KSB MIL 41000 Installation instructions

Control Valve
MIL 41000
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual MIL 41000
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 2023-08-25

Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Target group.....................................................................................................................................................6
1.3 Other applicable documents............................................................................................................................6
1.4 Symbols .............................................................................................................................................................6
1.5 Key to safety symbols/markings.......................................................................................................................6
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.3 Personnel qualification and training...............................................................................................................9
2.4 Consequences and risks caused by non-compliance with this manual .........................................................9
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the operator/user.......................................................................................................9
2.7 Safety information for maintenance, inspection and installation ..............................................................10
2.8 Unauthorised modes of operation................................................................................................................10
3 Transport/Storage/Disposal ................................................................................................................ 11
3.1 Checking the condition upon delivery..........................................................................................................11
3.2 Transport.........................................................................................................................................................11
3.3 Storage/preservation......................................................................................................................................13
3.4 Return to supplier...........................................................................................................................................13
3.5 Disposal ...........................................................................................................................................................13
4 Description of the Valve...................................................................................................................... 14
4.1 General description ........................................................................................................................................14
4.2 Product information.......................................................................................................................................14
4.3 Designation.....................................................................................................................................................14
4.4 Marking...........................................................................................................................................................15
4.5 Name plate......................................................................................................................................................16
4.6 Design details..................................................................................................................................................16
4.7 Function ..........................................................................................................................................................17
4.8 Scope of supply...............................................................................................................................................17
4.9 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
5.5 Valves with actuator.......................................................................................................................................21
5.6 Insulation ........................................................................................................................................................22
6 Commissioning/Start-up/Shutdown................................................................................................... 23
6.1 Commissioning/Start-up.................................................................................................................................23
6.2 Operating Limits.............................................................................................................................................23
6.3 Shutdown........................................................................................................................................................24
6.4 Returning to service .......................................................................................................................................24
7 Servicing/Maintenance........................................................................................................................ 25
7.1 Safety regulations...........................................................................................................................................25
7.2 Servicing/inspection........................................................................................................................................26
7.3 Tightening torques.........................................................................................................................................40

Contents
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8 Trouble-shooting.................................................................................................................................. 43
9 Related Documents.............................................................................................................................. 45
9.1 General assembly drawing with list of components ....................................................................................45
10 EU Declaration of Conformity for MIL 41000..................................................................................... 47
11 Certificate of Decontamination........................................................................................................... 48
Index ..................................................................................................................................................... 49

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 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.
In the event of damage, immediately contact your nearest KSB sales organisation
responsible to maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Type series booklet Description of the valve
Data sheet Description of the technical data for the auto-
matic recirculation valve
General assembly drawing Sectional drawing of the valve
List of components Description of all components
1.4 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
1.5 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 res-
ult in damage to the machine and its functions.

1 General
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Symbol Description
Explosion protection
This symbol identifies information about avoiding explosions in po-
tentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).
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
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
– Pressure class
– Nominal size
– Flow direction arrow
– 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 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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2.3 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.
▪Training on the valve 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.
▪Use suitable tools for maintenance, inspection and installation.
▪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.
▪Decontaminate valves which handle fluids posing a health hazard.
▪Protect the valve body and the bonnet 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. (ðSection6.1,Page23)
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8)

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/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.
CAUTION
Improper transport
Damage to the valve!
▷Protect the valve and components against external forces (e.g. impacts, blows,
vibrations).
To transport the valve, suspend it from the lifting tackle as illustrated.
A B C
Fig.1: Transporting the valve

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Table4: Transporting the valve
Photo Weight [kg] Transport
A <500 Attach the lifting accessory to the actuator’s eye-
bolt.
B > 500 to < 1200 Run the lifting accessories through the actuator
yoke.
C > 1200 Attach the lifting accessories to the flanges. Use
four ropes for transport. Tie them together dir-
ectly under the upper section of the actuator to
prevent the valve from tilting.
1. Upon receipt, unpack the valve and check it for in-transit damage.
2. Report any in-transit damage to the manufacturer immediately.
3. Dispose of packaging material in accordance with local regulations.

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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.
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.
For storing a valve which has already been operated, observe the measures to be
taken for shutdown. (ðSection6.3,Page24)
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
▪Cage-guided single-seated control valve
Valve for controlling fluids in industry, power stations, process engineering, chemical
and petrochemical engineering.
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 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 Designation
Table5: Designation example
Position
1 2 3 4 5 6 7
3 7 4 1 1 0 4
Table6: Designation key
Position Code Description
1-2 Actuator type
20 Manual actuation
37 Diaphragm actuator (air-to-close)
38 Diaphragm actuator (air-to-open)
67 Piston actuator (air-to-close)
68 Piston actuator (air-to-open)
90 Electric actuator
3-4 Design
41 Cage-guided single-seated control valve in straight-way
pattern
71 Cage-guided single-seated control valve in angle pattern
5 Valve disc design
0 Undefined
1 Low flow, unbalanced
2 With pressure-energised polymer seal ring (static)
3 With pressure-energised polymer seal ring (dynamic)
4 With pilot plug
5 With metal seal ring
6 With polymer seal ring
7 High flow, unbalanced
8 With pilot plug, soft-seated
9 With graphite seal ring
6 Trim characteristic
0 Undefined
1 Linear
2 Equal-percentage

