KSB BOACHEM ZXA User manual

1
Declaration of
conformity
----------------------------------------------------------------------------------------------------------
2
2 General instruction
--------------------------------------------------------------------------------------------------------------------
4
3 Safety -------------------------
----------------------------------------------------------------------------------------------------------------
4
3.1 Marking of instruction in the manual----------------------------------------------------------------------------------------------
4
3.2 Non-compliance with safety instruction
---------------------------------------------------------------------------------------------
5
3.3 Safety awareness---------------------------------------------------------------------------------------------------------------------
--
5
3.4 Safety instruction for the operator / user
---------------------------------------------------------------------------------------------
5
3.5 Safety instruction for maintenance, inspection and installation work------------
---------------------------------------------
5
3.6 Unauthorized modification and manufacture of spare parts----------------------------------------------------------------
5
3.7 Unauthorized modes of operation-------------------------------------------------------------------------------------------------
5
4 Transport and storage ---------------------------------------------------------------------------------------------------------------
5
4.1 Transport---------------------------------------------------------------------------------------------------------------
------------------
5
4.2 Storage-----------------------------------------------------------------------------------------------------------------------------------
5
5 Description I Related documents ----------------------------------------------------------------------------------------------
-----
5
5.1 Marking---------------------------------------------------------------------------------------------------------------------------------
--
5
5.2 Drawings / documentation----------------------------------------------------------------------------------------------
-----------------
6
5.3 List of components--------------------------------------------------------------------------------------------------------------------
9
5.4 Function----------------------------------------------------------------------------------------------------------------------------------
9
6 Installation ----------------------------------------------------------------------------------------------
-----------------------------------
10
6.1 General----------------------------------------------------------------------------------------------
-------------------------------------
10
6.2 Installation position--------------------------------------------------------------------------------------------------------------------
10
6.3 Installation instruction----------------------------------------------------------------------------------------------------------------
-
10
6.4 Valves with actuator----------------------------------------------------------------------------------------------
---------------------
10
6.5 Insulation--------------------------------------------------------------------------------------------------------------------------------
-
11
7 Commissioning I start-up! Shutdown
--------------------------------------------------------------------------------------------
11
7.1 Commissioning / start up----------------------------------------------------------------------------------------------
-----------------
11
7.2 Shutdown--------------------------------------------------------------------------------------------------------------------------------
11
8 Servicing I maintenance ----------------------------------------------------------------------------------------------
-----------------
11
8.1 Safety instruction----------------------------------------------------------------------------------------------------------------------
11
8.2 Maintenance----------------------------------------------------------------------------------------------------------------------------
12
8.3 Valve reassembly---------------------------------------------------------------------------------------------------------------------
-
12
9 Trouble-shooting -----------------------------------------------------------------------------------------------------------------------
12
9.1 General----------------------------------------------------------------------------------------------
-------------------------------------
12
9.2 Faults > Remedy----------------------------------------------------------------------------------------------
--------------------------
12
Operating instructions
V827080-10
BOACHEM
®
ZXA-ZYA
BOACHEM
®
ZXAB-ZYAB
Non-return Valves
BOACHEM
®
- RXA
Strainers
BOACHEM
®
- FSA
Shut-off Valves

Declaration of conformity
The Company:
KSB Italy S.p.A.
Via M. D’Azeglio, 32
20049 Concorezzo MI
Italy
Declare that the products are in accordance with the requirements of the European Pressure
Equipment Directive 97/23/EC applying the standards of Module H of this directive.
Description of the valve types:
BOACHEM
®
ZXAB
BOACHEM
®
ZYAB
BOACHEM
®
ZXA
BOACHEM
®
ZYA
BOACHEM
®
FSA
BOACHEM
®
RXA
PN 10-40
PN 10-40
PN 10-40
PN 10-40
PN 10-40
PN 10-40
Valves
EN
–
DIN
–
BS
–
ISO
--
Design
API 598 -- Testing of Valves / Strainers
DIN -- Material
Reference standards:
Fluid grou
ps 1 and 2
Module H
Types of fluid:
In accordance with:
TÜV Industrie Service GMBH
TÜV Sud Gruppe
Dudenstr. 28
D-68167 Mannheim
Name and address of the notified
body responsible for approval and
surveillance
Identification number of notified body:
0036
DG-0036-QS-425-05
Certificate number:
The valves having DN ≤25 comply with Directive 97/23/EC Article 3/3 should not be equipped by any
marking.
