KLINGER BALLOSTAR KHI User manual

wT 2860/02
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 2860/02
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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 ................................................................................... 10
7.4 Table of Weights ....................................................................................... 11
8Transportation and Storage .......................................................................12
9Operating Principle ....................................................................................13
10 Mode of Operation.....................................................................................14
11 Installation and Putting into Service Regulations .........................................17
11.1 Welding Instructions.................................................................................. 17
12 Service and Maintenance...........................................................................18
12.1 Disassembly.............................................................................................. 18
12.1.1 Disassembly for Seal Exchange at the Operating Stem......................... 18
12.1.2 Disassembly of Individual Parts for Exchange of Sealing Elements ........ 19
12.1.3 Disassembly of the Sealing Element ..................................................... 21
12.2 Assembly .................................................................................................. 22
12.2.1 Standard Lubricants............................................................................. 22
12.2.2 Installation of the Sealing Element......................................................... 22
12.2.3 Assembly of the Individual Parts ........................................................... 23
12.2.4 Inspection of Axial Orientation of the Ball .............................................. 24
13 Actuator Mounting .....................................................................................25
13.1 Fitting the Actuator.................................................................................... 25
14 Spare Parts List .........................................................................................26
15 Disposal ....................................................................................................31

wT 2860/02
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1Declaration of Conformity

wT 2860/02
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2Individual Parts Designation
1. Body
2. End piece
3. Operating stem
4. Ball
5. Trunnion
7. Top flange
8. Bush insert, upper part
10. Bush insert, lower part
12. Disc
13. Gasket
14. Gasket
15. Washer
16. Washer
17. O-ring
18. O-ring
19. O-ring (spiral wound
gasket)
20. O-ring
21. U-sleeve
22. Sealing element
23. Wire ring
24. Back-up ring
27. Top flange head screw
29. Circlip
30. O-ring (DN 700/800/1000)
31.1Fillister head screw
31.2Hexagon head screw
32 Hex nut
33 Stud bolt
34 Fillister head screw
35 Trunnion hexagon head
screw
36 Fitting key
37 Fitting key
38 Bearing bush
39 Bearing bush
43 Serrated washer
DN 125-200
DN 250-1000

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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. KHI
Manufacturer’s type designation
Size
DN and numeric value
Numeric value in mm, e.g. DN 80 or in inch,
e.g. 3”
PN / class
Numeric value for PN
/ class
Provides the max. permissible pressure at
ambient temperature, e.g. PN 40
FA-No.
Numbers / letters
FA-No. serves identification purposes
Material
e.g. 1.0619 or VIII
In accordance with material codes
CE
Market approval symbol

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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.
»it is prohibited to open screw connections (with the exception of those on hand
levers and handwheels), when pressurized (medium).
»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.
»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
IV
Brass
Nonferrous metal parts possible
VI
Spheroidal 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.
!
CAUTION
The diagrams illustrate all possible limitations of use of KLINGER valves.
The area of application for standard valves is from -10 °C up to +200 °C.
Special designs with a suitable sealing system exist for the temperature
range from -45 °C to -10 °C as well as from 200 °C to 260 °C.

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7.3 Tightening Torques
Tightening torques of the split body flange hex nuts (Pos. 32) for standard designs with
O-rings and designs with spiral wound gaskets (e.g. KHWI):
Nominal
size
Dimension
Tightening torques (Nm)
VII, VIII, X
Xc
Spiral wound
gasket
125,150
M 16
160
130
200
200
M 20
310
245
390
250
M 22
320
290
700
300
M 24
470
330
700
350
M 22
320
290
700
400
M 27
650
400
1,000
500
M 30
1,000
540
1,200
600
M 33
1,400
1,900
700
M 36
1,900
2,400
800
M 39
2,200
2,700
1000
M 39
2,500
Tightening torques of the trunnion hexagon head screw (Pos. 35):
Nominal
size
Dimension
Tightening torques
(Nm)
VII, VIII, X
Xc
125,150
M 24
270
270
200
M 30x2
540
540
250,300
M 36x1,5
900
900
350,400
M 48x1,5
2,100
2,100
500,600
M 60x2
5,300
700,800
M 85x2
19,800
1000
M 95x2
21,000
Tightening torques of the top flange head screws (Pos. 31):
Nominal
size
Dimension
Tightening torque (Nm)
VII, VIII, X
Xc
125,150
M 12
28
38
200
M 16
68
94
250,300
M 16
220
94
350,400
M 20
428
142
500,600
M 20
428
142
700,800
M 30
1,478
1000
M 36
1,827

