KSB BOA-H Mat P Installation instructions

Automated Globe Valves
BOA-H Mat P
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual BOA-H Mat P
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 15/03/2019

Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Installation of partly completed machinery....................................................................................................6
1.3 Target group.....................................................................................................................................................6
1.4 Other applicable documents............................................................................................................................6
1.5 Symbols .............................................................................................................................................................6
2 Safety...................................................................................................................................................... 7
2.1 Key to safety symbols/markings.......................................................................................................................7
2.2 General..............................................................................................................................................................7
2.3 Intended use .....................................................................................................................................................8
2.4 Personnel qualification and training...............................................................................................................8
2.5 Consequences and risks caused by non-compliance with this manual .........................................................8
2.6 Safety awareness ..............................................................................................................................................9
2.7 Safety information for the operator/user.......................................................................................................9
2.8 Safety information for maintenance, inspection and installation ................................................................9
2.9 Unauthorised modes of operation..................................................................................................................9
3 Transport/Temporary Storage/Disposal............................................................................................. 10
3.1 Checking the condition upon delivery..........................................................................................................10
3.2 Transport.........................................................................................................................................................10
3.3 Storage/preservation......................................................................................................................................10
3.4 Return to supplier...........................................................................................................................................11
3.5 Disposal ...........................................................................................................................................................12
4 Valve Description ................................................................................................................................. 13
4.1 General description ........................................................................................................................................13
4.2 Marking...........................................................................................................................................................13
4.3 Name plate......................................................................................................................................................14
4.4 Design details..................................................................................................................................................14
4.5 Function ..........................................................................................................................................................15
4.6 Scope of supply...............................................................................................................................................16
4.7 Noise characteristic.........................................................................................................................................16
5 Installation at Site................................................................................................................................ 17
5.1 General information/Safety regulations .......................................................................................................17
5.2 Installation position........................................................................................................................................17
5.3 Preparing the valve ........................................................................................................................................18
5.4 Piping ..............................................................................................................................................................19
5.5 Insulation ........................................................................................................................................................19
6 Commissioning/Start-up/Shutdown................................................................................................... 21
6.1 Commissioning/start-up .................................................................................................................................21
6.2 Operating limits..............................................................................................................................................22
6.3 Shutdown........................................................................................................................................................23
6.4 Returning to service .......................................................................................................................................23
7 Servicing/Maintenance........................................................................................................................ 24
7.1 Safety regulations...........................................................................................................................................24
7.2 Maintenance/inspection.................................................................................................................................25
7.3 Dismantling the valve.....................................................................................................................................26
7.4 Assembling the valve......................................................................................................................................28
7.5 Tightening torques.........................................................................................................................................30

Contents
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8 Trouble-shooting.................................................................................................................................. 31
9 Related Documents.............................................................................................................................. 32
9.1 General assembly drawing with list of components ....................................................................................32
9.2 Maximum permissible closing pressures .......................................................................................................33
9.3 Dimensions and weights of BOA-HMatP globe valve ................................................................................33
9.4 Dimensions and weights of actuator ............................................................................................................34
10 EU Declaration of Conformity for BOA-H Mat E, BOA-HMatP........................................................ 35
11 Certificate of Decontamination........................................................................................................... 36
Index ..................................................................................................................................................... 37

Glossary
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Glossary
Certificate of decontamination
A certificate of decontamination is enclosed by the
customer when returning the product to the
manufacturer to certify that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.
Pressure Equipment Directive (PED)
The 2014/68/EU Directive sets out the
requirements to be met by pressure equipment
intended to be placed on the market in the
European economic area.

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating manual describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
uniquely identify the valve and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB sales organisation
responsible to maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB refer to the sub-sections under
Installation at Site. (ðSection5,Page17)
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.4 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Type series booklet Description of the technical data of the valve
Actuator operating manual Proper and safe use of the actuator in all phases
of operation
Flow characteristics1) Information on Kv and zeta values
General assembly drawing2) Sectional drawing of the valve
Sub-supplier product literature3) Operating manuals and other product literature
for the accessories
Observe the relevant manufacturer's product literature for the accessories.
1.5 Symbols
Table2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1) If any
2) If inclusion in the scope of supply has been agreed; otherwise refer to the type series booklet.
3) If inclusion in the scope of supply has been agreed.