Michele Piccolo
(This document has been prepared electronically and is valid without signature)
Quality Assurance

Declaration for the purpose of EC Directive 94/9/EC dated 23 March 1994 /ATEX)
Herewith, we declare the valves of the series:
BOACHEM
®
Without electric or pneumatic actuators, as described in the relevant type series booklets,
do not have their own potential source of ignition and are thus not covered by article 1 of
the EC Directive 94/9/EC. Components such as electric or pneumatic actuators as well as
limit switches are, as a rule, covered by scope of the Directive described in Article 1,
94/9/EC, and shall be subjected to a conformity assessment procedure. Evidence of
conformity must be furnished (for ex. EC declaration of conformity).
Applied harmonized standards and EC Directives
EN 13463-1, EN 13463-5, EN 1127-1
_______________________________
EC Directive 97/23/EC
_______________________________
Michele Piccolo
Quality Assurance
(This document has been prepared electronically and is valid without signature)

2
General instructions 3
Safety
These operating instructions apply to all KSB shut-
off valves,
non-return valves and strainers
as described in section 5, unless
reference is made to other operating manuals in individual cases.
These operating instructions contain fundamental information which
must be complied with during installation, operation and maintenance.
Not only must the general safety instructions laid down in this chapter
on "Safety" be complied with, but also the safety instructions outlined
under specific headings.
Only correct installation, maintenance or repair will ensure smooth
operation of the valves.
The manufacturer shall not accept any liability if the instructions set
forth in this manual are not complied with.
3.1 Marking of instructions in the manual
The design, manufacture and testing of KSB valves are subject to a QM
syste
m to DIN EN ISO 9001 as well as the European Pressure
Equipment Directive 97/23/EC. Compliance with these requirements,
however, is based on normal, static loading, e.g.
The safety instructions contained in this manual whose non-
observance might cause haz
ards to persons are specially marked
with the general hazard sign, namely
-
flow velocities typical of the fluid handled
-
typical temperature gradients
Such measures may, for example, influence safety sign in accordance with DIN 4844— W 9.
The electrical danger warning sign is
-
materialselection
-
wallthickness
-
sealselection
-
protection of valve areas prone to wear
prevention of excessive pressures and temperatures
-
-
special designs for control operation, etc. safety sign in accordance with DIN 4844— W 8.
Valves exposed to creep-
rupture conditions have a limited service life
and have to meet the applicable regulations stipulated in the technical
codes. In case of corrosive or erosive action or something else that
could thin the thickness of the valves wall, they must be substituted so
to avoid the risk of leakage or structural failure.
The word
Caution
Caution
The valves must not be operated outside the
permissible operating range.
The limits are indicated
on the nam
e plate or currently applicable type series booklet. The
pressure-
temperature ratings, in particular, must not be exceeded.
Operation of the valves outside the above-
mentioned conditions may
result in overloads which may damage the valves.
is used to introduce safety instructions whose non-observance may
lead to damage to the valve and its functions.
Instructions attached directly to the valve (e.g. nominal pressure) must
always be complied with and be kept in a perfectly legible condition at
all times.
The type series booklets can be found at www.ksb.com — product
catalogue.
Non-observance of this warning may cause personal injury and
damage to property, for example:
-
injuries resulting from fluid leakage (cold/hot, toxic, under
pressure, ...),
impairment of the valve's function or its destruction.
The descriptions and instructions set forth in this manual refer to the
standard models but are also applicable to variants.
-
For actuated valves, the operating manual of the actuator must be
adhered to without fail.
These operating instructions do not take into account:
- anyeventualities and events which might occur duringinstallation,
operation and maintenance,
-
local regulations; the operator must ensure
that such regulations are
strictly observed by all, including the personnel called in for
installation.