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7.4 Table of Weights
This table provides a weight estimation of a PN 40 ball valve with flange connection (full
bore).
DN
Weight
(excl. gear box)
Weight
(incl. gear box)
150
85 kg
103 kg
200
160 kg
180 kg
250
240 kg
286 kg
300
410 kg
468 kg
350
620 kg
685 kg
400
856 kg
970 kg
500
1,330 kg
1,535 kg
600
1,863 kg
2,068 kg
700
3,350 kg
3,742 kg
800
5,055 kg
5,447 kg
1000*
7,480 kg
8,240 kg
*) only available with welding ends

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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 notified immediately of any kind of deviations. Regarding damage obviously resulting
from transportation, please contact the freight forwarder in charge of delivery.
Ballostar® KHI 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
Thanks to its "elastic sealing system" the ball valve guarantees absolute tightness in both
high-pressure and lowest-pressure scenarios. This is achieved by means of two elastic
sealing elements, which work independent of each other. The necessary contact force is
achieved a) through pre-stressing during assembly and b) by means of the differential
pressure created in the valve (Fig. 1).
The forces generated at the ball, comprising the shut-off section multiplied by the
prevailing differential pressure, are not transmitted to the sealing rings, but instead onto
the trunnions for the ball, installed for this purpose. As a consequence, in terms of
construction, the trunnion-mounting and sealing function are decoupled from each other.
The torque required to pivot the shut-off element is therefore kept low.
This mode of construction reduces wear and tear and increases the service life of the
valve.
Fig. 1

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10 Mode of Operation
During assembly of the body and the end piece, the sealing system is elastically
deformed. The two pre-stressed, elastic sealing elements made of stainless steel,
together with the sealing rings and a seal at the periphery, create a sealing system with
the ball both upstream and downstream of the ball valve. A back-up ring protects the
elastic sealing element against overstressing, a wire ring serves to lock the sealing unit.
(Fig. 2)
Due to the elasticity and up to a certain pressure, two primary sealing points are
continuously maintained in the bore. The differential areas at the sealing element cause
the pressure of the medium on the upstream side of the ball valve to press the sealing
ring onto the surface of the ball. If pressurization, exceeding the nominal pressure,
originates from the cavity between the sealing rings, then the sealing element on the non-
pressurized side or the downstream side is lifted from the ball surface. (Fig. 3)
The ball valve can be pressurized in both flow directions.
Thermal expansions are compensated by the elasticity of the sealing elements.
Ball
Wire ring
Back-up ring
U-sleeve, O-ring
Sealing ring
Fig. 2
Fig. 3
Pressure removal from cavity
when nominal pressure is
exceeded
Pressure of the
medium
Zero pressure

wT 2860/02
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Operating stem
In the closed state of the valve, the ball valve cavity can be discharged and/or vented or
depressurized by means of a special sealing system via a test/drain cock. This allows for
testing the function of both sealing rings following depressurization (Block & Bleed).
Furthermore, repair work can also be carried out on a depressurized section between the
two ball valves belonging to the pressurized pipe without hazard: The medium cannot
enter the repair section.
An operating stem is utilized to operate the ball. The connection stem-hub is achieved via
fitting keys. The tightness to atmosphere is ensured by means of consecutively arranged
O-rings. In order to simplify their replacement, they are located in the bush inserts. The
occurring bearing forces are absorbed by the bearing bushes.
Fig. 4
Pressure of the
medium
Pressure of the
medium
Test and drain cock
Fig. 5
Bush insert, upper part
O-Rings
Bush insert, lower part
Bearing bush
Fitting key
Ball

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In order to guarantee the centered orientation of the ball, a trunnion is located on the
opposite site. Guided into the vertical bore of the ball by a bearing bush, it is locked in
place by a hex screw to counter forces generated within the body. Tightness to
atmosphere is achieved through flat gaskets and O-rings.
In the standard design, the connection between the body and the end piece is sealed by
means of a static O-ring (Fig. 6a). A spiral wound gasket (Fig. 6b) is utilized for the high-
temperature design. The parts are held together by a bolted connection, i.e. the flanges
are pressed against each other across their entire surface. This serves to absorb the
occurring tensile and bending forces.
All seals and bearings are MAINTENANCE-FREE
Cushion joints
Circlip
Ball
Bearing bush
O-Ring static
Trunnion
Stud bolt
O-ring for DN 700, 800, 1000
PN 25/40
Hex nut
End piece
Body
Metallic gasket
Fig. 6a
Spiral wound
gasket
Fig. 6b

