KSB STAAL 40 AKD User manual

STAAL 40 AKD/AKDS, STAAL 100 AKD/AKDS,
AKG-A/AKGS-A, ZTS,
STAAL 40 AKK/AKKS, STAAL 100 AKK/AKKS,
AKR/AKRS, ZRS, VTS, UGS
Operating Manual

Legal information/Copyright
Operating Manual
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 13/09/2022

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
2.2.1 Prevention of foreseeable misuse.......................................................................................................9
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......................................................................................................................................12
3.4 Return to supplier...........................................................................................................................................13
3.5 Disposal ...........................................................................................................................................................13
4 Valve Description ................................................................................................................................. 14
4.1 Product information.......................................................................................................................................14
4.1.1 Product information as per Regulation No. 1907/2006(REACH) ....................................................14
4.1.2 Product information as per Pressure Equipment Directive 2014/68/EU(PED)................................14
4.1.3 Product information as per UK Pressure Equipment (Safety) Regulations 2016 ...........................14
4.1.4 Product information as per Directive 2014/34/EU (ATEX) ...............................................................14
4.1.5 Product information as per UK Equipment and Protective Systems Intended for Use in
Potentially Explosive Atmospheres Regulations 2016 .....................................................................14
4.2 Marking...........................................................................................................................................................14
4.3 Gate valves to DIN/EN with bolted bonnet...................................................................................................15
4.3.1 STAAL40AKD/AKDS..........................................................................................................................15
4.3.2 STAAL 100 AKD/AKDS........................................................................................................................17
4.4 Gate valves to DIN/EN in pressure seal design..............................................................................................18
4.4.1 AKG-A/AKGS-A...................................................................................................................................18
4.4.2 ZTS.......................................................................................................................................................20
4.5 Body pressure relief valve ..............................................................................................................................21
4.5.1 UGS .....................................................................................................................................................21
4.6 Swing check valves with bolted cover...........................................................................................................24
4.6.1 STAAL 40 AKK/AKKS..........................................................................................................................24
4.6.2 STAAL 100 AKK/AKKS........................................................................................................................25
4.7 Swing check valves with pressure seal cover ................................................................................................26
4.7.1 AKR/AKRS ...........................................................................................................................................26
4.7.2 ZRS ......................................................................................................................................................26
4.8 Line blind valve...............................................................................................................................................27
4.8.1 VTS ......................................................................................................................................................27
4.9 Scope of supply...............................................................................................................................................28
4.10 Dimensions and weights ................................................................................................................................28
5 Installation at Site................................................................................................................................ 29
5.1 General information/Safety regulations .......................................................................................................29
5.2 Installation position and location..................................................................................................................30