Caution
The valve must only be operated by qualified
personnel.
Incorrect operation of the valve may have a substantial impact on
the
entire system, for example:
-
leakage of the fluid handled,
-
system / machine brought to a standstill
- impairment / reduction / increase of the system's / machine's
function / effect.
For any queries you may have or in the case of damage, please contact
your nearest KSB sales office.
For any queries and repeat orders, in particular for purchasing spare
parts, please specify the type series / variant details, the order number,
as well as the year of construction, if possible.
The technical da
ta (operating data) of the valves are specified in the
technical literature (type series booklet, valve characteristic, chemical
resistance chart) of the respective valve (cf. section 5).
4

3.2 Non
-
compliance with safety instructions
Non-
compliance with safety instructions can jeopardize the safety of
personnel, the environment and the valve itself. Non-
compliance with
these safety instructions will also lead to forfeiture of any and all rights
to claims for damages.
4
The valves are deli
vered ready for operation, the obturator is in 'closed'
position and the line connection ports are closed with suitable material
(caps, plugs, covers).
Transport and storage
In particular, non-compliance can, for example, result in:
4.1 Transport
Suitable precautions shall be taken to prevent damage duringtransport.
−
failure of important valve / system functions,
−
failure of prescribed maintenance and servicing practices,
hazard to persons by electrical, mechanical and chemical effects,
hazard to the environment due to leakage of hazardous substances
Caution
The valves must never be suspended by the
handwheel or by the actuator, if any.
−
−
For transporting large valves, ropes shall be attached to the yoke arms
or to the cover flange.
3.3 Safety
awareness
Valves with actuators shall be transported by means of ropes attached
to the connection ports and yoke arms, taking into account the centre
of gravity.
It is imperative to comply with the safety instructions contained in this
manual, the releva
nt national health and safety regulations and the
operator's own internal work, operation and safety regulations. Use any lifting lugs provided.
3.4 Safety instructions for the operator / user
For the valve weights refer to the relevant manufacturer documentation
(type series booklet --> section 5.2; order confirmation).
Any hot or cold valve components (e. g. body components or
handwheel) that could pose a hazard must be equipped with a guard
by the operator.
After delivery and prior to installation,
check the valve for potential
damage acquired in transit.
Guards which are fitted to prevent accidental contact with moving parts
(e.g. coupling) must not be removed whilst the unit is operating.
4.2 Storage
KSB recommends that leakages (e.g. at the ste
m seal) of hazardous
fluids (e.g. explosive, toxic, hot) be contained so as to avoid any danger
to persons and the environment. All relevant laws must be heeded.
Storage / interim storage of the valves must ensure that even after a
prolonged period of storage the valves' function is not impaired.
The
following requirements must be met:
Electrical hazards must be eliminated. (For details please refer to VDE
regulations and the safety regulations laid down by the local energy
supply companies, for instance).
-
Storage is performed with the valve in the closed position (to protect
the seat / disc contact faces against damage),
-
Measures are taken to protect the valves against dirt, humidity, frost
and corrosion (e.g. by using foils or caps; indoor storage).
3.5 Safety instructions for maintenance,
inspection and installation work 5
Description / Related documents
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by qualified personnel.
5.
1
Marking
As a rule, work on the valve must only be carried out after the valve has
cooled down and valve pressure has been released. The fluid
temperature must be below the vaporization temperature limit in all
areas in contact with the fluid.
The valve
s are marked in accordance with the Pressure Equipment
Directive 97/23/EC and the pertinent standards on valve types/design,
as well as TRD 110 (German Steam Boiler Regulations) and TRB 801
No. 45 (German Pressure Vessel Regulations).
Work on (actuated) v
alves must be carried out only during standstill.
The shutdown procedure described in the manual for taking the valve
out of service must be adhered to without fail.
Marking includes as a minimum:
-
manufacturer
-
year of construction
Immediately following completion of the work, all safety-relevant and
protective devices must be re-installed and / or re-activated. -
type or order no.