2 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 Key to safety symbols/markings
Table3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
▪This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
▪Comply with all the safety instructions given in the individual sections of this
operating manual.
▪The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
▪The contents of this operating manual must be available to the specialist
personnel at the site at all times.
▪Information and markings attached directly to the product must always be
complied with and kept in a perfectly legible condition at all times. This applies
to, for example:
– Flow direction arrow
– Name plate
– Valve body material
▪The operator is responsible for ensuring compliance with all local regulations not
taken into account.
▪The design, manufacture and testing of the valve are subject to a QM system to
DINENISO9001 as well as the current European Pressure Equipment Directive.
▪Bear in mind that valves exposed to creep-rupture conditions have a limited
service life and have to meet the applicable regulations stipulated in the
technical codes.

2 Safety
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▪In the case of customised special variants, further restrictions may apply with
regard to the operating mode and service life. Refer to the relevant sales
documentation for applicable limitations.
▪The operator is responsible for ensuring compliance with all local regulations not
taken into account.
▪The operator is responsible for any eventualities or incidents which may occur
during installation performed by the customer, operation and maintenance.
2.3 Intended use
▪Only operate valves and actuators which are in perfect technical condition.
▪Do not operate partially assembled valves or actuators.
▪Only use the valve for fluids specified in the product literature. Take the design
and material variant into account.
▪Only operate the valve within the operating limits described in the other
applicable documents.
▪Only operate the actuator within the permissible ambient temperature limits.
▪Consult the manufacturer about any other modes of operation not described in
the product literature.
▪Do not use the valve or actuator as a foothold.
2.3.1 Prevention of foreseeable misuse
▪Never exceed the permissible application and operating limits specified in the
product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training
▪All personnel involved must be fully qualified to transport, install, operate,
maintain and inspect the product this manual refers to and be fully aware of the
interaction between the valve and the system.
▪The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
▪Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
▪Hands-on training at the valve and the actuator must always be supervised by
specialist technical personnel.
2.5 Consequences and risks caused by non-compliance with this manual
▪Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances

2 Safety
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2.6 Safety awareness
In addition to the safety information contained in this operating manual and the
intended use, the following safety regulations shall be complied with:
▪Accident prevention, health regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.7 Safety information for the operator/user
Actuator-operated valves are intended for use in areas which cannot be accessed by
unauthorised persons. Operation of these valves in areas which can be accessed by
unauthorised persons is only permitted if appropriate protective devices are fitted at
the site. This must be ensured by the operator.
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Contain any leakage of hazardous fluids (e.g. explosive, toxic, hot) so as to avoid
any danger to persons and the environment. Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2.8 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the valve require the manufacturer's prior
consent.
▪Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation are
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Only carry out work on the valve during standstill of the entire system.
▪The valve body must have cooled down to ambient temperature.
▪The pressure in the valve body must have been released and the valve must have
been drained.
▪When taking the valve out of service always adhere to the procedure described
in the manual.
▪The actuator must be disconnected from the external source of energy.
▪Decontaminate valves which handle fluids posing a health hazard.
▪Protect the valve body and body bonnet/cover from any impacts.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning.
2.9 Unauthorised modes of operation
Never operate the automated globe valve outside the limits stated in the operating
manual.
The warranty relating to the operating reliability and safety of the automated globe
valve supplied is only valid if the valve is used in accordance with its intended use .

3 Transport/Temporary Storage/Disposal
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3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
DANGER
The valve/actuator unit could slip out of the suspension arrangement.
Danger to life from falling parts!
▷Only transport the valve/actuator unit in the specified position.
▷Never attach lifting accessories to the actuator.
▷Observe the information on weights, centre of gravity and fastening points.
▷Observe the applicable local accident prevention regulations.
▷Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
To transport the valve, suspend it from the lifting tackle as illustrated.
Fig.1: Transporting a valve with pneumatic actuator
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storing the valve:

3 Transport/Temporary Storage/Disposal
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CAUTION
Damage due to frost, humidity or dirt
Corrosion/contamination of the valve!
▷Store the valve in a dry, dust-free and vibration-free, frost-proof room where
the atmospheric humidity is as constant as possible.
▷Protect the valve against contamination, e.g. with suitable caps or film.
CAUTION
Damage due to excessive valve closing force
Damage to the seat/disc interface!
▷Store the valve in the closed position.
▷For soft-seated valves, ensure that the valve is closed using little force only. This
will prevent premature cold flow (compression set) of the thermoplastic
material.
Storage and/or temporary storage of the valves must ensure that even after a
prolonged period of storage the valves’ function is not impaired.
The temperature in the storage room must not exceed +40°C.
Cover the actuators to protect them from dust and dirt, and protect them from
mechanical damage.
If properly stored indoors, the equipment is protected for a maximum of 12months.
New valves are supplied by our factory duly prepared for storage.
For storing a valve which has already been operated, observe the measures to be
taken for shutdown. (ðSection6.3,Page23)
3.4 Return to supplier
1. Drain the valve as described in the manual.
2. Flush and clean the valve, particularly if it has been used for handling noxious,
explosive, hot or other hazardous fluids.
3. If the valve has handled fluids whose residues could lead to corrosion damage in
the presence of atmospheric humidity or could ignite upon contact with oxygen
also neutralise the valve and blow through with anhydrous inert gas to ensure
drying.
4. When returning valves used for handling Fluids in Group1 always complete and
enclose a certificate of decontamination.
Indicate any safety measures and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination

3 Transport/Temporary Storage/Disposal
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3.5 Disposal
WARNING
Fluids handled, consumables and supplies which are hot or pose a health hazard
Hazard to persons and the environment!
▷Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
▷Wear safety clothing and a protective mask if required.
▷Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the valve.
Collect greases and other lubricants during dismantling.
2. Separate and sort the valve materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner.

4 Valve Description
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4 Valve Description
4.1 General description
▪Automated globe valve with pneumatic actuator
Valve for shutting off fluids in industrial plant, process engineering, plant
engineering, cooling circuits and heating systems.
4.2 Marking
Table4: General marking
Parameter Values
Nominal size DN ...
Nominal pressure class PN ...
Manufacturer KSB
Type series/Model BOA-...
Year of construction 20..
Material .......
Flow direction arrow →
Traceability of the material .......
CE marking
Identification number of the notified body 0036
Customer's marking e.g. plant/system No., etc.
Factory marking Inspector’s stamp mark on the
flange following the successful
final inspection and testing of
the valve
In accordance with the current European Pressure Equipment Directive (PED) the
valves are marked as shown in the following table:
Fluids in Groups 1 and 2
PN DN
≤25 32 40 50 65 80 100 125 150 ≥200
10
16
25
≥40
Fig.2: Fluids in Groups 1 and 2
Fluid groups In accordance with Article13 Para.1 of the European Pressure Equipment Directive
(PED) 2014/68/EU, Group1 comprises all fluids posing physical or health hazards, e.g.
fluids defined asFluids in Group 1
▪Explosive
▪Extremely flammable
▪Highly flammable
▪Very toxic
▪Toxic
▪Oxidising
Group 2 comprises all other fluids not referred to in Group 1.

4 Valve Description
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4.3 Name plate
PA-N Antrieb
Auftrag / Pos.:
order No. / pos.: 2120000000 / 0000
Max. Betriebsdruck
lowable operating pressure 6 bar
Funktion
operation Feder schließt
Federanzahl:
number of springs: 4Antrieb:
actuator: PA-N xxx IP67
Federbereich:
spring range: 1,7 - 2,7 bar
1 2 3
4 5 6 7 8 9
Fig.3: Actuator name plate (example)
1 Order number 2 Order item number
3 Product name 4 Spring range
5 Maximum operating pressure 6 Number of springs
7 Function 8 Actuator size
9 Enclosure
Name der Baureihe (pneum.)
Auftrag / Pos.:
order No. / pos.: 2120000000 / 0000
Kvs: ...
Stellort / TAG-Nr. ......................
Stellhub:
stroke: .... mm
DN
PN
...
Kennlinie:
characteristic: ...........
PTFE: Tmax. 250 °C
1 2 3
4 5 6 7 8 9 10 11 12
Fig.4: Valve name plate (example)
1 Order number 2 Order item number
3 Product name 4 Nominal pressure class
5 Nominal size (DN) 6 Kvs value
7 Characteristic curve 8 Actuator stroke
9 Point of control 10 Tag number
11 Stem seal 12 Maximum application temperature
[°C]
4.4 Design details
Design
Globe valve:
▪Straight-way pattern with horizontal seat
▪Throttling plug ≤DN100
▪On/off disc ≥DN125
▪Spring-loaded PTFE V-packing ≤250°C
▪Graphite gland packing ≤350°C
▪Flanges to DIN EN 1092-2 Type 21
▪Leakage rateA
▪Exterior coating: blue,RAL5002
▪The valves satisfy the safety requirements of AnnexI of the European Pressure
Equipment Directive2014/68/EU (PED) for fluids in Groups1and2.

