Spirax Sarco Spira-trol KE73 User manual

IM-S24-25
Issue 1 - 2008
© Copyright 2008
3.563.5275.210
Series K
DN125, DN150 and DN200 Control Valves
Installation and Maintenance Instructions
1. Safery informations
2. Operation
3. Installation and commisioning
4. Maintenance
5. Spares
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.

ATTENZIONE
Lavorare in sicurezza con apparecchiature
in ghisa e vapore
Working safely with cast iron products on steam
Informazioni di sicurezza supplementari - Additional Informations for safety
Lavorare insicurezza conprodotti
in ghisa per linee vapore
I prodotti di ghisa sono comunemente presenti
in molti sistemi a vapore.
Se installati correttamente, in accordo alle
migliori pratiche ingegneristiche, sono dispositivi
totalmente sicuri.
Tuttavia la ghisa, a causa delle sue proprietà
meccaniche, è meno malleabile di altri materiali
come la ghisa sferoidale o l’acciaio al carbonio.
Di seguito sono indicate le migliori pratiche
ingegneristiche necessarie per evitare i colpi
d'ariete e garantire condizioni di lavoro sicure
sui sistemi a vapore.
Movimentazione in sicurezza
La ghisa è un materiale fragile: in caso di
caduta accidentale il prodotto in ghisa non è
più utilizzabile. Per informazioni più dettagliate
consultare il manuale d'istruzioni del prodotto.
Rimuovere la targhetta prima di effettuare la
messa in servizio.
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 prac-
tices required to prevent waterhammer and
ensure safe working conditions on a steam
system.
Safe Handling
CastIronisa brittlematerial.If theproduct isdropped
during installation and there is any risk of damage
the product should not be used unless it is fully
inspectedand pressuretested bythe manufacturer.
Please remove label before commissioning

Vapore
Steam
Flusso
Flow
Esempi di esecuzioni corrette ( ) ed errate ( ) sulle linee vapore:
Steam Mains - Do's and Dont's:
Flusso
Flow
Prevenzione dai colpi d’ariete - Prevention of water hammer
Scarico condensa nelle linee vapore - Steam trapping on steam mains:
Intervalli di 30÷50 m. intervals
Pendenza - Gradient 1:100
Vapore
Steam Gruppo di scarico
Trap set
Condensa - Condasate
Pendenza - Gradient 1:100
Gruppo di scarico
Trap set
Gruppo di scarico
Trap set
Condensa - Condasate
Condensa - Condasate
Vapore
Steam

Prevenzione delle sollecitazioni di trazione
Prevention of tensile stressing
Evitare il disallineamento delle tubazioni - Pipe misalignment:
Installazione dei prodotti o loro rimontaggio post-manutenzione:
Installing products or re-assembling after maintenance:
Evitare l’eccessivo serraggio.
Utilizzare le coppie di serraggio
raccomandate.
Do not over tighten.
Use correct torque gures.
Per garantire l’uniformità del carico e dell'allineamento,
i bulloni delle ange devono essere serrati in modo
graduale e in sequenza, come indicato in gura.
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.

Dilatazioni termiche - Thermal expansion:
Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una
consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione.
Examples showing the use of expansion bellows. It is highly recommended that expert advise is
sought from the bellows manufacturer.
Guide
Guides
Distanza breve
Short distance
Punto di ssaggio
Fixing point
Movimento assiale
Axial movement
Distanza
media
Medium
distance
Tiranti limitatori
Limit rods
Piccolo
movimento
laterale
Small
lateral
movement
Piccolo
movimento
laterale
Small
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
Guide
Guides
Guide
Guides
Guide
Guides
Punto di ssaggio
Fixing point
Tiranti limitatori
Limit rods
Movimento assiale
Axial movement

3.563.5275.210
2
1. Safety informations
I) The products have been specifically designed for use on water, steam, diathermic oil, air or
condensate which are in Group 2 of the above mentioned Pressure Equipment Directive.
The products’ use on other fluids within Group 2 or fluids within Group 1 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 before installation.
Safe operation of these products can only be guaranteed if they are properly installed,
commissioned, used and maintained by qualified personnel (see Section 11 on this document) 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.
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
below comply with the requirements of the European Pressure Equipment Directive 97/23/EC
and carry the mark when so required. The products fall within the following Pressure Equipment
Directive categories:
KE73, KE43 DN125 to DN200 valves
Product DN PS Group 1 Group 1 Group 2 Group 2
Gas Liquid Gas Liquid
125 2 SEP 1 SEP
KE73, KE63, KE43 150 16 bar 3 2 1 SEP
200 3 2 1 SEP
125 2 2 1 SEP
KE73, KE63, KE43 150 25 bar 3 2 2 SEP
200 3 2 2 SEP
125 3 2 2 SEP
KE63, KE43 150 40 bar 3 2 2 SEP
200 3 2 2 SEP

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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.
3. Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
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.
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.
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.
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.
8. Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
9. Tools and consumables
Before starting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.
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.
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.

3.563.5275.210
4
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.
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 232°C (450°F).
Many products are not self-draining. Take due care when dismantling or removing the product
from an installation (refer to 'Maintenance instructions').
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.
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.
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.

