KSB MIL 90000 Installation instructions

Automatic Recirculation Valve
MIL 90000
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual MIL 90000
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 06/10/2022

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
2.3 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...........................................................................................................................................12
3.5 Disposal ...........................................................................................................................................................12
4 Description of the Valve...................................................................................................................... 13
4.1 General description ........................................................................................................................................13
4.2 Product information.......................................................................................................................................13
4.2.1 Product information as per Pressure Equipment Directive 2014/68/EU(PED)................................13
4.2.2 Product information as per Regulation No. 1907/2006(REACH) ....................................................13
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...............................................................................................................................................18
4.9 Noise characteristic.........................................................................................................................................18
5 Installation at Site................................................................................................................................ 19
5.1 General information/Safety regulations .......................................................................................................19
5.2 Installation position........................................................................................................................................19
5.3 Preparing the valve ........................................................................................................................................20
5.4 Piping ..............................................................................................................................................................20
5.4.1 Flange connection..............................................................................................................................20
6 Commissioning/Start-up/Shutdown................................................................................................... 21
6.1 Commissioning/Start-up.................................................................................................................................21
6.1.1 Prerequisites for commissioning/start-up .........................................................................................21
6.1.2 Starting up the system.......................................................................................................................21
6.2 Operating limits..............................................................................................................................................21
6.2.1 Pressure/temperature ratings............................................................................................................21
6.2.2 Ambient temperature........................................................................................................................22
6.3 Shutdown........................................................................................................................................................22
6.3.1 Measures to be taken for shutdown ................................................................................................22
7 Servicing/Maintenance........................................................................................................................ 23
7.1 Safety regulations...........................................................................................................................................23

Contents
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7.2 Servicing/Inspection........................................................................................................................................23
7.2.1 Supervision of operation...................................................................................................................23
7.2.2 Inspection work..................................................................................................................................24
7.2.3 Dismantling the valve........................................................................................................................24
7.2.4 Assembling the valve.........................................................................................................................25
7.3 Tightening torques.........................................................................................................................................26
7.4 Returning to service .......................................................................................................................................27
8 Trouble-shooting.................................................................................................................................. 28
9 Related Documents.............................................................................................................................. 30
9.1 General assembly drawing with list of components ....................................................................................30
9.2 Dimensions and weights ................................................................................................................................32
10 EU Declaration of Conformity for MIL90000..................................................................................... 34
11 Certificate of Decontamination........................................................................................................... 35
Index ..................................................................................................................................................... 36

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
automatic recirculation valve
General assembly drawing Sectional drawing with list of components
Dimensional drawing Dimensions of the valve
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
result 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
potentially 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 in accordance with EN13463-1 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 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21)
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 could slip out of the suspension arrangement
Danger to life from falling parts!
▷Only transport the valve in the specified position.
▷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.
Fig.1: Transporting the valve
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.

3 Transport/Storage/Disposal
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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22)
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
▪Automatic recirculation valve
Process fluid controlled valve which automatically maintains the minimum flow rate
required to ensure the operational reliability of the pump, protecting the centrifugal
pump against overheating, loss of stability and cavitation. As soon as the main flow
rate drops below a certain value, the valve opens its bypass wide enough for the
minimum flow rate required by the pump to be recirculated, even when the main
flow rate is zero at that time.
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 Description of the Valve
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4.3 Designation
Table4: Designation example
Position
123456789
90-------
Table5: Designation key
Position Code Description
1-2 Type
90 Automatic recirculation valve
3 Design
1 Single-stage
2 Two-stage
3 Multistage
4 Size
2 1 1/2 inches
3 2 inches
4 2 1/2 inches
5 3inches
6 4inches
7 5 inches
8 6inches
9 8inches
A 10inches
B 12 inches
5 Pressure class
1 Class 150
2 Class 300
3 Class 600
4 Class 900
5 Class 1500
6 Class 2500
K PN 40
D PN 64
E PN 100
F PN 160
G PN 250
H PN 320
J PN 400
6 Connection
F Flanged ends
W Butt weld end
7 Installation position
V Vertical
H Horizontal
8 Bypass option
S Standard
O Oversized
R Reduced
9 Valve body material
C Carbon steel

