................................................................................6
6.1 General Notes on Safety ....................................................................................... 6
6.2 Safety Instructions for Operators ........................................................................... 6
6.3 Hazard Warnings .................................................................................................. 7
7Technical Data ......................................................................................................9
7.1 Material codes...................................................................................................... 9
7.2 P/T Diagrams ....................................................................................................... 9
7.3 Tightening Torques and Width Across Flats..........................................................11
7.4 Table of Weights..................................................................................................11
7.5 Material Combinations .........................................................................................12
7.6 Exploded View KHA-FL, KHA-FK .........................................................................13
7.7 Exploded View KHA-G, KHA-SK, KHA-SL............................................................14
7.8 Sealing Element for Special Requirements............................................................15
7.9 Special Requirements Stuffing Box.......................................................................16
8Transportation and Storage.................................................................................17
9Operating Principle..............................................................................................18
10 Mode of Operation ..............................................................................................18
11 Installation and Putting into Service Regulations...................................................20
11.1 Welding Instructions ............................................................................................21
11.1.1 Welding Instructions for Short Design (KHA-SK)..............................................21
11.1.2 Welding Instructions for Long Design (KHA-SL)...............................................22
12 Service and Maintenance ....................................................................................22
12.1 Seal Replacement................................................................................................22
12.1.1 Seal Replacement on the Operating Stem.......................................................22
12.1.2 Replacement of Sealing Elements (Flange Connection)....................................23
12.1.3 Replacement of Sealing Elements (Welded and Threaded Ends)......................23
12.2 Standard Lubricants ............................................................................................23
13 Actuator Mounting ..............................................................................................24
13.1 Fitting the Actuator ..............................................................................................24
14 Spare Parts List ..................................................................................................25
15 Disposal..............................................................................................................25

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1Declaration of Conformity

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2Individual Parts Designation
Durchgehende nummerierung
5 4 1 18 2 14 13
11
15
16
17
8
6
10
9
3
7
1. Body
2. End piece
3. Operating stem
4. Ball
5. Sealing element
6. Loading ring
7. Labyrinth stuffing box
8. Slip ring
9. Antistatic disc
10. Female support ring
11. Lever
12. Additional label
13. Screw bolt
14. Hexagon nut
15. Stuffing box nut
16. Belleville washer
17. Loading ring
18. Supporting ring
12

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3Proper Use
This product is exclusively intended to shut off or convey media within the approved
pressure and temperature limits after installation in a pipeline system.
Please see the P/T diagram (pressure temperature diagram) for the permissible threshold
values in accordance with the utilized materials.
This operating manual must unconditionally be brought to the attention of the
corresponding personnel!
Prior to installation and putting into service for the first time, please read the operating
manual carefully and pay attention to the hazard and safety notes!
!
CAUTION
Non-compliance with the hazard and safety notes of this operating
manual may result in the creation of hazards and loss of the
manufacturer's warranty.
Please contact the manufacturer under [phone] for further
details.
Subject to technical alterations and misprints!
4Testing of KLINGER Valves
KLINGER Valves are pressure-tested in accordance with EN 12266-1. The pressure test
comprises the tests P10, P11 and P12. Testing the resistance to pressure of the ball
(P20) is not included in the standard package.
5Labeling of the Valves
Each valve is provided with the following data listed either on the body or on a type
plate.
Designation
Comment
Manufacturer
KLINGER
Please see the operation manual for the
address
Model
e.g. KHA
Manufacturer’s type designation
Size
DN and numeric value
Numeric value in mm, e.g. DN 80 or inches,
e.g. 3“
PN / Class
Numeric value for PN
/ Class
Provides the max. permissible pressure at
ambient temperature
FA-No.
Numbers / letters
FA-No. serves identification purposes
Material
e.g. 1.0619 or VII
In accordance with material codes
CE
Market approval designation

