Spirax Sarco Spira-trol K Series User manual

IM-S24-42 CTLS Issue 10
1
1. Safety information
2. General product information
3. Installation and
commissioning
4. Maintenance:
DN15 - DN100
5. Maintenance:
DN125 - DN300
6. Spare parts
© Copyright 2018
Printed in France
3740050/10
Spira-trolTM
K and L Series
Two-port Control Valves
Installation and Maintenance Instructions
IM-S24-42
CTLS Issue 10

IM-S24-42 CTLS Issue 10
2
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER

IM-S24-42 CTLS Issue 10
3
Safe operation of these products can only be guaranteed if they are properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11) in compliance
with the operating instructions. General installation and safety instructions for pipeline and plant
construction, as well as the proper use of tools and safety equipment must also be complied with.
Safety note - Handling precautions
PTFE
Within its working temperature range PTFE is a completely inert material, but when heated
to its sintering temperature it gives rise to gaseous decomposition products or fumes which
can produce unpleasant effects if inhaled. The inhalation of these fumes is easily prevented
by applying local exhaust ventilation to atmosphere as near to their source as possible.
Smoking should be prohibited in workshops where PTFE is handled because tobacco
contaminated with PTFE will during burning give rise to polymer fumes. It is therefore
important to avoid contamination of clothing, especially the pockets, with PTFE and to
maintain a reasonable standard or personal cleanliness by washing hands and removing any
PTFE particles lodged under the fingernails.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended use/application.
The products listed on pages 4 to 10 comply with the requirements of the European Pressure
Equipment Directive (PED), carry the mark when so required and fall within the Pressure
Equipment Directive categories stated.
i) The products have been specifically designed for use with liquids and gases which are in
Groups 1 and 2 of the above mentioned Pressure Equipment Directive.The products’ use on
other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted to
confirm the suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and minimum values.
If the maximum operating limits of the product are lower than those of the system in which it
is being fitted, or if malfunction of the product could result in a dangerous overpressure or
overtemperature occurrence, ensure a safety device is included in the system to prevent such
over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be induced by
any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
v) Remove protection covers from all connections and protective film from all name-plates, where
appropriate, before installation on steam or other high temperature applications.
1. Safety information

IM-S24-42 CTLS Issue 10
4
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER
KE valves
Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
KE43
PN40
DN15 - DN25 SEP SEP SEP SEP
DN32 2SEP SEP SEP
DN40 - DN50 2 1 SEP SEP
DN65 - DN100 212SEP
DN125 - DN200 322SEP
DN250 3221
DN300 3321
PN25
DN200 3 2 2 SEP
DN250 - DN300 3221
PN16
DN125 2 1 SEP SEP
DN150 - DN200 212SEP
DN250 - DN300 322SEP
JIS 20
KS 20
DN15 - DN25 SEP SEP SEP SEP
DN32 2SEP SEP SEP
DN40 - DN50 2 1 SEP SEP
DN65 - DN100 212SEP
DN125 - DN200 212SEP
DN250 3221
DN300 3321
JIS 10
KS 10
DN125 2 1 SEP SEP
DN150 - DN250 212SEP
DN300 322SEP

IM-S24-42 CTLS Issue 10
5
KE valves (continued)
Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
KE61 PN40
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP SEP SEP
DN40 - DN50 2 1 SEP SEP
KE63
PN40
DN15 - DN25 SEP SEP SEP SEP
DN32 2SEP SEP SEP
DN40 - DN50 2 1 SEP SEP
DN65 - DN100 212SEP
DN125 - DN200 322SEP
DN250 3221
DN300 3321
PN25
DN200 3 2 2 SEP
DN250 - DN300 3221
PN16
DN125 2 1 SEP SEP
DN150 - DN200 212SEP
DN250 - DN300 322SEP
JIS 20
KS 20
DN15 - DN25 SEP SEP SEP SEP
DN32 2SEP SEP SEP
DN40 - DN50 2 1 SEP SEP
DN65 - DN100 212SEP
DN125 - DN200 212SEP
DN200 3221
DN300 3321
JIS 10
KS 10
DN125 2 1 SEP SEP
DN150 - DN250 212SEP
DN300 322SEP