Contents
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5.3 Welding into the pipeline..............................................................................................................................31
5.4 Valves with actuator.......................................................................................................................................31
5.5 Insulation ........................................................................................................................................................32
5.6 Body pressure relief valve ..............................................................................................................................34
6 Commissioning/Start-up/Shutdown................................................................................................... 39
6.1 Commissioning/Start-up.................................................................................................................................39
6.1.1 Prerequisites for commissioning/start-up .........................................................................................39
6.1.2 Valve actuation ..................................................................................................................................41
6.1.3 Information on the mechanical components...................................................................................42
6.2 Operating limits..............................................................................................................................................43
6.2.1 Pressure/temperature ratings for STAAL40AKD/AKDS ..................................................................43
6.2.2 Pressure/temperature ratings for STAAL100AKD/AKDS ................................................................43
6.2.3 Pressure/temperature ratings for AKG-A/AKGS-A ...........................................................................43
6.2.4 Pressure/temperature ratings for ZTS...............................................................................................44
6.2.5 Pressure/temperature ratings for STAAL40AKK/AKKS ..................................................................45
6.2.6 Pressure/temperature ratings for STAAL100AKK/AKKS ................................................................45
6.2.7 Pressure/temperature ratings for AKR/AKRS....................................................................................45
6.2.8 Pressure/temperature ratings for ZRS...............................................................................................46
6.2.9 Pressure/temperature ratings for VTS...............................................................................................47
6.3 Shutdown........................................................................................................................................................48
6.3.1 Measures to be taken for shutdown ................................................................................................48
6.3.2 Servicing/Maintenance ......................................................................................................................48
7 Servicing/Maintenance........................................................................................................................ 50
7.1 Safety regulations...........................................................................................................................................50
8 Trouble-shooting.................................................................................................................................. 51
9 Related Documents.............................................................................................................................. 52
9.1 General assembly drawing with list of components for STAAL40AKD/AKDS ..........................................52
9.2 General assembly drawing with list of components for STAAL100AKD/AKDS ........................................55
9.3 General assembly drawing with list of components for AKG-A/AKGS-A....................................................57
9.4 General assembly drawing with list of components for ZTS .......................................................................58
9.5 General assembly drawing with list of components for UGS ......................................................................60
9.6 General assembly drawing with list of components for STAAL40AKK/AKKS...........................................61
9.7 General assembly drawing with list of components for STAAL100AKK/AKKS.........................................62
9.8 General assembly drawing with list of components for AKR/AKRS............................................................64
9.9 General assembly drawing with list of components for ZRS .......................................................................65
9.10 General assembly drawing with list of components for VTS.......................................................................66
10 EU Declaration of Conformity............................................................................................................. 67
10.1 EU Declaration of Conformity for STAAL40, STAAL100, AKG-A/AKGS-A, AKR/AKRS, ZTS, ZRS, VTS, UGS ..
67
11 UK Declaration of Conformity............................................................................................................. 68
11.1 UK Declaration of Conformity for STAAL40, STAAL100, AKG-A/AKGS-A, AKR/AKRS, ZTS, ZRS, VTS, UGS..
68
Index ..................................................................................................................................................... 69

Glossary
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Glossary
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.
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
Flow characteristics Information on Kv values and zeta values
General assembly drawing1) Sectional drawing of the valve
Sub-supplier product literature2) Operating manuals and other product literature
for the accessories
Observe the relevant manufacturer's product literature for the accessories.
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.
1If included in agreed scope of supply; otherwise refer to the type series booklet.
2If included in agreed scope of supply

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Symbol Description
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.

2 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
– 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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2.2.1 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.
▪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.
▪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 body bonnet/cover from any impacts.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page39)
2.8 Unauthorised modes of operation
▪The valve is operated outside the specified limits.
▪The valve is not operated in accordance with the intended use.
▪Use gate valves exclusively for fully open or fully closed service. An intermediate
position (throttling function) is not permitted.

3 Transport/Storage/Disposal
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3 Transport/Storage/Disposal
3.1 Checking the condition upon delivery
The valve is delivered ready for operation. Its line connection ports may still be closed
with caps if applicable.
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
Transport the valve in the closed position.
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.
▷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 aids on the actuator are not suitable for suspending the entire valve/
actuator assembly.
To transport the valve, suspend it from the lifting tackle as illustrated.

3 Transport/Storage/Disposal
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Fig.1: Transporting the valve
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
Incorrect storage
Damage due to dirt, corrosion, humidity and/or frost!
▷Close the valve using little force and store in the closed position.
▷Store the valve in a frost-proof room where the atmospheric humidity is as
constant as possible.
▷Protect the valve from dust during storage, e.g. with suitable caps or foils.
▷Protect the valve from contact with solvents, lubricants, fuels or other
chemicals.
▷Store the valve in vibration-free conditions.
If properly stored indoors, the equipment is protected for a maximum of 12 months.
NOTE
If the valves are fitted with actuators, ensure that the actuator's operating manual
is also observed.