Please observe all instructions set out in section 7.Commissioning /
start-up before returning the valve to service.
-
-
PN or max. permissible pressure/temperature
−
material
3.6 Unauthoriz
ed modification and manufacture
of spare parts
The CE marking on the valve means it is in conformity with the
European Pressure Equipment Directive 97/23/EC.
Modificatio
ns or alterations of the valve supplied are only permitted
after consultation with the manufacturer. Original spare parts and
accessories authorized by the manufacturer ensure safety. The use of
other parts can invalidate any liability of the manufacturer
for
consequential damage.
3.7 Unauthorized modes of operation
The warranty relating to the operating reliability and safety of the valve
supplied is only valid if the equipment is used in accordance with its
designated use as described in section 2 General of this manua
l. The
limits stated in the technical literature must not be exceeded under any
circumstances.
5
150
Class
≥300
PN
10
16
25
>40
DN
≥25 32 40 50 65 80 100 125 150 ≥200
DN

Type DN PN Material Type series booklet No.
Boachem
®
ZYA 15-200 10/40 1.4408 623083/1-10
Boachem
®
ZXA 15-300 10/40 1.4408 623082/1-10
5.2 Drawings / documentation
The sectional drawings below provide examples of the general design / configuration of the valves. For illustrations relating to specific valve series
and further information please refer to the respective type series booklets.
5.2.1 Shut
-
off valves with gland packing
Sectional drawings
(shut-off valves with gland packing)
BOACHEM
®
ZYA
BOACHEM
®
ZXA
6

Type DN PN Material Type series booklet No.
Boachem
®
ZYAB 15-200 10/40 1.4408 623081/1-10
Boachem
®
ZXAB 15-200 10/40 1.4408 623080/5-10
5.2.2 Shut-off valves with bellows
Sectional drawings
(shut-off valves with bellows)
BOACHEM
®
ZXAB
BOACHEM
®
ZYAB
7

Type DN PN Material Type series booklet No.
Boachem
®
FSA 15-400 10/40 1.4408 623085/1-10
Type DN PN Material Type series booklet No.
Boachem
®
RXA 15-300 10/40 1.4408 623084/1-10
5.2.4 Non-return valves
Sectional drawings
(non-return valves)
BOACHEM
®
RXA
5.2.5 Strainers
Sectional drawing
(strainer)
BOACHEM
®
FSA
8

Part No.
Description
1 Body
2 Disc
3 Sleve
4 Stem
5 Leader Board
6 Spiral Wound Gasket
7 Bolt
8 Nut
9 Bonnet
10 Stem Packing
11 Gland
12 Gland Flange
13 Filter
14 Framework
15 Pin
16 Yoke
17 Orientation Block
18 Inner Hexed Angle Bolt
19 Bearing
20 Stem Nut
21 Screw
22 Lock Nut
23 Handwheel
24 Bearing Gland
25 Grease Nipple
26 Taper Pin
27 Welded Ring
28 Bellow
29 Gasket
30 Bowl Board
31 Packing
32 Stop Plate
33 Nipple
34 Screwed Sleve
35 Plug
36 Lifting Eye
37 Spring
38 Half Ring
39 Disc Cape
40
Eye Bolt
5.4.2
Non
-
return valves
Non-
return valves are check valves which close automatically if
fluid flow is reversed. Non-
return valves with separate cover consist
of the pressure-retaining components of body (1) and cover (9
), as
well
as the functional unit.
The body (1) and cover (9) are connected by studs (7) and nuts (8
),
and the joint is sealed off by the joint ring (29).
5.4 Function
The high-pressure non-
return valve RGS is in pressure seal
design. It is sealed by the bonnet (9),join
t ring (29) and segmental
ring (9). The joint ring is pre-loaded via the nuts (8).
5.4.1 Shut-off valves with bolted bonnet
The valves consist of the pressure-retaining parts, i.e. body (1)and
yoke (16) or bonnet (9), and the functional unit.
The check valve disc (2) is guided in the cover (9) or bonnet (9
).