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6Safety Instructions
This operation manual must be brought to the attention of the operating personnel.
6.1 General Notes on Safety
The safety instructions for valves also apply to the pipeline systems, into which they are
installed. This operating manual exclusively focuses on safety instructions, which are to
be additionally complied with for valves.
6.2 Safety Instructions for Operators
!
Danger
to Life
A valve with a permissive pressure/temperature range that is not sufficient
for the operating conditions may not be operated! This range is to be derived
from the P/T diagram. With regard to materials, pressures or temperatures
not listed there, contacting the manufacturer is mandatory.
Ignoring this regulation can result in life-threatening situations and can cause
damage to the pipeline system.
!
Danger
to Life
It must be ensured that materials selected for the parts coming into contact
with the media are suitable for the utilized media. The manufacturer takes
no responsibility for damages resulting from corrosion or through aggressive
media.
Ignoring this regulation can result in life-threatening situations and can cause
damage to the pipeline system.
The following items do not lie in the scope of responsibility of the manufacturer. As a
consequence, when utilizing the valve, it must be ensured that
»the valve is only utilized in accordance with its proper use, as illustrated under
"Proper Use".
»the actuator unit, which is subsequently mounted on the valve, is adjusted to the
valve and correctly adjusted in the end position.
»when connecting a valve actuator to the power grid, the safety notices of the
actuator manufacturer are complied with.
»the valves are correctly implemented into the system, especially those connected
to the pipeline system by means of welding.
»no additional tensions bear on the valves.
»the operation parameters and operating conditions have been clarified with the
manufacturer of the valve and that operating conditions such as vibrations, water
hammers, pressure surges, erosion etc. are to be avoided.
»pipeline system connections and valves, which are operated at operating
temperatures > 50 °C or < -20 °C, are protected against contact.
»during welding procedures, the safety regulations of the plant operator and/or
plant constructor are to be complied with.
»the valve is only operated and maintained by trained personnel.
»valves, which are utilized with hazardous media (inflammable, corrosive, harmful
to health etc.), are to be handled in accordance with their dangers. The
corresponding handling regulations are the responsibility of the plant operator.
»all ergonomic hazards are to be considered by the plant operator, such as e.g.
accessibility, gauges etc.

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»when applying internal pressure for the first time (pressure test, trial operation) a
sufficient safety distance is to be maintained.
»when pressurized (medium), it is prohibited to open screw connections (with the
exception of those on hand levers and handwheels).
»installation and removal of valves is only carried out with a depressurized and
drained pipeline.
»all connections, following loosening, are again correctly tightened afterwards.
»no screws are loosened on pressure-retaining parts, unless described so in the
operation manual.
»no screwed connections are forcibly opened.
»that during longer shutdown periods, in the event of freezing media, the valve is
drained and/or that depressurization is achieved in case of expanding media.
6.3 Hazard Warnings
Mechanical hazards:
»Beware of possible sharp or protruding parts posing risk of injury.
»Extra care is required during putting into operation: Do not reach into the bore
opening during the valve closing process, as this poses a risk of injury.
»Be careful of falling parts during transportation, maintenance and putting into
operation.
»When manipulating lifting appliances, the safety regulations for lifting appliances
must be complied with.
»Unauthorized and improper handling can result in undesired and spontaneous
pressure loss and can result in significant damage.
»With regard to valves featuring a mounting bracket it must be ensured that moving
valve parts do not result in a risk of injury.
Electrical hazards:
»With regard to valves featuring electric actuators, the operating manual and the
safety instructions of the actuator manufacturer must be complied with.
Thermal hazards:
»During operation, the surfaces of valves may feature high / low temperatures.
Caution: Burn hazard.
»Caution: The hot surfaces can cause self-ignition of flammable materials through
either contact or heat emission.
Hazard generated by noise:
»Depending on the application conditions, high levels of noise can be created by
the cavitation processes, which bear the risk of hearing damage.
»Opening an internally pressurized valve can result in major noise exposure as a
result of exiting media; hearing damage hazard.
Vibration hazard:
»Caution: Abrupt opening or closing of a valve can lead to undesired surges and
vibrations in the pipe, which may possibly damage the valve or the pipeline system.