IM-S24-42 CTLS Issue 10
6
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER
KE valves (continued)
Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
KE71 PN25
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN40 1SEP SEP SEP
DN50 2 1 SEP SEP
KE73
PN25
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN40 1SEP SEP SEP
DN50 - DN80 2 1 SEP SEP
DN100 - DN125 212SEP
DN150 - DN200 322SEP
PN16
DN65 - DN125 2 1 SEP SEP
DN150 - DN200 212SEP
JIS 10
KS 10
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN65 1SEP SEP SEP
DN80 - DN125 2 1 SEP SEP
DN150 - DN200 212SEP
KEA valves
Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
KEA41
KEA42 ASME 300
DN15 - DN25 SEP SEP SEP SEP
DN32 2SEP SEP SEP
DN40 - DN50 212SEP
KEA43
ASME 150
DN150 212SEP
DN200 - DN250 322SEP
DN300 3321
ASME 300
DN15 - DN25 SEP SEP SEP SEP
DN32 2SEP SEP SEP
DN40 - DN100 212SEP
DN150 - DN200 322SEP
DN250 3221
DN300 3321
JIS 20
KS 20
DN15 - DN25 SEP SEP SEP SEP
DN32 2SEP SEP SEP
DN40 - DN50 1 1 SEP SEP
DN65 - DN100 212SEP

IM-S24-42 CTLS Issue 10
7
KEA valves (continued)
Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
KEA61
KEA62 ASME 300
DN15 - DN25 SEP SEP SEP SEP
DN32 2SEP SEP SEP
DN40 - DN50 212SEP
KEA63
ASME 150
DN150 212SEP
DN200 - DN250 322SEP
DN300 3321
ASME 300
DN15 - DN25 SEP SEP SEP SEP
DN32 2SEP SEP SEP
DN40 2 1 SEP SEP
DN50 - DN100 212SEP
DN150 - DN200 322SEP
DN250 3221
DN300 3321
JIS 20
KS 20
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP SEP SEP
DN40 - DN50 2 1 SEP SEP
DN65 - DN100 212SEP
KEA71 ASME 250
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP SEP SEP
DN40 - DN50 2 1 SEP SEP
KEA73
ASME 125
DN15 - DN25 SEP SEP SEP SEP
DN40 - DN65 1SEP SEP SEP
DN80 - DN100 2 1 SEP SEP
DN150 - DN200 212SEP
ASME 250
DN15 - DN25 SEP SEP SEP SEP
DN40 - DN65 2 1 SEP SEP
DN80 - DN100 212SEP
DN150 - DN200 322SEP
JIS 10
KS 10
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN65 1SEP SEP SEP
DN80 - DN100 2 1 SEP SEP

IM-S24-42 CTLS Issue 10
8
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER
LE valves
Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
LE31
LE33 PN16
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN50 1SEP SEP SEP
DN65 - DN100 2 1 SEP SEP
LE43
LE63
JIS 10
KS 10
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN65 1SEP SEP SEP
DN80 - DN100 2 1 SEP SEP
LEA valves
Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
LEA31
LEA33
ASME 125
JIS 10
KS 10
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN65 1SEP SEP SEP
DN80 - DN100 2 1 SEP SEP
LEA43
LEA63
ASME 150
JIS 10
KS 10
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN65 1SEP SEP SEP
DN80 - DN100 2 1 SEP SEP
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.