The position of the check valve disc (2
) is determined both by the
flowconditions and by the spring (37), if any.
The body (1) and yoke (16) or bonnet (9) are connected by nuts (8),
and the joint issealed off by the joint ring.
On shut-off valves with gland packing,
the trim mainly consists of the
valve disc (2), stem (4) or throttling disc stem (2); the actua
ting
element is a handwheel (23) or actuator.
5.4.3 Strainers
Strainers feature the same pressure-retaining components and
sealingdesign as non-return valves with separate cover (9)
The stem (4) passage in the yoke (16
) is sealed by the gland
packing (10), which is tightened by means of two nuts (8
) at the
gland cover.
The strainer insert (13
) is clamped between the body seat and
the
cover, where it removes particles from the flow, depending on
the mesh size selected.
The contact faces of body (1) and/or valve disc (2) are made of rust-
proof materials.
On shut-off valves with bellows and back-
up gland, the trim
mainly consists of the valve disc (2), stem (4), and bellows (28
); the
actuating element is a handwheel (23) or actuator.
The passage of the stem (4) in the yoke (16) or bonnet (9) i
s
sealed off by the bellows (28)in accordance with the
German clean
air regulations. The back-up gland packing (31) is tighte
ned by
means of two nuts (8) at the gland cover.
The bellows-type stem seal is maintenance-free.
The contact faces of body (1) and/or valve disc (2) are made of
rust-proof materials.
5.3 List of components
9

6
Installation
We recommend to fit shut-
off valves in the pipeline on both sides of the
strainer, so that the strainer can be replaced or cleaned without having
to drain the entire system. Strainers shall be installed with suffi
cient
clearance
for removing the strainer insert. In both horizontal and vertical
pipes, we recommend to install the strainer with the strainer insert
hanging downwards to facilitate cleaning. Compliance with the
directional arrow is essential. On strainer
s with magnetic insert we
recommend to remove the entire cover to clean the magnet.
6.1 General
As a rule, the engineering contractor, construction company or
operator/user are responsible for the positioning and installation
of
the valves.
Planning and
installation errors may impair the reliable function of the
valves and pose a substantial safety hazard.
Compliance with the
following requirements is of particular importance:
Please note: When replacing the strainer insert make sure that
the weld of th
e insert is not located in the strainer outlet port, so as
to attain an optimum (high) Kv value.
Caution
The piping must be laid such that detrimental thrust
and torsional forces are kept away from the valve
6.2.4 Special designs
body (1) during installation and operation to avoid both leakage and
damage to the body.
Valves with separate throttling valve disc
shall always be
installed in
such a way that the pressure to be sealed off lies
beneath the disc, to ensure a reliable throttling effect.
Caution
The caps on the connection ports shall be removed
immediately prior to installation.
For higher differential pressures integral throttling valve disc-
stem connections are required. In such
cases we recommend
to install the
Valves so that the pressure lies above the disc.
When painting the pipelines and valves, do not apply paint to
the bolts, stems and plastic components(valve function will be
impaired). If construction work is still in progress, the valves must be
protected against dust
, sand and building material (cover with suitable
material).
If you have questions concerning optimum valve selection
or
permissible differential pressures for valves with throttling
discs, please contact the valve manufacturer.
Do not use valve handwheels as footholds.
Drainage, vent or manual start-up pipes are normally fitted with
valve combinations consisting of a shut-off valve (pressure
beneath the disc)
For safety reasons, valves and piping systems operated at high
(>50 °C) or low (< 0 °C) temperatures must be insul ated, or a
and a throttling valve (integral throttling disc—stem
connection, pressure above the disc).
warning sign must point out the risk of personal injury involved when
touching the hot or cold components
.
Valves with external moving elements must be fitted with protective
covers, or other suitable measures must be taken to prevent accidents.
Valves with pilot plug are always installed so that the pressure
to be sealed off lies above the plug.
Valves used as dead-end valves in a pipeline should be
protected against unauthorized or unintentional opening, to
If the valves are to be used as dead-end valves, double shut-off
should be ensured for safety reasons.
prevent damage to property and/or personal injury.