3 Transport/Storage/Disposal
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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 Valve Description
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4 Valve Description
4.1 Product information
4.1.1 Product information as per Regulation No. 1907/2006(REACH)
For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see https://
www.ksb.com/ksb-en/About-KSB/Corporate-responsibility/reach/ .
4.1.2 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.
4.1.3 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.
4.1.4 Product information as per Directive 2014/34/EU (ATEX)
The valves do not have a potential internal source of ignition and can be used in
potentially explosive atmospheres, Group II, category 2 (zones 1+21) and category 3
(zone 2+22) to ATEX 2014/34/EU.
4.1.5 Product information as per UK Equipment and Protective Systems Intended for
Use in Potentially Explosive Atmospheres Regulations 2016
The valves do not have a potential internal source of ignition and can be used in
accordance with the UK’s Equipment and Protective Systems Intended for Use in
Potentially Explosive Atmospheres Regulations 2016 in potentially explosive
atmospheres, Group II, category 2 (zones 1+21) and category 3 (zone 2+22).
4.2 Marking
Table4: General marking
Description Marking
Nominal size DN ...
Nominal pressure class and/or max.
permissible pressure/temperature
PN ... / ... bar / ... °C
Manufacturer KSB
Type series/model and/or order number NORI...
Year of construction 20..
Material .......
Flow direction arrow →
Traceability of the material .......
CE marking
Identification number of the notified
body 0036
UKCA marking
Identification number of the approved
body 0168
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:

4 Valve Description
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Fluids in Groups 1 and 2
Class PN DN
≤25 32 40 50 65 80 100 125 150 ≥200
10
16
≥
25
≥≥40
150
300
Fig.2: CE marking
Class PN DN
≤25 32 40 50 65 80 100 125 150 200
10
16
25
≥≥40
150
300
≥
Fig.3: UKCA marking
Fluid groups In accordance with the current regulations or directives for pressure equipment,
Group 1 comprises: all fluids posing physical or health hazards, e.g. fluids defined as
▪Explosive
▪Extremely flammable
▪Highly flammable
▪Flammable: The maximum allowable temperature is above flashpoint.
▪Very toxic
▪Toxic
▪Oxidising
Group 2 comprises all other fluids not referred to in Group 1.
4.3 Gate valves to DIN/EN with bolted bonnet
4.3.1 STAAL40AKD/AKDS
Fig.4: STAAL40AKD/AKDS
4.3.1.1 General description
▪Gate valve with bolted bonnet
Valve for preventing backflow in industrial plants, power stations, process
engineering and shipbuilding.
4.3.1.2 Design details
Design
▪Body of forged or welded steel construction
▪Bolted cover
▪Non-rotating stem with external screw
▪Split wedge
▪Standard position indicator ≤ DN200
▪Yoke head suitable for mounting electric actuators (DINISO5210)

4 Valve Description
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Variants
▪Stem protecting tube
▪Stem protecting tube with position indicator (≥ DN250)
▪Stem protecting tube with position switch (≥ DN250)
▪Position switch(es) mounted on yoke (≤DN200)
▪Bypass
▪Drain branch
▪Barrier water connection
▪Electric actuators
▪Bevel gear and spur gear (recommended from≥DN700)
▪Installation kit for actuators and manual gearboxes
▪Seat/disc interface made of wear-resistant and corrosion-proof Stellite
▪Stem made of 1.4122
▪TA-Luft-compliant model (with or without spring loading) for applications to
VDI2440 at temperatures ≤ 250°C and > 250°C (400°C maximum)
▪Other flange designs or butt weld end designs
▪Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /
Pressure Vessel Regulations – or to customer specification
▪≥DN900 on request
4.3.1.3 Function
Design The gate valve comprises the pressure-retaining parts, i.e. body 100 and yoke 166, the
functional unit (stem 200, wedge/disc holder 367 and flexibly mounted wedge discs
360), and the actuating element.
Function The valve is actuated using a handwheel, manual gearbox or electric actuator.
Sealing Body 100 and yoke 166 are connected by studs 902.1 or grub screws 904 and nuts
920.1, and the joint is sealed to atmosphere by joint ring 411.1.
The seating faces of body 100 and wedge discs 360 are hard-faced. Gland packing
461, which seals off stem 200, is tightened via gland follower 452 by means of studs
902.3 or hinged bolts and nuts 920.2.

