0570.87/2-10Operating Instructions

Gate, Globe and Check ValvesASME class 150 (800) - 2500

SICCA 150 - 600,types GTC, GLC, SCC

SICCA 800 - 2500,types GTF, GLF, PCF

SICCA 900 - 2500,types GTC, GLC, SCC

GTC 900 � 2500 GLF 800 - 2500 SCC 150 - 600

1 Declaration of Conformity 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Safety Symbols in these Operating Instructions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Qualification of Personnel and Training 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Danger on Nonobservance of the Safety Instructions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Safety Consciousness 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Safety Instructions for the User / Operator 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Safety lnstructions for Maintenance, Inspection and Installation work 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Unauthorized Modification and Manufacturing of Spare Parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 Inadmissible Modes of Operation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Transport & Interim Storage 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Transport 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Interim Storage 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Description / Related Documents 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Marking 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Drawings / Documents 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 List of Components 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Functioning Principle 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 General 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Installation position 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Welding Instructions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Actuated Valves 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Commissioning / Decommissioning 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Commissioning 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Decommissioning 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Maintenance / Repair 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Safety Instructions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Valve Reassembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 General 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Faults & Remedies 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Valve weight (in kg) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Do�s and Dont�s 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIN ISO 9001 PED 97/23/EC

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1 Declaration of Conformity

Hereby we, KSB Pumps Limited151 Mettupalayam RoadN.S.N. PalayamCoimbatore - 641 031Registered Office: MumbaiIndia

declare that the valves listed below comply with the requirements of the Pressure Equipment Directive 97/23/EC.

Description of the valve types: Gate, Globe and Check Valves� SICCA type GTF, GLF, PCF class 800-2500 1/2� - 2�� SICCA type GTC, GLC, SCC class 150-2500 2� - 12�

Reference standards and codes: ASME B16.34, API 598, ASTM / ASME, API 600, API 602, BS 5352, BS 1873, BS 1868

Suitable for: Fluid group 1 and 2

Conformity Assessment Procedure: Module H

Name and address of the authorizing andmonitoring notified body:

RWTÜV Anlagentechnik GmbHP.O. Box 103261Kurfürstenstr. 5845032 Essen Germany

Number of notified body: 0044

Number of Certificate: 04202244010019

Valves with a nominal pipe size below and including 1 inch comply with the Pressure Equipment Directive97/23/EC Art. 3 §3. They must not bear neither the CE-Label nor the number of the notified body.

V. VISWANATHAN V. VENUGOPALAN

Head � Quality Assurance Head � Engineering

(This document was prepared electronically and is valid without signature)

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2 GeneralThese operating instructions apply to KSB � Gate, Globe andCheck valves (see section 5).

Design, manufacturing and testing of the KSB valves aresubject to a QA system according to EN ISO 9001 and to theEuropean Pressure Equipment Directive 97/23/EC (PED) aswell as ASME B16.34, API 600 etc.

Correct installation and maintenance will ensure trouble freeoperation of the valves.

The manufacturer does not assume any liability for thesevalves if the operating instructions are not being observed.

The valves are marked to ASME B16.34 if required with anarrow indicating the flow direction, Nominal size, Class,material of body, manufacturer.

ATTENTION The valves must not be operated beyond thelimits defined in the operating instructions/contractualdocumentation/type leaflet. Any use beyond the aboveconditions will lead to overload which the valves cannotwithstand.

Nonobservance of this warning may lead to personalinjury or property damage, e.g.:

� Injury caused by escaping fluids (cold/hot, toxic or underpressure)

� Incorrect operation or destruction of the valve.

The descriptions and instructions in this manual refer to thestandard versions but also apply to the related variants.

These operating instructions do not consider:

� incidents which may occur during installation, operation andmaintenance.

� the local safety regulations. lt is the user�s responsibility toensure that they are observed, also by the installation staffinvolved.

For actuated valves, the specified connection parameters andthe installation and maintenance instructions � including theoperating manual for the actuator � must be observed.

ATTENTION Handling a valve requires skilled andexperienced personnel.