6.3 Installation instructions
6.2 Installation position
6.3.1 Flanged valves
The mating flange faces must be clean and undamaged.
The valve bodies are marked with an arrow indicating flow direction, if
necessary. The valves must be installed such that the flow direction of
the fluid corresponds to the direction shown by the arrow cast on the
The gaskets on the mating flangesmust be properly
centered. Only fasteners and sealing elements made
of approved
valve body. If no directional arrow is cast on the valve body, the valve
can be installed in any position.
materials shall be used. For the flange connection between valve
and pipe use all flange bolt holes provided.
6.2.1 Shut
-
off valves
Shut-off valves can be installed in any po
sition. However, the best
installation position is with the stem pointing vertically upwards. Valves
with bellows should not be installed with the stem pointing
downwards,
if possible, to prevent dirt deposits between the folds of
the bellows.
Use suitable tools to tighten the bolts evenly and crosswise at
the permissible torques.
6.3.2 Welding instructions
Shut-
off valves must be installed in the line so as to ensure that the fluid
enters the valve beneath the disc and flows out above the disc.
However,
they can also be installed in lines with alternating flow. If the
valves are to be used for throttling applications, a throttling valve disc
must be used. For flow incidence on throttling valve discs please refer
to the respective type series booklets. If
in doubt, please contact the
KSB factory.
Responsibility for welding the valves into the piping and for any
heat
treatment required lies with the respective contractor or
the plant operator.
Caution
When welding valves with butt or socket weld
ends into the piping or when performing welding
jobs on a
pipeline after
the valves have been installed (pipeline installation)
make
sure that no contamination enters the valve body and stays
there, to
prevent damage to the seat/disc interface or stem
guiding ele
ments.
Caution
When welding the valve into the pipeline, take
special
precautions e.g. welding in several steps,
so that the
temperature rise in the middle of the valve body does not exceed
the max. permissible operating temperature.
The valve must be
in 'open' position during welding.
6.2.2 Non-return valves
Caution
The welding cable (opposite pole) must not be
attached to functional valve elements, to
prevent scorching.
To ensure proper operation, non-return valve
s must always be installed
in such away tha the fluid enters the valve beneath the check
valve disc (2). When equipped with a spring (37
), they can be used in
both
pipes with upward flow and pipes with downward flow.
On valves with socket weld ends, the
insertion depth given in
the
applicable technical code must be complied with. A gap
between the
pipe end and the socket base will prevent
impermissiblestresses inthe weld.
Non-return valves without closing spring (37) shall only be installed in
horizon
tal position with the cover pointing upwards in horizontal pipes.
6.2.3 Strainers
6.4 Valves with actuator
Strainers shall always be installed in such a way that the fluid flows
through the strainer insert from the inside towards the outside
(cage effect of the strainer insert).
Valves with transmission gear and/or actuators must be installed
with the stem in vertical position, if possible. If this requirement
cannot be
met, adequately support the actuator on site or consult
the manufacturer.
10

Electrical connection shall be effected by suitably trained
personnel only.
Only Boachem
®
ZXAB and Boachem
®
ZYAB can be
supplied with the electric or pneumatic actuator.
important for valves installed in heat transfer systems to DIN 4754.
6.5 Insulation
7.1.4 Valves with actuator
If the valve is to be insulated, make sure that the insulation does not
impair the function of the valve. KSB recommends to make sure that the
sealing areas at the cover joints and at the stem passage (gland
packing) are easily accessible and visible.
On valves with electric / pneumatic /hydraulic actuators, the
strokes / actuating forces must be limited.
Electrical actuators are factory-set ready for operation. They shall be
wired as follows:
Globe valve "CLOSE" torque-dependent
7 Commissioning / start-up / shutdown
(Please also refer to section 6 Installation)
Globe valve "OPEN" travel-dependent
7.1 Commissioning / start
-
up
The wiring diagrams are given in the terminal boxes.
For pneumatic/hydraulic a
ctuators, the control pressures specified
in the order shall be complied with. Non-
observance may damage
the actuator.