4 Valve Description
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4.3.2 STAAL 100 AKD/AKDS
Fig.5: STAAL100AKD/
AKDS
4.3.2.1 General description
▪Gate valve with bolted bonnet
Valve for preventing backflow in industrial plants, power stations, process
engineering and shipbuilding.
4.3.2.2 Design details
Design
▪Body of forged or welded steel construction
▪Bolted cover
▪Non-rotating stem with external screw
▪Split wedge
▪Yoke head suitable for mounting electric and pneumatic actuators (DINISO5210)
Variants
▪Stem protecting tube
▪Stem protecting tube with position indicator
▪Limit switch(es)
▪Bypass
▪Drain branch
▪Hard-faced back seat
▪Threaded bush free from non-ferrous metals
▪Electric actuators
▪Pneumatic actuators
▪Spur gear
▪Bevel gear
▪Actuating bush for remote actuation
▪Other flange designs or butt weld end designs
▪Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /
Pressure Vessel Regulations – or to customer specification
▪Die-forged model for DN300/250 on request.
▪DN 600 and above on request.
4.3.2.3 Function
Design The gate valve comprises the pressure-retaining parts, i.e. body 100 and yoke 166, the
functional unit (stem 200, wedge/disc holder 367 and flexibly mounted wedge discs
360), and the actuating element.
Function The valve is actuated using a handwheel, manual gearbox or electric actuator.
Sealing Body 100 and yoke 166 are connected by studs 902.1 or grub screws 904 and nuts
920.1, and the joint is sealed to atmosphere by joint ring 411.1.
The seating faces of body 100 and wedge discs 360 are hard-faced. Gland packing
461, which seals off stem 200, is tightened via gland follower 452 by means of studs
902.3 or hinged bolts and nuts 920.2.

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4.4 Gate valves to DIN/EN in pressure seal design
4.4.1 AKG-A/AKGS-A
Fig.6: AKG-A/AKGS-A
4.4.1.1 General description
▪Gate valve with pressure seal bonnet
Valve for preventing backflow in industrial plants, power stations, process
engineering and shipbuilding.
4.4.1.2 Design details
Design
▪Pressure seal design
▪Non-rotating stem
▪Split wedge
▪Yoke head suitable for mounting electric and pneumatic actuators (DINISO5210)
Variants
▪Body made of forged steel
▪Position indicator
▪Limit switch(es)
▪Drain branch
▪Hard-faced back seat
▪Disc spring supported yoke head
▪Parallel discs
▪Bypass
▪Spur gear
▪Bevel gear
▪Electric actuators
▪Pneumatic actuators
▪Actuating bush for remote actuation
▪Other flange designs
▪Other butt weld end versions
▪Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /
Pressure Vessel Regulations – or to customer specification
4.4.1.3 Function
Design Gate valves with wedge discs 360 comprise body 100 with welded stellited seat rings
515, wedge discs 360 with stellited seating faces, bonnet 139 with gland packing 461
and yoke 166 with the actuating element.
Sealing Shut-off is performed by two wedge discs 360 pressed against seat rings 515; they are
flexibly mounted in wedge/disc holder 367 and supported by replaceable thrust
inserts 553 via pins 563.
Wedge/disc holder 367 is screwed onto stem 200. A retainer prevents wedge discs 360
from twisting in wedge/disc holder 367. To prevent twisting of the obturator
components, the wedge/disc holder is guided in the body by lateral guide ribs 752.
The valve is equipped with a pressure seal bonnet.
The pressure inside body 100 presses bonnet 139 against joint ring 411.1, which is
supported by compression ring 501. Studs 902.2 and hexagon nuts 920.6, which are
supported by thrust plate 414, ensure that bonnet 139 is held in position against joint
ring 411.1, even if there is no pressure inside body 100.

