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