IM-S24-42 CTLS Issue 10
9
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other part of the system or any personnel
at risk?
Dangers might include isolation of vents or protective devices or the rendering ineffective of
controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system
shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of closed valves.
Do not assume that the system has depressurised even when the pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns and consider
whether protective clothing (including safety glasses) is required.
PTFE SEALS
If seals made from PTFE have been subjected to a temperature approaching 260 °C (500 °F) or
higher, they will give off toxic fumes, which if inhaled are likely to cause temporary discomfort.
It is essential for a no smoking rule to be enforced in all areas where PTFE is stored, handled or
processed as persons inhaling the fumes from burning tobacco contaminated with PTFE particles
can develop 'polymer fume fever'.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and/or others in the vicinity require any protective clothing to protect against
the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and
dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the product according
to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where there is no
such system, it is recommended that a responsible person should know what work is going on
and, where necessary, arrange to have an assistant whose primary responsibility is safety. Post
‘warning notices’ if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.

IM-S24-42 CTLS Issue 10
10
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the maximum
permitted operating conditions the surface temperature of some products may reach temperatures
of 538 °C (1 000 °F).
Many products are not self-draining. Take due care when dismantling or removing the product from
an installation (refer to 'Maintenance instructions').
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken. However, if
the valve is fitted with a Viton or PTFE seat, special care must be taken to avoid potential health
hazards associated with decomposition/burning of these seats.
PTFE:
- Can only be disposed of by approved methods, not incineration.
- Keep PTFE waste in a separate container, do not mix it with other rubbish, and consign it to
a landfill site.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law,
when returning products to Spirax Sarco they must provide information on any hazards and the
precautions to be taken due to contamination residues or mechanical damage which may present a
health, safety or environmental risk. This information must be provided in writing including Health
and Safety data sheets relating to any substances identified as hazardous or potentially hazardous.
1.17 Working safely with cast iron products on steam
Cast iron products are commonly found on steam and
condensate systems. If installed correctly using good steam
engineering practices, it is perfectly safe. However, because
of its mechanical properties, it is less forgiving compared
to other materials such as SG iron or carbon steel. The
following are the good engineering practices required to
prevent waterhammer and ensure safe working conditions
on a steam system.
Safe Handling
Cast Iron is a brittle material. If the product is dropped during
installation and there is any risk of damage the product should
not be used unless it is fully inspected and pressure tested by
the manufacturer.

IM-S24-42 CTLS Issue 10
11
Prevention of waterhammer
Steam trapping on steam mains:
Steam Mains - Do's and Don'ts:
Steam Steam
Flow Flow
30 - 50 metre intervals
Gradient 1:100
Gradient 1:100
Trap set
Trap set
Trap set
Condensate
Condensate
Condensate
Steam
Steam

IM-S24-42 CTLS Issue 10
12
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER
Prevention of tensile stressing
Pipe misalignment:
Installing products or re-assembling after maintenance:
Thermal expansion:
Do not over tighten.

1
1
4 2
3
8
2
6
3
7
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.
Guides
Guides
Limit
rods
Limit rods
Fixing point
Medium
distance
Small lateral
movement
Small lateral
movement
Large lateral
movement
Large lateral
movement
Short
distance Fixing point
Axial
movement
Axial movement
Guides
Guides
5
4

IM-S24-42 CTLS Issue 10
13
2.1 General description
Spira-trolTM is a range of two-port single seat globe valves with cage-retained seats conforming to either EN
(DIN) or ASME standards. These valves are available as follows:
- DN15 to DN200 (½" to 8") with a choice of three body materials.
- DN250 and DN300 (10" and 12") with a choice of two body materials.
These valves, when used in conjunction with a pneumatic or electric linear actuator
provide modulating control or on/off service.
Spira-trolTM valve characteristic - options:
KE and KEA Equal percentage (E) - Suitable for most modulating process control
LE and LEA applications providing good control at low flowrates.
KF and KFA Fast opening (F) - For on/off applications only.
KL and KLA Linear (L) - Primarily for liquid flow control where the differential
LL and LLA pressures across the valve is constant.
Important note: Throughout this document, reference has been made to the standard KE, KEA, LE and
LEA control valves. With the exception of trim type, all derivatives are identical.
Spira-trolTM two-port control valves are compatible with the following actuators
and positioners:
Electric
DN15 - DN100: AEL5, AEL6, EL3500, EL5600 and EL7200
DN125 - DN300: EL5600
Pneumatic
All sizes: PN1000, PN9000
DN125 - DN300: PN1000, PN9000 and TN2000
Positioners
PP5 (pneumatic) or EP5 (electropneumatic)
ISP5 (intrinsically safe electropneumatic)
SP200is, SP400 and SP500 (microprocessor based electropneumatic)
SP300 (digital communications)
Refer to the relevant Technical Information sheet for further details.
2. General product information