4 Valve Description
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Actuators (technical data refers to basic configuration):
▪Spring-to-close or air-to-close design (on request)
Max. control pressure 6bar
Mechanical or inductive limit switches
Variants
Globe valve:
▪Valve disc with PTFE gasket (≤200°C)
▪Other flange designs
▪High-temperature resistant paint (grey aluminium)
▪Certification to customer specification
4.5 Function
411
350
200
161
100
461
Fig.5: Sectional drawing
100 Body 161 Body bonnet
200 Stem 350 Valve disc
411 Bonnet gasket 461 Stem seal
Design The automated globe valve with pneumatic actuator consists of the pressure-
retaining parts, i.e. body 100 and body bonnet 161, and the functional unit (stem 200
and valve disc 350).
Function The valve is operated by a pneumatic actuating element (actuator).
Sealing Body 100 and body bonnet 161 are joined by studs 902, and the joint is sealed to
atmosphere by joint ring 411.
On the standard valve design, the passage of stem 200 is sealed by means of either a
PTFE V-packing or a graphite gland packing 461. The PTFE V-packing stem seal is
maintenance-free.

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4.6 Scope of supply
The following items are included in the scope of supply:
▪Automated globe valve
▪Valve operating manual
▪Actuator operating manual
4.7 Noise characteristic
When operated within the operating conditions documented in the order
confirmation and/or characteristic curves booklets, the valve will not exceed a sound
pressure level of 80dB in acc. with IEC60534-8-4. Unfavourable piping layouts or off-
design operating conditions may give rise to physical phenomena like cavitation,
resulting in significantly higher sound pressure levels.

5 Installation at Site
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5 Installation at Site
5.1 General information/Safety regulations
The consultant, construction company or operator are responsible for positioning
and installing the valves. Planning errors and installation errors may impair the
reliable function of the valves and pose a substantial safety hazard.
WARNING
Damage to pressure enclosure or add-on parts
Leakage from or rupture of the valve
Valve/add-on parts not functional
▷Check the valve for in-transit damage prior to installation.
▷Check any add-on parts for in-transit damage.
▷Do not install damaged valves.
CAUTION
Welding in close proximity to soft-seated valves
Damage to the seat/disc interface!
▷Ensure that the valve is not heated beyond the specified temperature limits.
(ðSection6.2,Page22)
5.2 Installation position
WARNING
Installation of the valve with the stem pointing downwards
Damage to the valve!
▷Install the valve with the stem pointing upwards or to the side.
▷Observe the permissible installation position.
CAUTION
Actuators installed in an inclined position of 30° or more off the vertical
No valve function!
▷Support actuators > 13kg.

5 Installation at Site
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Fig.6: PA-N300 to PA-N540
Install the actuator with sufficient clearance for removal.
NOTE
For the valves to reach the documented Kv values, the flow direction must
correspond to the flow direction arrow.
5.3 Preparing the valve
CAUTION
Outdoor installation
Damage due to corrosion!
▷Provide weather-proof protection to protect the valve against moisture.
1. Thoroughly clean, flush and blow through all vessels, piping and connections.
2. Remove the valve's flange covers before installing it in the piping.
3. Check that the inside of the valve is free from any foreign objects. Remove any
foreign objects.
4. If required, install a strainer in the piping.

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5.4 Piping
WARNING
Impermissible piping forces
Leakage from or rupture of the valve body!
▷Connect the pipes to the valve without transmitting any stresses or strains.
▷Take constructional measures to prevent any piping forces from being
transmitted to the valve.
CAUTION
Painting pipes and actuator
Valve function impaired!
▷Protect stem, plastic components and actuator elements prior to applying paint.
5.4.1 Flanged connection
Fasteners Only use fasteners (e.g. to DINEN1515-4) and flange gaskets (e.g. to DINEN1514)
made of materials approved for the respective nominal valve size. Always use all
flange bolt holes provided when connecting the valve to the pipe.
NOTE
Exception: DN 65 PN 16
When using steel flanges to DINEN1092-1 in conjunction with cast iron valves with
flanges machined to DINEN1092-2, ensure that for nominal size DN65 classed
PN16 the mating flanges are fitted offset by 22.5°.
Flanged connection
DN65 PN10/16 (steel/steel):
DINEN1092-1 with DINEN1092-1: bolts
through 8holes
DN65 PN10/16 (steel/cast iron):
DINEN1092-1 with DINEN1092-2: bolt
hole circle to DINEN1092-1 rotated by
22.5°, bolts through 4holes, 4holes free
üThe mating flange faces are clean and undamaged.
1. Use an appropriate tool to evenly tighten the fasteners crosswise.
5.5 Insulation
WARNING
Cold/hot piping and/or valve
Risk of thermal injury!
▷Insulate the valve.
▷Fit warning signs.

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CAUTION
Condensation forming in air-conditioning systems, cooling systems and
refrigerating systems
Ice forming!
Actuating element blockage!
Damage due to corrosion!
▷Insulate the valve to prevent diffusion.