KSB BOAX-B Installation instructions

Butterfly Valve
BOAX-B
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual BOAX-B
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 2023-01-24

Contents
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Contents
Glossary .................................................................................................................................................. 6
1 General.................................................................................................................................................... 7
1.1 Principles ...........................................................................................................................................................7
1.2 Installation of partly completed machinery....................................................................................................7
1.3 Target group.....................................................................................................................................................7
1.4 Other applicable documents............................................................................................................................7
1.5 Symbols .............................................................................................................................................................7
1.6 Key to safety symbols/markings.......................................................................................................................8
2 Safety...................................................................................................................................................... 9
2.1 General..............................................................................................................................................................9
2.2 Intended use .....................................................................................................................................................9
2.2.1 Prevention of foreseeable misuse.................................................................................................... 10
2.3 Personnel qualification and training.............................................................................................................10
2.4 Consequences and risks caused by non-compliance with this manual .......................................................10
2.5 Safety awareness ............................................................................................................................................10
2.6 Safety information for the operator/user.....................................................................................................10
2.7 Safety information for maintenance, inspection and installation ..............................................................11
2.8 Unauthorised modes of operation................................................................................................................11
3 Transport/Storage/Disposal ................................................................................................................ 12
3.1 Checking the condition upon delivery..........................................................................................................12
3.2 Transport.........................................................................................................................................................12
3.3 Storage/preservation......................................................................................................................................13
3.4 Return to supplier...........................................................................................................................................14
3.5 Disposal ...........................................................................................................................................................14
4 Description of the Valve...................................................................................................................... 15
4.1 General description ........................................................................................................................................15
4.2 Product information.......................................................................................................................................15
4.2.1 Product information as per Pressure Equipment Directive 2014/68/EU(PED)............................... 15
4.2.2 Product information as per UK Pressure Equipment (Safety) Regulations 2016........................... 15
4.2.3 EC Machinery Directive 2006/42/EC.................................................................................................. 15
4.2.4 Product information as per Regulation No. 1907/2006(REACH) ................................................... 15
4.3 Code ................................................................................................................................................................15
4.4 Name plate......................................................................................................................................................16
4.5 Design details..................................................................................................................................................16
4.6 Function ..........................................................................................................................................................17
4.7 Scope of supply...............................................................................................................................................17
4.8 Noise characteristic.........................................................................................................................................17
5 Installation at Site................................................................................................................................ 18
5.1 General information/Safety regulations .......................................................................................................18
5.2 Installation position........................................................................................................................................18
5.3 Preparing the valve ........................................................................................................................................19
5.4 Piping ..............................................................................................................................................................19
5.4.1 Flange connection............................................................................................................................. 19
5.4.2 Fasteners for flange connections ..................................................................................................... 21
5.4.2.1 Bolting and weights for wafer-type body - T1........................................................................21
5.4.2.2 Bolting and weights for semi-lug body - T2............................................................................22
5.4.2.3 Bolting and weights for full-lug body - T4..............................................................................23
5.4.2.4 Bolting/weights for flanged body with flat faces - T5 DN 650-1000 (DN 150-600 on request).
25
5.4.3 Dead-end service............................................................................................................................... 27
5.5 Valve with actuator........................................................................................................................................27
5.6 Insulation ........................................................................................................................................................28