IM-S24-42 CTLS Issue 10
14
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER
2.2 Technical data
Plug design Parabolic
Leakage
Metal-to-metal Standard seat Class IV with the option of Class V
Soft seal
Balanced Class IV
Unbalanced Class VI
Rangeability
Equal 50:1
Linear 30:1
Fast opening 10:1
Travel
DN15 to DN50 (½" to 2") 20 mm (¾")
DN65 to DN100 (2½" to 4") 30 mm (1")
DN125 to DN300 (5" to 12")
Pressure/temperature limits
KE4_ see Section 2.3
KE6_ see Section 2.4
KE7_ see Section 2.5
KEA4_ see Section 2.6
KEA6_ see Section 2.7
KEA7_ see Section 2.8
LE3_ see Section 2.9
LE4_ see Section 2.10
LE6_ see Section 2.11
LEA3_ see Section 2.12
LEA4_ see Section 2.13
LEA6_ see Section 2.14

IM-S24-42 CTLS Issue 10
15
Fig. 3
DN15 to DN100
KE, KEA and LEA valves
Fig. 2
DN15 - DN100 KE and KEA
with bellows seal (B) and (C)
Fig. 4
DN15 - DN100
KE, KEA, LE and LEA with bellows seal (D)
Fig. 1
DN125 - DN300
Extended bonnet

IM-S24-42 CTLS Issue 10
16
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER
300
250
200
150
100
50
0
-10
0 4 8 12 16
Bellows only
Maximum operating temperature
Minimum operating temperature -10 °C
Note: For lower operating temperatures consult
Spirax Sarco.
Maximum differental
pressures
See relevant actuator
Technical Information
sheet
Maximum cold hydraulic test
pressure of: 60 bar g
Warning: If the valve is fitted with a bellows it must
be removed if hydraulic testing is to be done.
Note: When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows
must be read in conjunction with the valve pressure/temperature limits shown above.
2.3 Pressure/temperature limits
0 10 14 16 20 25 30 34 40
400
300
250
200
100
0
-10
Temperature °C
Pressure bar g
A
B
ECD
F
F
E D C B
Steam
saturation
curve
Temperature °C
Pressure bar g
Bellows B
Steam
saturation
curve
KE43 (Carbon steel)
The product must not be used in this region.
High temperature packing is required for use in this region.
High temperature bolting and packing is required for use in this region.
A - BFlanged EN 1092 PN40. A - E Flanged EN 1092 PN16.
A - CFlanged JIS/KS 20. F - F Flanged JIS/KS 10.
A - DFlanged EN 1092 PN25.

IM-S24-42 CTLS Issue 10
17
300
250
200
150
100
50
0
-10
0 4 8 12 16
400
300
200
100
0
-10
0 4 8 12 16
Notes:
1.  °C, the external
moving parts of the valve and actuator must be heat traced to maintain normal operation.
2. When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows
must be read in conjunction with the valve pressure/temperature limits shown in table below.
Body design conditions PN40
Maximum design pressure 40 bar g @ 50 °C
Maximum design temperature 400 °C
Minimum design temperature -10 °C
Maximum operating temperature
PTFE soft seat (G) 200 °C
Standard packing PTFE chevron
250 °CPEEK seat (K and P)
Extended bonnet (E) with PTFE chevron
High temperature packing (H)
400 °C
Extended bonnet (E) with graphite packing
Note: We recommend that an extended bonnet (E) with graphite packing is used where valve operation is
above 300 °C.
Bellows C Bellows D
Temperature °C
Pressure bar g
Temperature °C
Pressure bar g
Steam
saturation
curve
Steam
saturation
curve
The product must not be used in this region.