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Electromagnetic radiation hazard:
»The hazards resulting from possibly created electromagnetic radiation are to be
consulted in the operating manual of the actuator manufacturer.
Hazards linked to the operational environment:
»The ambient atmosphere and the ambient temperature are to be set in a manner
that has no negative influence on the valve, the actuator of the valve, and the
medium.
Transportation hazards:
»Please see the chapter “Transportation and Storage” for transportation hazards.
Maintenance hazards:
»All maintenance and repair tasks with the exception of lubricating and subsequent
sealing of stuffing boxes are without exception to be carried out in an
unpressurized state. Where required, the valve may have to be drained prior to
servicing.
»Valves may only be removed from pipeline systems in an unpressurized and empty
state.
»Attention must be paid to exiting media when resealing.
»Caution: (Fire and chemical) burn hazard and risk of poisoning caused by valves
utilized in dangerous media. Attention must be paid to medium residues during
maintenance and putting into operation tasks.
»Maintenance and repairs may only be carried out by qualified personnel.
Placing out of operation hazards:
»When placing out of operation, the valves must be emptied fully and attention must
be paid to hazards resulting from medium residue.
»Should valves be no longer used, they are to be disposed of correctly.
Hazards when opening drain valves:
»Danger of exiting medium. If utilized in high temperature water systems, the drain
ball valve may only be opened after it has been ensured that the drain line is either
correspondingly pressurized or that the temperature is less than 100°C (avoidance
of steam hammers in the clearance volume).
Material failure hazard:
»Parts made of grey cast iron are especially sensitive to brittle fracture and impact.
This aspect must be considered in the course of material selection.

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7Technical Data
7.1 Material codes
The main criterion of the material codes is the basic material of the body.
Symbol
Body
Interior Parts
III
Grey cast iron
Without nonferrous metal parts
VII
Cast steel
Nonferrous metal parts possible
VIII
Cast steel
Without nonferrous metal part
X
Stainless steel
Parts coming into contact with
the medium are acid-resistant
Xc
Stainless steel
All parts acid-resistant
The above table may also contain material codes unavailable for this product.
7.2 P/T Diagrams
The applicable maximum limitations of use regarding pressure and temperature are
defined by their mutual interdependency. A P/T diagram is an ideal tool in order to select
a suitable valve for pre-defined operational characteristics.

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CAUTION
The diagrams illustrate all possible limitations of use of KLINGER valves.

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7.3 Tightening Torques and Width Across Flats
Nominal width mid-body section
15
20
25
32
40
50
65
80
100
125
Tightening torque stuffing box nut (Nm)
5
15
15
25
25
20
20
40
40
40
Tightening torque body screws Xc (Nm)
9
25
25
40
55
75
70
100
130
145
Tightening torque body screws VIII (Nm)
9
20
20
30
40
60
60
80
110
120
Tightening torque body screws III (Nm)
9
20
20
30
40
60
60
70
110
120
AF hexagon screw stop
8
10
10
13
13
13
13
19
19
19
AF body screws KHA-FL,SL,SK,G
10
13
13
17
19
22
19
24
24
24
AF body screws KHA-FK-VIII, Xc
22
22
24
AF body screws KHA-FK-III
19
22
22
Tolerance for stuffing box nut tightening torque + 10 %
Tolerance for body screw tightening torque 10 %
7.4 Table of Weights
This table features a weight estimate of a PN 40 valve with flange connections (full bore).
Nominal size
Weight
10
2.3 kg
15
2.4 kg
20
3.7 kg
25
4.7 kg
32
7.4 kg
40
9.8 kg
50
14.5 kg
65
20.6 kg
80
31.6 kg
100
44.8 kg
125
75.7 kg

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7.5 Material Combinations
Pos.
Individual Parts
Materials
VIII
Xc
III
1
Body
1.0619 Zn/Fe
phrf
1.4408
1.0619 Zn/Fe phrf
2
End piece
1.0619 Zn/Fe
phrf
1.4408
0.6025 (0.7040) Zn/Fe
phrf
3
Operating stem
1.4104
1.4571
1.4104
4
Ball
1.4401 (1.4408 from DN 65 upwards)
5
Sealing element
Xc –KFC
6
Loading ring
1.4404
7
Labyrinth stuffing box
K –Flon / 4401 / Graphite
8
Slip ring 2x
KFC –15
9
Antistatic disc
1.4401
10
Female support ring
1.4404
11
Lever
1.4006/1.4408
12
Additional label (standard version does
not have additional label)
1.4310
13
Screw bolt (hexagon screw)
8.8-A2L
A4-70
8.8-A2L
14
Hexagon nut
8-A2L
A 4
8-A2L
15
Stuffing box nut
1.4404
16
Belleville washer
1.4310
17
Loading ring
1.4404
18
Supporting ring
Sint D10/Sint
C39
1.4404
--------
Subject to technical change
5 4 1 18 2 14 13
11
15
16
17
8
6
10
9
3
7
12