Contents
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6 Commissioning/Start-up/Shutdown................................................................................................... 29
6.1 Commissioning................................................................................................................................................29
6.1.1 Prerequisites for commissioning ...................................................................................................... 29
6.1.2 Actuation/operation ......................................................................................................................... 29
6.1.2.1 Actuating element – lever ........................................................................................................29
6.1.2.2 Actuating element – manual gearbox.....................................................................................29
6.1.2.3 Actuating element – electric actuator .....................................................................................30
6.1.2.4 Actuating element – pneumatic actuator ...............................................................................30
6.1.3 Functional test................................................................................................................................... 30
6.2 Operating Limits.............................................................................................................................................30
6.2.1 Ambient temperature....................................................................................................................... 30
6.3 Shutdown........................................................................................................................................................31
6.3.1 Measures to be taken for shutdown................................................................................................ 31
6.3.1.1 Valve with lever ........................................................................................................................31
6.3.1.2 Valve with manual gearbox .....................................................................................................31
6.3.1.3 Valve with electric actuator .....................................................................................................31
6.4 Returning to service .......................................................................................................................................31
7 Servicing/Maintenance........................................................................................................................ 32
7.1 Safety regulations...........................................................................................................................................32
7.2 Servicing/inspection........................................................................................................................................32
7.2.1 Supervision of operation .................................................................................................................. 32
7.2.2 Tools required ................................................................................................................................... 33
7.2.3 Inspection work................................................................................................................................. 33
7.2.3.1 Lubrication ................................................................................................................................33
7.2.4 Dismantling the valve ....................................................................................................................... 33
7.2.4.1 General information/Safety regulations..................................................................................33
7.2.4.2 Preparing the valve...................................................................................................................33
7.2.4.3 Removing the actuator.............................................................................................................34
7.2.4.4 Dismantling the piping.............................................................................................................34
7.2.4.5 Dismantling the valve (DN>200 only) ....................................................................................34
7.2.5 Assembling the valve ........................................................................................................................ 34
7.2.5.1 General information/Safety regulations..................................................................................34
7.2.5.2 Mounting the actuator.............................................................................................................34
7.2.5.3 Connecting the piping..............................................................................................................35
7.2.5.4 Assembling the valve ................................................................................................................35
7.3 Spare parts stock.............................................................................................................................................35
7.3.1 Ordering spare parts......................................................................................................................... 35
8 Trouble-shooting.................................................................................................................................. 37
9 Related Documents.............................................................................................................................. 38
9.1 General assembly drawing with list of components ....................................................................................38
9.2 Dimensions and weights ................................................................................................................................40
9.2.1 Dimensions of BOAX-B ..................................................................................................................... 40
9.2.2 Dimensions and weights of BOAX-B + lever CR+/CM+ ................................................................... 41
9.2.3 Dimensions and weights of BOAX-B + manual gearbox MA+ ....................................................... 41
9.2.4 Dimensions and weights of BOAX-B + MS manual gearbox.......................................................... 42
9.2.5 Dimensions and weights of BOAX-B + MC manual gearbox.......................................................... 43
9.2.6 Dimensions and weights of BOAX-B + ACTAIREVO pneumatic actuator..................................... 45
9.2.7 Dimensions and weights of BOAX-B + DYNACTAIREVO pneumatic actuator ............................. 46
9.2.8 Dimensions and weights of BOAX-B + electric actuator ................................................................ 47
9.3 Flange dimensions..........................................................................................................................................48
10 EU Declaration of Conformity............................................................................................................. 50
10.1 EU Declaration of Conformity in accordance with the European Pressure Equipment Directive for
Butterfly Valves...............................................................................................................................................51
11 UK Declaration of Conformity............................................................................................................. 54
11.1 UK Declaration of Conformity for Butterfly Valves......................................................................................54

Contents
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12 Certificate of Decontamination........................................................................................................... 57
Index ..................................................................................................................................................... 58

Glossary
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Glossary
ATEX 2014/34/EU
The acronym ATEX is the French abbreviation for
explosive atmospheres: “Atmosphère explosible”.
The ATEX product directive 2014/34/EU lays down
rules to be met by equipment and protective
systems intended for use in potentially explosive
atmospheres in the European Union (EU).
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.
Equipment and Protective Systems Intended for
Use in Potentially Explosive Atmospheres
Regulations 2016
The product regulations Equipment and Protective
Systems Intended for Use in Potentially Explosive
Atmospheres Regulations 2016 lay down rules to
be met by equipment and protective systems
intended for use in potentially explosive
atmospheres in the United Kingdom (except
Northern Ireland).
Pressure Equipment (Safety) Regulations 2016
(PER)
The Pressure Equipment (Safety) Regulations 2016
set out the requirements to be met by pressure
equipment intended to be placed on the UK
market (except Northern Ireland).
Pressure Equipment Directive 2014/68/EU (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, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in 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.
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 valve
General assembly drawing1) Sectional drawing of the valve
Sub-supplier product literature Operating manuals and other product literature
describing accessories and integrated machinery
components
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
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
1If included in agreed scope of supply

1 General
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1.6 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.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX) and the UK's Equipment and Protective Systems
Intended for Use in Potentially Explosive Atmospheres Regulations
2016.
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 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 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:
– Manufacturer
– Type designation
– Nominal pressure
– Nominal size
– Year of construction
– 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 regulations and directives for pressure
equipment.
▪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.
▪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.
2.2 Intended use
▪Only operate valves which are in perfect technical condition.
▪Do not operate the valve in partially assembled condition.
▪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.
▪The valve's design and rating are based on predominantly static loading in
accordance with the codes applied. Consult the manufacturer if the valve is
subjected to dynamic loads or any other additional influences.
▪Consult the manufacturer about any other modes of operation not described in
the product literature.
▪Do not use the valve as a foothold.