4 Description of the Valve
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Position Code Description
9 S Stainless steel
A Alloyed steel
D Duplex stainless steel
4.4 Marking
Table6: General marking
Parameter Values
Nominal size [inch] NPS ...
Nominal pressure class Class ...
Manufacturer KSB
Type series/Model MIL ...
Year of construction 20..
Material .......
Flow direction arrow →
Traceability of the material .......
CE marking(if required and possible)
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 Nominal size
5 Nominal pressure 6 Body end
7 Leakage class 8 Valve body material
9 Trim material 10 Maximum pressure [kg/cm2]
11 Minimum pressure [kg/cm2] 12 Minimum application temperature
[°C]
13 Maximum application temperature
[°C]
4.6 Design details
Design
▪Automatic Recirculation Valve to ASME B16.34
▪Body made of forged steel
▪Check valve function in main flow direction
▪Integrated control valve in the bypass
▪Hard-faced seat of lift check valve in the main flow direction
▪Bypass with multistage throttling distance
▪Leakage class IV in accordance with ANSI FCI 70.2: check valve in main flow
direction (all designs)
▪Leakage class IV in accordance with ANSI FCI 70.2: control valve in bypass (design
903/902)
▪Flanged ends

4 Description of the Valve
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4.7 Function
Design The valve has one inlet port and two outlet ports. The main outlet port connects to
the main process and the bypass port connects back to the deaerator.
Function The main flow lifts the check disc (6). The check disc (6) changes its position
depending on the flow rate of the pump and transfers this motion to the lever (9) of
the bypass system. The motion of the lever (9) is transferred to the multistage bypass
plug (19). In the bypass, the pressure and flow rate are reduced to the minimum flow
conditions along a multistage throttling distance (low cavitation and low noise). As a
result of modulating control, the sum of main flow rate and bypass flow rate is
almost constant. The valve is flow-controlled and does not require an external
control system or auxiliary energy.
High flow rate: The check disc (6) is fully open and the bypass system is fully closed.
Reduced flow rate: If the flow rate is reduced, the check disc (6) closes and the bypass
system opens.
Low flow rate: If the flow rate drops below the pump's minimum flow value, the
check disc (6) fully closes and the bypass system fully opens. The entire minimum flow
rate is routed through the bypass system.
● No process flow required
● No main flow
● Flow through bypass only
Inlet
Outlet
Bypass
Fig.4: Valve with closed check disc and open bypass
● Process flow starts
● Partial flow through main valve outlet
● Partial flow through bypass
Outlet
Bypass
Inlet
Fig.5: Valve with open check disc and open bypass

4 Description of the Valve
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● Check disc in half open
● Main flow is increasing
● No flow through bypass
● Switching point
Outlet
Bypass
Inlet
Fig.6: Valve with open check disc and closed bypass
Outlet
Bypass
Inlet
● Increasing process flow required
● Main flow reaches maximum
● No flow through bypass
Fig.7: Valve with open check disc at maximum travel and closed bypass
4.8 Scope of supply
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
The valve bodies are marked with an arrow indicating the flow direction.
Install the valves in such a way that the actual flow direction of the fluid matches the
arrow on the valve body.
Install the valve in a vertical position with an upward flow direction. Deviations in
installation position require prior consultation with KSB.
CAUTION
Frequency shocks caused by pressure pulsation of the fluid handled
Damage to the valve!
▷The distance between the pump discharge nozzle and valve connection flange
must not exceed a straight pipe run of 3m.
▷A straight upstream stabilisation distance is essential.
Install the valve directly at the pump discharge nozzle. If it cannot be installed
directly at the pump nozzle, it must be installed as close to the pump discharge
nozzle as possible. The distance between the pump discharge nozzle and valve
connection flange must not exceed a straight pipe run of 3m. If the valve cannot be
installed directly at the discharge nozzle, the valve requires a straight upstream
stabilisation distance of at least 2x DN (no pipe bends).
To stabilise turbulent flows, a straight stabilisation distance of at least 3x DN is
recommended downstream of the bypass port and of 1m downstream of the valve
outlet port. No pipe bends are permitted downstream of the bypass port.

5 Installation at Site
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To Prozess
Straight pipe run ≥ 3 x DN
Straight pipe run ≥ 1 m
Pump
Tank
1) Optimum distance
2) 3 m max., taking into account a straight pipe run
≥ 2 x DN
MIL 90000
Bypass pipe
Fit suitable throttling orifice as close
to the tank as possible
Fig.8: Schematic diagram of the installation conditions
5.3 Preparing the valve
1. Thoroughly clean, flush and blow 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. Remove any
foreign objects.
4. If required, install a strainer in the pipe upstream of the pump suction nozzle.
Recommended mesh width: 0.3mm to 0.5mm.
5.4 Piping
5.4.1 Flange connection
Fasteners For the flange connection between the valve and piping and between the valve and
pump, use the flange bolt holes provided.
Flange connection üThe mating flange faces are clean and undamaged.
üVerify that the pipe is correctly aligned and the flanges are parallel.
1. Use an appropriate tool to evenly tighten the fasteners crosswise.
(ðSection7.3,Page26)