IM-S24-42 CTLS Issue 10
18
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER
0 10 14 16 20 25 30 34 40
400
350
300
250
200
100
0
PTFE -29
Graphite -50
Temperature °C
Pressure bar g
F
B
E CDF
A E D C B
Steam
saturation
curve
Bellows only
Maximum operating temperature
Minimum operating
temperature
PTFE packing -29 °C
Graphite packing -50 °C
Note: For lower operating temperatures consult
Spirax Sarco.
Maximum differental
pressures
See relevant actuator
Technical Information
sheet
Maximum cold hydraulic test
pressure of: 60 bar g
Warning: If the valve is fitted with a bellows it must
be removed if hydraulic testing is to be done.
Note: When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows
must be read in conjunction with the valve pressure/temperature limits shown above.
0 4 8 12 16
300
250
200
150
100
20
0
-29
Temperature °C
Pressure bar g
Bellows B
Steam
saturation
curve
2.4 Pressure/temperature limits
KE61 and KE63 (Stainless steel)
The product must not be used in this region.
High temperature packing is required for use in this region.
High temperature bolting and packing is required for use in this region.
A - BFlanged EN 1092 PN40. A - E Flanged EN 1092 PN16.
A - CFlanged JIS/KS 20. F - F Flanged JIS/KS 10.
A - DFlanged EN 1092 PN25.

IM-S24-42 CTLS Issue 10
19
0 4 8 12 16
300
250
200
150
100
50
0
-50
0 4 8 12 16
400
300
200
100
0
-50
Notes:
1.  °C, the external
moving parts of the valve and actuator must be heat traced to maintain normal operation.
2. When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows
must be read in conjunction with the valve pressure/temperature limits shown in table below.
Body design conditions PN40
Maximum design pressure 40 bar g @ 50 °C
Maximum design temperature 400 °C
Minimum design temperature -50 °C
Maximum operating temperature
PTFE soft seat (G) 200 °C
Standard packing PTFE chevron
250 °CPEEK seat (K and P)
Extended bonnet (E) with PTFE chevron
High temperature packing (H)
400 °C
Extended bonnet (E) with graphite packing
Note: We recommend that an extended bonnet (E) with graphite packing is used where valve operation is
above 300 °C.
The product must not be used in this region.
Bellows D
Temperature °C
Pressure bar g
Temperature °C
Pressure bar g
Steam
saturation
curve
Steam
saturation
curve
Bellows C

IM-S24-42 CTLS Issue 10
20
start of text under grey section header box
start of text continuing from previous page
TRANSLATION RUN OVER
2.5 Pressure/temperature limits
KE71 and KE73 (SG iron)
0 5 10 14 15 16 20 25
350
300
250
200
100
0
-10
Temperature °C
Pressure bar g
A
DEF
F
Steam
saturation
curve
The product must not be used in this region.
High temperature packing is required for use in this region.
High temperature bolting and packing is required for use in this region.
A - DFlanged EN 1092 PN25 and Screwed BSP.
A - E Flanged EN 1092 PN16.
F - F Flanged JIS/KS 10.
Bellows only
Maximum operating temperature
Minimum operating temperature -10 °C
Note: For lower operating temperatures consult
Spirax Sarco.
Maximum differental
pressures
See relevant actuator
Technical Information
sheet
Maximum cold hydraulic test
pressure of: 38 bar g
Warning: If the valve is fitted with a bellows it must
be removed if hydraulic testing is to be done.
Note: When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows
must be read in conjunction with the valve pressure/temperature limits shown above.
300
250
200
150
100
50
0
-10 0 4 8 12 16
Temperature °C
Pressure bar g
Bellows B
Steam
saturation
curve