3.563.5275.210 5
2. Operation
2.1 General Description
With the development of modern industrial processes, experience has shown that the advantage
of precise control instruments will be lost unless the associated control valves have good operating
and flow characteristics. The range of KE valves have been designed to meet these requirements
and embody a precise characteristic having a high turndown ratio.
2.2 Technical details and ratings
Maximum allowable body pressure at 120°C
SG Iron (KE 73) 25 bar
Carbon Steel (KE 43) 40 bar
Maximum temperatures:
SG Iron 350°C
Carbon Steel 400°C
Refer to appropriate TI sheets for relevant Pressure/temperature Relationships.
2.3 Nomenclature
KE 73 SG Iron Valves
KE 43 Cast Steel Valves
3. Installation and commisioning
3.1. Installation
The valve should be installed in such a position as to allow full access to valve and actuator for
maintenance purposes. Prior to fitting the valve the pipework should be flushed clear to remove
any debris or other particles.
Remove the flange protectors and fit the valve into the pipeline taking notice of direction of flow
arrow on the body.
Care should be taken to prevent any strain being imposed on the valve body due to pipe
misalignement. Tighten flange bolts evenly. Check flange bolts for tightness after 24 hours of
operation.
Care should be taken to ensure that the valve/actuator spindle is not painted or coated with any
other substance.
When carrying out maintenance of the valve care should be taken to avoid damage to the valve
plug, stem and seat.
3.2 Bypass arrangements
It is reccomended that isolating valves be fitted upstream and downstream of the control valve. A
bypass can be fitted around the valve with a manual regulating valve allowing the process to be
controlled whilst the control valve is isolated for maintenance.
3.3 Commissioning
For commissioning instructions refer to the Operation, Installation and Maintenance Instructions,
covering Spirax Sarco Actuators.

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4. Maintenance
4.1. Procedure for renewing stem seals (Fig.2.)
a) Isolate the valve.
b) Remove actuator from valve.Refer to Installation and Maintenance Instructions covering Spirax
Sarco Actuators.
c) Remove locknut (1).
CAUTION: Care should be taken in removing the stem seal since fluid under pressure may be
trapped between the isolating valves.
d) Unscrew the bonnet nuts (8) and withdraw the bonnet (12) taking care not to damage the
spindle surface.
e) Unscrew and remove gland nut (2). By mean of a hooked tool in soft metal like brass, remove
the gland ring set (3), the washers (6) and the spring (4).
f) Examine parts for signs of damage or deterioration and renew as necessary. Note that score
marks or scaly deposits on the valve stem (5) will lead to early failure of the seals.
Clean parts taking care to avoid scratching the stem or bore of the packing chamber.
See paragraph 4.3 for renewing valve stem (5).
g) Refit the bonnet and finger tighten the bonnet nuts.
h) Insert washers, spring and new gland ring seals into the packing chamber following the
sequence shown in fig.1, care being taken to avoid damage to the sealing edges.
i) Refit the gland nut (2) and tighten until resistance is felt and unscrew two turns.
j) Ensure that the stem (5) moves freely.
k) Refit valve lock nut (1).
l) Bring the valve back into service
m) Check for leakage at gland.
Chart of Recommended Torques (Nm)
Size Seat Bonnet Nuts Plug Nut & Lock Nut
DN (9) (8) (13/14)
150 270-290 150-160 230-250
200 320-340 110-120 230-250

3.563.5275.210 7
1
2
5
6
4
3
6
12
8
Fig. 1

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4.2 Procedure for renewing valve stem, plug and seat.
a) Isolate and remove valve from the pipeline.
CAUTION: Care should be taken in removing the valve since fluid under pressure may be trapped
between the isolating valves.
b) Remove actuator from valve. Refer to Installation and Maintenance Instructions covering Spirax
Sarco Actuators.
c) Remove locknut (1).
d) Unscrew the nuts (8) securing the bonnet and withdraw the bonnet (12).
e) Remove the gland packing as per paragraph 4.1.
f) Unscrew the locking nut (14) and the nut (13) and withdraw the stem & valve plug assembly (10).
g) Unscrew and remove the valve seat (9).
h) Lightly smear the threads of the new seat with silicon grease. Insert the new seat (9) into the
body. Tighten to the correct torque (see chart).
i) Carefully insert the new stem & valve plug assembly (10).
j) Using a new gasket (15) refit the bonnet. Replace and finger tighten the bonnet nuts (8) and,
while pushing the valve stem so that the valve plug is on the seat, finally tighten them to the
correct torque.
k) Fit new stem seal assembly as described in paragraph 4.1 (h), ensuring valve stem (5) moves
freely after assembly.
l) Refit actuator and connect actuator to valve stem.
m) Bring valve back into service.
n) Check for leakage around all gasket joints.
4.3 Procedure for renewing valve stem
Follow the instructions given in paragraph 4.2 a) to f).
g) Remove lock pin (16). Unscrew the stem (5) from the adaptor (17).
h) Fit the new stem (5) into the adaptor (17).
Drill a 5mm diameter hole in the stem in line with that in the adaptor. Refit the lock pin (16).
Complete the reassembling by following the instructions given in paragraph 4.2 i) to n).

3.563.5275.210 9
1
5
12
8
15
16
17
10
9
13
14
Fig. 2

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10
5. Spare
5.1 Spares parts
DN 150 and DN 200 KE43, KE73
AVAILABLE SPARES
Valve Gland Seal Kit (PTFE Chevrons) A
Valve spindle B
Valve plug & spindle kit B,C
Valve seat D
Bonnet gasket (Pkt of 3) E
How to order
Always order spares by using the description given in the column headed available spare and
stating the size and type of valve.
Example: 1 - Valve plug & spindle Kit for DN150 KE73 Control Valve.
E
C
D
B
A
Fig. 3

3.563.5275.210 11

3.563.5275.210 Issue 1 - 2008.02
Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20054 Nova Milanese (MI) - Tel.: [phone] - Fax: [phone]