4 Valve Description
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0570.81/22-EN
For fitting a body pressure relief valve, (ðSection4.5.1,Page21) (see type series
booklet 7300.1) a connection branch 131.2 with connection dimensions Ø22mm/
14.1mm (or 12.3mm) is welded to body 100. The connection branch is supplied
closed.
Body pressure relief valves, if ordered, are supplied unassembled, i.e. attached loosely
to the gate valve.
Instead of fitting a body pressure relief valve, the operator may also provide a means
of pressure balancing between the body’s middle section and the gate valve’s
pressurised connection branch, e.g.:
▪a pressure balancing hole in the seat ring or
▪an external balancing line.
In this case the gate valve can be used for one flow direction only.
If gate valves and swing check valves in pressure seal design (bonnet 139) are fitted in
close proximity to one another, meaning that the trapped liquid could heat up if the
valves are closed, the operator must fit a body pressure relief valve.
Gland packing 461, which seals off stem 200, is tightened via gland follower 452 by
means of studs 902.3 and nuts 920.1. Stem 200 is moved in the axial direction by the
rotating threaded bush 544, which is fitted with cylindrical roller bearings 323. Stem
200 lifts off wedge discs 360 or presses them against seat rings 515.
Threaded bush 544 is positioned in the yoke head by intermediate flange 729 and
hexagon socket head cap screws 914.1. Handwheel 961 sits on threaded bush 544, to
which it is keyed using key 940. It is secured by circlip 932.
The stop nut 920.3 fitted on stem 200 serves as a travel stop in closing direction. It
prevents jamming of the wedge assembly in the seat and is secured by parallel pin
562.3.
Fig.7: Parallel discs
Unlike wedge gate valve designs, slide gate valves feature two parallel discs 368,
which are flexibly mounted in disc holder 367. The discs are supported and pressed
against seat rings 515 by replaceable disc springs 950.1 with parallel pin 562.1.

4 Valve Description
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0570.81/22-EN
4.4.2 ZTS
Fig.8: ZTS
4.4.2.1 General description
▪Gate valve with pressure seal bonnet
Valve for preventing backflow in industrial plants, power stations, process
engineering and shipbuilding.
4.4.2.2 Design details
Design
▪Body made of forged steel
▪Pressure seal design
▪Non-rotating stem
▪Split wedge
▪Yoke head suitable for mounting electric and pneumatic actuators (DINISO5210)
▪Seat/disc interface made of wear-resistant and corrosion-proof Stellite
Variants
▪Flanged ends
▪Bypass
▪Drain branch
▪Parallel discs
▪Pressure relief connections (3-branch system)
▪Pressure relief hole in seat ring
▪Hard-faced back seat
▪Lantern ring in gland packing
▪Disc spring supported threaded bush
▪Packing combination for high-temperature applications
▪Pressure seal joint ring capped with stainless steel
▪Position indicator
▪Limit switch(es)
▪Spur gear
▪Bevel gear
▪Electric actuators
▪Pneumatic actuators
▪Actuating bush for remote actuation
▪Threaded bush free from non-ferrous metals
▪Locking device
▪Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /
Pressure Vessel Regulations – or to customer specification
4.4.2.3 Function
Design Gate valves with wedge discs 360 comprise body 100 with welded stellited seat rings
515, wedge discs 360 with stellited seating faces, bonnet 139 with gland packing 461
and yoke 166 with the actuating element.
Sealing Shut-off is performed by two wedge discs 360 pressed against seat rings 515; they are
flexibly mounted in wedge/disc holder 367 and supported by replaceable thrust
inserts 553 via pins 563.