2 Safety
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2.2.1 Prevention of foreseeable misuse
▪Never exceed the permissible application and operating limits specified in the
data sheet or product literature regarding temperature, etc.
▪Observe all safety information and instructions in this manual.
2.3 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.
2.4 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
2.5 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
2.6 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 accessible to
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
touch rotating parts.
▪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 Safety
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2.7 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.
▪Carry out work on the valve during standstill only.
▪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 the actuating element 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.
2.8 Unauthorised modes of operation
▪The valve is operated outside the limits stated in the operating manual.
▪The valve is not operated in accordance with the intended use.
(ðSection2.2,Page9)

3 Transport/Storage/Disposal
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3 Transport/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 could slip out of the suspension arrangement
Danger to life from falling parts!
▷Only transport the valve in the specified position.
▷Never attach lifting accessories to the handwheel, valve disc, neck or 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.
▷For valves with actuators observe the relevant actuator operating manual.
Transport devices on the actuator are not suitable for suspending the entire
valve/actuator assembly.
CAUTION
Damage due to excessive valve closing force
Damage to the seat/disc interface!
▷Transport the valve in half open condition.
To transport the valve, suspend it from the lifting tackle as illustrated.
Fig.1: Transporting a valve with electric actuator

3 Transport/Storage/Disposal
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Fig.2: Transporting a valve with actuator in a vertical position
Fig.3: Transporting a valve in a horizontal position
Fig.4: Transporting a valve in a horizontal position
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:
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.

3 Transport/Storage/Disposal
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CAUTION
Damage due to incorrect storage in closed position
Damage to the seat/disc interface!
▷Store the valve in half open condition.
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31)
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
3.5 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 Description of the Valve
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4 Description of the Valve
4.1 General description
▪Centred-disc butterfly valve with lever, manual gearbox, electric or pneumatic
actuator
Valve for shutting off and controlling fluids in the water industry, in water supply,
water treatment, drainage, irrigation, building services, heating systems, air-
conditioning systems and drinking water supply.
4.2 Product information
4.2.1 Product information as per Pressure Equipment Directive 2014/68/EU(PED)
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.
4.2.2 Product information as per UK Pressure Equipment (Safety) Regulations 2016
The valves satisfy the safety requirements of the UK Pressure Equipment (Safety)
Regulations 2016 (PER) for fluids in Groups 1and2.
4.2.3 EC Machinery Directive 2006/42/EC
Valves with actuators can meet the requirements of the 2006/42/EC Machinery
Directive for partly completed machinery.
4.2.4 Product information as per Regulation No. 1907/2006(REACH)
For information as per European chemicals regulation (EC) No. 1907/2006 (REACH)
see https://www.ksb.com/en-global/company/corporate-responsibility/reach.
4.3 Code
In accordance with the current regulations and directives for pressure equipment the
valves are marked as shown in the following table:
Fluids in Groups 1 and 2
Fig.5: CE conformity marking
Fig.6: UKCA conformity marking
Fluid groups In accordance with the current regulations or directives for pressure equipment,
Group 1 comprises all fluids posing physical or health hazards. Examples:
▪Explosive
▪Extremely flammable
▪Highly flammable
▪Very toxic
▪Toxic
▪Oxidising
Group 2 comprises all other fluids not referred to in Group 1.

4 Description of the Valve
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4.4 Name plate
Fig.7: BOAX-B name plate (Example: CE and UKCA)
1 Valve type 2 In-house material code
3 Nominal pressure 4 Maximum permissible pressure
5 Maximum permissible pressure for
dead-end service or downstream
dismantling
6 Pipe flange connection
7 Month and year of construction 8 Serial number
9 CE symbol with identification
number of the notified body
10 Valve diameter
4.5 Design details
Design
▪Wafer-type body with flat faces - T1: DN 650 - 1000
▪Semi-lug body - T2: DN 40 - 600
▪Full-lug body with raised faces - T4: DN 40 - 600
▪Flanged body with flat faces - T5: DN 650 to 1000 (DN 150 to 600 on request)
▪Dead-end service and downstream dismantling possible with body types T2, T4
and T5
▪Elastomer liner: thicker elastomer in the area of the shaft passage ensures leak-
proof sealing to atmosphere
▪The spherically machined valve disc ensures perfectly tight shut-off.
▪Face-to-face length to ISO5752-20 and EN558-1-20
▪EN, ASME connections
▪Top flange and square valve shaft end to ISO5211
▪Marking in accordance with EN19
▪Absolutely tight shut-off in either direction of flow in accordance with
EN12266-1, leakage rateA, and ISO5208, categoryA.
▪Design to EN 593 and ISO 10631
▪Body with polyurethane coating, thickness 80µm, colour: RAL5012 (light blue),
in compliance with water specifications.
▪Valve discs made of nodular cast iron, epoxy-coated, thickness 80μm, colour:
reddish brown, suitable for drinking water
▪The valves can be installed between all commercial mating flanges and line
connections without requiring any flange gaskets. The elastomer liner alone
provides a tight seal at the flange connections.
▪Standard manual actuation:
– CR+/ CM+ quarter-turn levers
– MA+ manual gearbox
– MS/MC manual gearboxes