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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® KHI ball valves can be installed in any given orientation. Installation should be
executed in the "open" position (supplied state) in order to avoid damaging the surface
of the ball.
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.
Installation of valves with flange ends may only be carried out by qualified personnel in
accordance with EN 1591. It must in this case be observed that no additional tension is
exerted on the valve, such as for example as the result of selecting a too large distance
between the to be bolted 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.
11.1Welding Instructions
The ball valve must be in the OPEN position during the entire welding process. This
ensures that damaging the ball surface is avoided.
The applicable welding and quality-technical requirements and their respective standards
must be complied with during welding.
The welding temperature may not exceed 200 °C at a distance of 115 mm from the
welding seam for nominal sizes of up to DN 350, and, with regard to nominal sizes DN
400, this temperature may not be exceeded at a distance of 170 mm.

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The preferred welding methods for the creation of welding seams are:
-Manual electro-welding
-TIG
-MAG / MIG
The welding seam sequence is defined
as follows:
Vertical-down weld: A- C- D- B
Rising weld: A- C- B- D
12 Service and Maintenance
Maintenance and inspection intervals are to be determined by the operator dependent
on the operating mode, as these valves can be utilized under a number of different
operating conditions.
In order to increase service life at low activation counts, we recommend carrying out an
activation from time to time. For this purpose it is fully sufficient to only shift the ball by a
few angular degrees.
Maintenance and inspection work may only be carried out by trained personnel.
Prior to the start of service and maintenance work, it must be ensured that the pipeline
system is depressurized and that no medium residues are contained within.
In the event of tightness to atmosphere not being achieved at certain positions, the
tightening torques at the corresponding positions should be checked for their conformity
with the tightening torque table.
When removing an actuator, it is necessary to protect it against rotation prior to loosening
of the connecting screws.
12.1Disassembly
12.1.1 Disassembly for Seal Exchange at the Operating Stem
»Depressurize the pipe system
»Bring the valve into the OPEN position
»Remove valve lever and actuating unit respectively
»Loosen top flange head screws (Pos. 31) and lift top flange (Pos. 7) over the end
of the operating stem
»Remove washer (Pos. 16) –please note that these must be reinstalled in the
correct amount and strength during assembly
»Pull the bush insert –upper part (Pos. 8) out of the body –use the extraction
groove
0
D
B
A
C
3
9
6

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»Exchange the seals (Pos. 17, 20) in accordance with the spare parts list. Clean
the spare parts and treat them with a suitable type of grease to simplify
installation
»Inspect the bearing surface (Pos. 38). Should any damage be found –exchange
the bearings
»Installation in the reverse order
12.1.2 Disassembly of Individual Parts for Exchange of Sealing
Elements
»Bring valve into the OPEN position
»Depressurize the pipe system
»Remove valve from the pipe system. For improved handling during disassembly of
the individual parts, place body on connection flange. Place on an appropriate
material that does not lead to damaging of the contact surface
»Mark the removal positions of the parts with regard to each other! (Fig. 8)
»Loosen hex nuts (Pos. 32), lift end piece (Pos. 2) and place on connecting face
Fig. 7
Extraction
groove
Mark
Mark
Fig. 8
19
2
32

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»Remove seal (Pos. 19)
»Withdraw hexagon head screw (Pos. 35) from trunnion (Pos. 5), remove flat gasket
(Pos. 14)
»Remove circlip (Pos. 29) from ball hub, remove discs (Pos. 12) for vertical centering
»Push trunnion (Pos. 5) into the bore of the ball (careful application of force), remove
flat gasket (Pos.13)
!
CAUTION
A washer must be used in the same amount and strength for installation!
»Remove consoles etc.
»Withdraw head screws (Pos. 31) and pull out flange (Pos. 7) over end of operating
stem. Remove washer (Pos. 16).
5
29
13
14
12
35
Bearing Bush (Pos. 39), in the
event of undamaged bearing
surface, remains in the ball
hub.
Fig. 9
Fig. 10
15
20
10
8
31
7
3
17
16