7.1.1 General
Closing and opening torques or actuating forces shall be enquired from
the manufacturer, if necessary.
Prior to commissioning / start-
up compare the material, pressure and
temperature data on the valves with the operating conditions of the
piping to check the material's chemical resistance and stability under
7.2 Shutdown
In the event of prolonged shutdowns, KSB recommends to drain fluids
which change their physical condition due to changes in concentration,
load. Surge pressure (water hammer), which might occur, must not
exceed the max. permissible pressure. Safety measures are
polymerization, crystallization, solidification, etc., from the piping. If
required, flush the piping with the valves fully opened.
required to be taken.
In new systems and particularly after repair, the complete piping system
must be thoroughlyflushed with the va
lves fully opened so that particles
and / or welding beads that might damage the seat/disc interface are
removed.
8
Servicing / maintenance
8.1
Safety instructions
If the piping system is cleaned by means of a pickling procedure,
responsibility for
the compatibility of the pickling media used and the
pickling procedure itself lies with the pickling company.
Repair and maintenance work must only be performed by qualified
personnel taking into account the relevant health and safety
regulations.
Venti
ng the valve by undoing the bonnet/cover bolting or removing the
gland packing is dangerous and therefore not permitted.
It is imperative that the below safety instructions and the general
information on safety as per section 2, Safety, be observed for al
l
servicing and maintenance work to be performed.
To prevent damage to the valve material or joint seals, the usual start-
up
and shutdown velocities must be adhered to.
7.1.2 Valve actuation
Caution
Always use suitable spare parts and tools, even in
emergencies, to ensure proper functioning of the
The valves are closed by turning the handwheel in clockwise
direction and opened by turning it in counter-
clockwise direction (top
view direction symbols are found on the top of the handwheel.
valves.
8.1.1
Valve dismantling
Caution
Valves with handwheels may only be actuated by
hand. As the valve can be damaged by applying
Before removing the complete valve from the pipeline or before repair
or maintenance work to the valve itself, i.e.
excessive forces, it is not allowed to use additional levers to move the
-
prior to undoing the flange bolting between valve and pipe
handwheel.
-
prior to undoing the cover/yoke or pressure seal bonnet/cover from
Shut-off valves are normally used in such away that they are either fully
open or fully closed. the body
-
prior to removing any drain or vent plugs
prior to undoing the gland cover to replace packing rings
prior to removing an actuator bolted directly to the yoke head
For control functions in continuous operation, throttling disc should be -
fitted.
-
Caution
Performing throttling operations without a throttling
disc may result in an excessive noise level, -
prior to opening the yoke head for maintenance work to the bearing
and threaded bush
excessive wear or even destruction of the valve by cavitation.
7.1.3 Functional test
KSB recommends to check the following functions:
Valve pressure must be released and the valve must be
allowed to cool down such that the temperature is below
the fluid's
vaporization temperature in all areas in contact with the fluid in order to
effectively prevent any risk of scalding.
Check the shut-off function of the installed valves prior to
commissioning / start-up by opening and closing them several times.
Check the gland packing for leakage when it is subjected to full
operating
pressure and temperature for the first time. Re-tighten the
nuts (8) at
the gland cover evently, if necessary.
On valves in pressure seal design, the hex. head bolts (7) pre-
loading the bonnet (9) and the joint ring must always be
tightened under
operating conditions such that leakage at the
bonnet/cover, which
might be caused by the bonnet (9) sinking as a result of l
ow pressure
inside the body (1), is avoided.
The bonnet/cover bolting (7) with the joint ring shall be
gradually
tightened crosswise, evenly and in clockwise direction after
the first
loading or heating up of the valves and in the event of leakage
at the
joint ring
. For tightening torques please contact the manufactur
er, if
necessary.
Caution
Open the valve by two full handwheel turns before
re-tightening nuts (8), to prevent jamming of the
seat.
Re-tightening the nuts (8) of the bonnet/cover bolting is particularly
11

Danger of death when opening a valve under pressure!