4 Description of the Valve
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Actuator variants
▪Electric actuators
▪ACTAIR EVO/ DYNACTAIR EVO pneumatic actuators
Automation options
▪AMTROBOX for open/closed position signalling
▪AMTRONIC U on/off control unit
▪SMARTRONIC U positioner
4.6 Function
Design The butterfly valve consists of the pressure-retaining parts, i.e. body 100, actuating
shaft 213, the functional unit (shaft 210, valve disc 550), elastomer liner 413 and the
actuating element.
Function The valve is actuated via a lever, manual gearbox electric or pneumatic actuator.
Sealing Valve disc 550 and the actuating shaft are joined by keys 940 or splining and sealed
to atmosphere by elastomer liner 413.
Shaft anti-blow out
function
DN ≤ 200: Shaft anti-blow out ensured by pressing the shaft into the valve disc and
body.
DN > 200: The shaft anti-blow out device prevents the shaft from being pushed out
of the pressurised body when the valve and actuator are separated. This function
requires the use of supplementary components.
4.7 Scope of supply
The following items are included in the scope of supply:
▪Valve with actuating element
▪Valve operating manual
▪Actuator operating manual
4.8 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
Responsibility for positioning and installing the valve lies with the consultant, the
engineering contractor or the operator. Planning errors and installation errors can
prevent 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.
5.2 Installation position
DANGER
Dead-end valve
High-pressure hazard!
Risk of burns!
▷Protect the valve against unauthorised and/or unintentional opening.
A valve installed at the end of a pipe in combination with a blind flange must not be
used as a dead-end valve.
Recommended upstream and downstream stabilisation distances
Fig.8: Recommended minimum distance between the valve and a tee or elbow
If the actual distances are shorter than the minimum distances in drawings 1, 2, 3 and
4, the valve disc must be positioned at an opening angle of 70°.
Upstream and downstream stabilisation distances are also required for valves
installed on the pump discharge side.

5 Installation at Site
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8411.801/16-EN
Preferred installation
position DN≤600
If the valve is actuated via a lever, a horizontal shaft installation position is preferred.
If the valve is actuated via an electric or pneumatic actuator, there is no preference
for a horizontal or vertical shaft installation position.
Preferred installation
position DN>600
Fig.9: Installation position: horizontal shaft
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 air through all vessels, piping and
connections.
2. Remove the valve’s flange covers before installing it in the pipe.
3. Check that the inside of the valve is free from any foreign objects and remove
them if applicable.
4. If required, install a strainer in the piping.
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 structural measures to prevent any piping forces from being transmitted
to the valve.
▷Avoid mechanical loads beyond normal levels, e.g. piping forces, moments and
vibrations.
CAUTION
Painting pipes and actuator
Valve function impaired!
▷Protect stem, plastic components and actuator elements prior to applying paint.
▪For any further work (e.g. construction work, cleaning measures) protect the
valve and the piping against contamination (e.g. by covering it with a tarpaulin).
5.4.1 Flange connection
Fasteners Only use fasteners, e.g. to DINEN1515-4, made of materials approved for the
respective nominal valve size. Always use all flange bolt holes provided when
connecting the valve to the pipe.

5 Installation at Site
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CAUTION
Improper installation
Damage to the liner!
▷Do not use a seal between body and flange.
▷Provide sufficient clearance when inserting the valve into the pipe.
▷Make sure that the body is correctly centred between the pipe flanges.
Coated flange ▪Direct installation between rubber-coated flanges or with expansion bellows is
not permitted. Please contact KSB.
▪Installation between flanges made of polyethylene:
– Installation between flanges with flat faces is permitted.
– Installation between flanges with grooved faces is not permitted.
Flange connection
1) 1)
Fig.10: Minimum dimension for installation in the pipe
1) Face-to-face length + 40mm
üThe mating flange faces are clean and undamaged (Ra≤ 25µm).
üVerify that the piping is correctly aligned. Verify that the flanges are parallel.
üThe inside diameter of the pipe flanges is within the permissible minimum and
maximum diameter limits. (ðSection9.3,Page48)
üOpen and close the valve to check that the valve disc rotates freely.
1. Move the valve into the open position. Open it as far as possible without the
valve disc protruding beyond the body.
2. Move the pipe flanges as far apart as required to achieve a sufficient clearance
between the flange faces and the protruding liner faces.
3. Insert the valve between the two flanges and centre it using the tie bolts.
4. Tighten the fasteners evenly and crosswise with a suitable tool until contact is
established between the body and the pipe flanges (metal-to-metal contact).
5. Actuate the valve several times to verify that the valve disc rotates freely.