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Lever
7.6 Exploded View KHA-FL, KHA-FK
*In the event that a single-part sealing element is installed, the supporting ring must be removed.
Cap screw
Screw bolt
Hexagon nut
KHA-FL
KHA-FK
Ball Supporting ring* Sealing element
Sealing Supporting Body
element ring*
Additional label
(not included in
standard
version)
Hexagon nut
Slip ring
Operating stem
Stuffing box nut
Stuffing box
Antistatic disc
Belleville washer
Loading ring
Slip ring
Female support ring

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7.7 Exploded View KHA-G, KHA-SK, KHA-SL
*In the event that a single-part sealing element is installed, the supporting ring must be removed.
Additional label
(optional)
Lever
Sealing element
Slip ring
Operating stem
Ball
Supporting
ring*
KHA-SL
KHA-SK
KHA-G
Antistatic disc
Stuffing box nut
Hexagon nut
Hexagon screw
Sealing Supporting Body
element ring*
Stuffing box
Female support ring
Slip ring
Loading ring
Belleville washer

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7.8 Sealing Element for Special Requirements
Due to a modular kit of system components, the sealing elements can be fitted with
special gaskets in accordance with the requirements. This can also be achieved with
already installed ball valves.All sealing elements are pre-installed in a pre-finished state!
CAUTION: The ball and the sealing ring must be lubricated during installation.
METALLIC Sealing Element METAL-Special Temp. 400 °C
Sealing Element
For abrasive media and media featuring particulate matter. Also for heavily polluted and
granular media or displaying a tendency towards crystallization.
VITON Sealing Element FIRE SAFE Sealing Element Single-Part Sealing Element
(eg. Low and high (eg. Gas applications)
vacuum range)
Viton
K-Flon
KFC-25
KFC-25
Graphite
Spacer ring Viton sealing ring
Graphite disc
Hard metal layer
Sleeve
K-Flon
Hard chromium
plating ball surface
Hard metal layer
Sleeve K-Flon
Graphite
Hard chromium
Plating ball surface
Hartmetall Beschichtung
Hartverchromung
Graphite disc

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7.9 Special Requirements Stuffing Box
Labyrinth stuffing box
Graphite stuffing box
Stuffing box set with O-
ring sealing
Area of application:
- Low and high vacuum
- Gas applications
Area of application:
- High-temperature
Area of application:
- Ideal for most applications

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8Transportation and Storage
Check the shipment immediately upon receipt for completeness of delivery and transport
damage. Furthermore, it should be ensured that the valves and possibly mounted
actuators have not been damaged during transport. Please also check that the supplied
valves (types, nominal sizes etc.) correspond with the order. KLINGER Fluid Control is to
be immediately notified of any kind of deviations. Regarding damage obviously resulting
from transportation, please contact the freight forwarder in charge of delivery.
Ballostar® ball valves are supplied in the OPEN position with the connections covered in
order to protect against dirt and damage. These covers may only be removed
immediately prior to installation.
»Storage in the default factory packaging.
»The valves are to be stored in closed rooms, in a non-aggressive atmosphere,
and protected against humidity and contaminants.
»In the event that protective sheeting or shrinking foils are used, it must be
ensured –through adequate measures –that the atmosphere within the covers
remain free of condensation.
»Corresponding protective measures are recommended for storage in dusty
rooms.
»In order to avoid mix-ups, all stored parts should be labeled in accordance with
the shipping notes and stored in the correct place.
»The temperature in the storage rooms should not exceed the limits -20 °C and
+50 °C. Rapid temperature changes are to be avoided whenever possible
(condensate water).
»Possible changes originating from KLINGER Fluid Control and having an impact
on storage will be announced in a timely manner in the form of a circular.
»The operation manual is part of the delivery and must be stored with the item.
This ensures that all important information and documents can be passed on.
»Lift lines suitable for the weight and the lifting aids on the valve (to the extent
present) are to be used for manipulation purposes.
Damages resulting from incorrect storage or manipulation free KLINGER Fluid Control
from any obligations derivable from the warranty, guarantee and product liability.