If toxic or easily inflammable fluids were handled, or fluids whose
residues may cause corrosion in conjunction with air humidity, drain the
valve and flush or vent it.
-
Leakage at the seat
Possible causes:
If required, wear safety clothing and a protective mask!
-
contaminations/solids in the fluid
Depending on the installation position, fluid residues may be left in the
valve; these must be collected and properly disposed of. -
erosion, corrosion, abrasion
-
excessive loads from pipeline forces or thermal stresses
Prior to any transport, flush and drain the valve thoroughly.
If you have any questions please contact the manufacturer.
> Rework the seat / disc contact faces at the valve disc
and body
using
a suitable reseating tool after the valve has been
dismantled. The re-
seating process of the seat / disc contact faces
shall be continued
until the contact faces exhibit a uniform bright
surface.
8.1.2 Removing actuators
If actuators powered by an external source of energy (electric,
pneumatic, hydraulic) need to be removed from the valves or
-
Leakage at the cover gasket
dismantled, the energy supply must be shut down prior to starting any
work and the instruction in sections 3, 8.1.1
and the operating manual
of the actuator must be observed. Possible causes:
-
gasket has settled as aresult of high temperaturefluctuations
impermissible pressure loads
-
Actuators with integrated spring mechanism contain pre
-loaded
spings. They shall only be dismantled with extreme care, using
-
poor maintenance
the requisite locking devices.
If you have any questions please contact the manufacturer. -
poor gasket resistance to temperature and fluid handled
8.2 Maintenance
●
Bolted bonnet/cover
> Re-tighten the bonnet/cover bolting (19) - (9)
> Replace the gasket (29)
after having removed the bonnet/cover bolting (9). Clean the
sealing surfaces carefully before inserting a new gasket.
The operator/user is responsible for fixing appropriate inspection and
servicing intervals as required by the service conditions of the valv
es.
The service life of valves can be prolonged by:
actuating the valve (open-close) at least once or twice a year
−
−
lubricating the movable parts such as stem (4) and gland bolts (not
for oxygen valves) with standardized lubricants to DIN 51825,
−
adding or changing packing rings in the gland packing (31) in time,
−
re-tightening or replacing the cover gasket (29) in time.
The safety instructions in sections 3, 8 and the instructions in sections
9 must be complied with.
-
Leakage at the gland
packing
Possible causes:
8.3 Valve reassembly
Valve reassembly shall be effected in reverse order to dismantling.
-
worn packing material
-
poor maintenance
To maintain functional reliability, new gaskets and gland packings
shall be used whenever the valve is reassembled.
-
poor packing resistance to temperature and fluid handled
After
reassembly and prior to commissioning / start-up,the
valves shall be subjected to a leak test in accordance with DIN
3230, Part 3.
> Re-tighten the gland packing at the nuts (8) of the gland
cover
(9). Make sure that the friction forces at the stem do not increase
too much.
9
Trouble
-
shooting
> Replace the packing rings of thegland packing (31): Undo the nuts
(8) and lift off the gland cover (9).
9.1 General
Clean the gland packing chamber carefully before inserting new
packing rings. Split packing rings shall be inserted in such a way
that the cut edges are offset by 120°-180°.
KSB valves are robust in design. Nevertheless, malfunctions e
.g.
caused by maloperation, lack of maintenance or improper use
cannot be ruled out completely.
Caution
Do not use additional sealing agents for non-
asbestos gaskets and packing rings. With
All repair and maintenance work shall be performed by qua
lified
personnel using suitable tools and original spare parts.
anti-adhesive coatings, only use agents explicitly recommended by
the seal element manufacturer.
We recommend to have this work performed by our service personnel.
The safety instructions in sections 3 and 8 must be complied with.
If you have any questions please contact the manufacturer.
KSB Italia S.p.A.
Via Massimo D’azeglio, 32
– 20049 Concorezzo (MI)
Tel. [phone] – Fax [phone] – http://www.ksb.it
All valve components have been designed to be largely
maintenance-free. They materials of the moving parts have been
selected for minimum wear.
9.2
-
Faults > Remedy