4 Description of the Valve
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Position Code Description
6 3 Modified equal-percentage
X On/off
7 Seat type
0 Undefined
1 Standard
2 Single-stage, anti-cavitation/ low-noise version
3 Multistage, version with diffuser seat
4 Multistage, low-noise version
5 Multistage, directional diffuser
6 Multistage, anti-cavitation version, flow-to-open
7 Multistage, anti-cavitation version, flow-to-close
8 Low-flow control
9 High pressure, micro flow
X Multistage, with valve disc control
4.4 Marking
Table7: General marking
Parameter Values
Nominal size [inch] NPS ...
Nominal pressure class Class ...
Manufacturer's mark KSB
Type series/Model MIL ...
Year of construction 20..
Material .......
Flow direction arrow →
Traceability of the material .......
CE conformity marking(if required and possible)
Identification number of the notified body 0045
Customer’s marking E.g. plant/system No., etc.
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
Class
＜1”
1 ¼”
1 ½”
2”
＞2”
25
32
40
50
＞50
150
＞300
Fig.2: CE conformity marking: Fluids in Groups 1 and 2
Fluid groups In accordance with the current regulations and directives for pressure equipment,
Group1 comprises all fluids posing physical or health hazards, e.g. fluids defined as
▪Explosive
▪Extremely flammable
▪Highly flammable
▪Very toxic
▪Toxic
▪Oxidising
Fluid group 2 comprises all other fluids not referred to in Group1.

4 Description of the Valve
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4.5 Name plate
Fig.3: Valve name plate (example)
1 TAG number 2 Serial number
3 Model number 4 Design
5 Nominal valve size 6 Cv value
7 Valve body material 8 Actuator stroke
9 Leakage class 10 Trim material
11 Gland packing material 12 Actuator size
13 Spring range 14 Actuating signal
4.6 Design details
Design
▪Cage-guided single-seated control valve
▪PTFE gland packing ≤180°C
▪Graphite gland packing >180°C
▪Clamped seat ring
▪Rangeability 100:1 for version with standard trim
▪Standard bonnet: temperature range -29°C to 566°C
▪Leakage classes III and IV to ANSI FCI 70.2
Variants
▪Two-stage design with anti-cavitation/ low-noise plug
▪Balanced valve disc with spring-loaded, metal, polymer or graphite seal ring
▪Balanced valve disc with pilot plug
▪Unbalanced valve disc without seal ring
▪Eco-Lock gland packing to ISO15848-1 fugitive emission requirements
▪Spring-loaded gland packing (live loading)
▪Rangeability 50:1 for version with anti-cavitation/ low-noise trim
▪Extended bonnet: temperature range -100°C to -30°C
▪Cryogenic bonnet: temperature range -196°C to -100°C
▪Flanged body with raised-face flanges (RF)
▪Flanged body with ring joint flanges (RTJ)

4 Description of the Valve
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▪Butt weld ends (BW)
▪Angle pattern with polymer seal ring MIL71000
▪Leakage class V to ANSI FCI 70.2
4.7 Function
Design Rugged, heavy valve disc guiding section provides maximum support and valve disc
stability. The valve disc is guided to its seat by the cage. This valve disc guiding
feature prevents trim vibrations and offers various options of reducing noise and
preventing cavitation.
Stem sealed by gland
packing
The gland packing is tightened at the gland follower (4) by studs (2) and nuts (3).
Function The valve is operated by a pneumatic actuating element (actuator).
4.8 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪Valve
▪Actuator
▪Valve operating manual
▪Actuator operating manual
4.9 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
Control valves with actuators should preferably be installed vertically in horizontal
pipes (position1). Installation with the stem in an inclined or horizontal position, e.g.
in vertical pipes (positions 2 and 5), is also permitted. Site-supplied supports must be
provided for actuators installed in a horizontal position (position5a). Avoid any
installation positions with the actuator hanging downward (positions 3 and 4, risk of
malfunction).
1
2
2
3
4
4
5
5
5a
Fig.4: Installation positions
The valve bodies are marked with an arrow indicating the flow direction.

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Install the valves in such a way that the actual flow direction of the fluid matches the
arrow on the valve body.
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, pipes and connections.
2. Remove the protective covers on both body ends before installing the valve in
the pipe.
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 pipe.
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
Weld beads, scale and other impurities
Damage to the valve!
▷Take suitable measures to protect the valve against impurities.
▷Remove any impurities from the piping.
▷If necessary, install a strainer.
CAUTION
Painting of the piping
Valve function impaired!
Loss of important information provided on the valve!
▷Protect stem and plastic components prior to applying paint.
▷Protect printed name plates prior to applying paint.
5.4.1 Flange connection
Fasteners Only use fasteners and sealing elements of approved materials. Always use all flange
bolt holes provided when connecting the valve to the pipe.

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Flange connection
1
2
3
4
5
6 7
8
1
2
3
4
1
2
3
4
10
8
5
6
7
11
12
9
1
2
3
5
6
4
Fig.5: Sequence for flange bolt tightening
üThe mating flange faces are clean and undamaged.
üFasteners and sealing elements are available.
üVerify that the pipe is correctly aligned and the flanges are parallel.
1. Align the valve between the pipe flanges.
2. Use an appropriate tool to evenly tighten the fasteners in the specified
tightening sequence.
5.4.2 Welding the valve into the pipe
Responsibility for welding the valve into the pipe and for any heat treatment
required lies with the commissioned construction company or the plant operator.
CAUTION
Weld beads, scale and other impurities
Damage to the valve!
▷Take suitable measures to protect the valve against impurities.
▷Remove any impurities from the piping.
▷If necessary, install a strainer.
CAUTION
Incorrect earthing during welding work on the piping
Damage to the valve (scorching)!
▷Never earth the electric welding equipment on the valve’s functional parts.