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9Operating Principle
With its "elastic sealing system" the ball valve guarantees full tightness at both high and
lowest pressures. The necessary contact forces between the ball-shaped shut-off section
and the sealing elements are generated by the pressure differential created in the shut-
off valve. With regard to this sealing principle, the "FLOATING BALL", it is important that
the shut-off section between the two sealing rings is movable. These rings carry out a
double function: They guide the ball and act as force transducers.
DISTRIBUTION OF FORCES
This principle is used in combination with ball valves of smaller nominal sizes. As the
nominal sizes increase, so do the forces which have to be absorbed by the sealing rings.
In order to achieve a long service life and to keep the torques for the pivoting of the ball
as low as possible, this three-component design is not suitable for all nominal sizes.
10 Mode of Operation
The two pre-stressed elastic sealing elements made of stainless steel with KFC sealing
rings, a K-Flon sleeve at the upstream and downstream side of the ball valve and the ball
create the sealing system.
The pressure of the medium presses the ball onto the downstream sealing element. At
the same time, the upstream element is also pressed against the ball. The Ballostar® ball
valve is maintenance-free and can be pressurized in both flow directions.

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The U-sleeve on the outer circumference of the holding disc is fully chambered (only refers
to holding disc design) and provides tightness to atmosphere towards the body
connector section.
The seal of the operating unit (operating stem) is formed by a STUFFING BOX supported
by a Belleville spring washer.
This type of seal is virtually maintenance-free, has a low setting behavior and only minor
contact forces are necessary to achieve tightness.
The Belleville spring washer is positioned in a manner that a contact force is always
exerted on the stuffing box. This ensures that temperature and pressure differences are
compensated for.
F1 + F2 + FV
FV
FV
F2
F1
F2
Exerted forces:
F1….Force of the medium exerted
on the ball
F2…Force of the medium exerted
on the sealing element
Fv….Pre-stress force of the
sealing element
F1+F2+Fv….Total force exerted
on the seat ring

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2
The retaining washer negates movement of the sealing ring in radial direction (1), against
the rear (2) and against the bore (3). The ball presses against the sealing ring (4). The
sealing ring can therefore neither set nor shift, as it is enclosed on all sides (applies to
retaining washer).
11 Installation and Putting into Service Regulations
In order to protect against impurities and damage, the connections of the valves are
covered. We recommend removal of these covers only prior to installation.
Ballostar® ball valves can be installed in every orientation. Installation should be carried
out in the OPEN position (delivery state) in order to avoid damage to the ball surface.
Valves with welding ends may generally be welded into a pipework by means of fusing
welding procedures. In this context, the welding and quality requirements and their norms
are to be complied with. As a consequence, welding may only be carried out by qualified
personnel. The safety regulations of the plant operator and/or the plant manufacturer are
also to be complied with.
The installation of valves with flange ends may only be carried out by qualified personnel
in accordance with EN 1591. In this context it must be ensured that no additional tensions
affect the valve, such as e.g. a too large gap between the to be screwed flanges.
Following installation and prior to putting into service, it must be ensured that solids and
impurities, which are not part of the medium, have been removed from the pipeline
system and/or from the facility.
A pressure and a function test must be carried out prior to putting into operation. Prior to
putting into service of valves in steam pipes, proper condensate draining must be ensured
in order to avoid steam hammer hazards. In extreme cases, a steam hammer may lead
to breaking of the valve. Rapid increases in temperature and pressure are to be avoided
during all operation phases (start –operation –shutting down).
The maximum permissible test pressure is 1.1 x PN if the valve is in a closed state. The
valve must be open when testing the pipe pressure (1.5 x PN).
The ball valves are also to be secured against toppling or falling down during
transportation to the place of installation. Furthermore, they are to be protected against
colliding with each other or other forms of damage.
3
1
4