The personnel in charge of operation, maintenance andinstallation of this valve must be aware of the interactionbetween the valve and the plant.

Operator�s errors concerning the valve may have seriousconsequences for the entire plant, e.g.:

� fluid may escape� downtime of the plant/machine� adverse effect/reduction/increase of the efficiency/function

of a plant/machine.

For further questions or in case of damage to the valve, pleasecontact your KSB Sales Office.

For further questions and supplementary orders, especiallywhen ordering spare parts, please always state the type seriesversion and serial no. (Serial No. is punched at top flange ofthe valve on KSB letter side)

The specifications (operating data) of the valves are listed inthe technical documentation & type leaflet of the related valve(see also section 5).

When returning valves to the manufacturer, please refer tosection 4

3 SafetyThis manual contains basic instructions to be complied withduring operation and maintenance. lt is therefore vital for thefitter and the operator/user to read this manual beforeinstalling/ commissioning the valve. Also, this manual mustalways be available at the site where the valve is installed.

lt is not enough to observe the general instructions listed in thesection �safety�, the specific safety instructions listed in theother sections should also be observed.

3.1 Safety Symbols in these OperatingInstructions

Safety instructions put forth in this instruction manual whosenonobservance would involve the risk of personal injury arespecially marked with the general hazard symbol:

in accordance with DIN 4844 (safety sign W9), or with theelectric voltage warning sign:

In accordance with DIN 4844 (safety sign W 8),

Safety instructions whose nonobservance would involvehazard to the valve and jeopardize its operation have beenmarked with the word

ATTENTIONlnstructions directly attached to the valve, (e.g. nominalpressure) must be complied with and maintained in a legiblecondition.

3.2 Qualification of Personnel and TrainingThe personnel for operation, maintenance, Inspection andInstallation must be adequately qualified for the work involved.The personnel�s responsibilities, competence andsupervision must be clearly defined by the user. lf thepersonnel in question is not already in possession of therequisite know-how, appropriate training and instructionsmust be provided. lf deemed necessary, themanufacturer/supplier will provide such training andinstructions at the user�s request. In addition, the user isresponsible for ensuring that the contents of these operatinginstructions are fully understood by the personnel in question.

3.3 Danger on Nonobservance of the SafetyInstructions

Nonobservance of the safety instructions may lead topersonal injury and also to danger for the environment and thevalve itself. Nonobservance of these safety instructions willalso forfeit the user�s warranty.

Such noncompliance could, for example, result in:

� failure of essential functions of the valve/plant� failure of prescribed maintenance and repair practices� hazard to people by electrical, mechanical or chemical

effects� hazard to the environment due to leakage of hazardous

substances

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3.4 Safety ConsciousnessThe safety instructions contained in this manual, theapplicable national accident prevention regulations and any ofthe user�s own applicable internal work, operation or safetyinstructions must be fully complied with.

3.5 Safety Instructions for the User / OperatorAny hot or cold parts or moving parts of the valve (e.g. body,handwheel or couplings etc.) that could pose a hazard must beprotected by the user against accidental contact.

Leakage (e.g. at the stem seal) of hazardous substance (e.g.explosive, toxic, hot) must be drained so as to avoid all dangerto people or the environment. All relevant laws must beobserved.

Electrical hazards must be effectively prevented. (For details,please refer to the VDE standards and/or the local energysupply utility regulations).

3.6 Safety lnstructions for Maintenance,Inspection and Installation work

The user is responsible for ensuring that all maintenance,inspection and installation work is carried out by authorized,adequately qualified staff who are thoroughly familiar with thisinstruction manual.

All work on a valve may only be performed when the valve isun-pressurized and has cooled down. This means that thetemperature of the medium in all the valve�s chambers must belower than the vaporization point of the medium.

All work on actuated valves may only be done after theactuator has been disconnected from its energy supply. Theprocedure described in the operating instructions to shut downthe actuator must be observed.

Valves in contact with hazardous media must bedecontaminated.

Immediately following completion of the work, all safetyrelevant and protective devices must be reinstalled and/orre-enabled.

Prior to recommissioning, refer to the points listed undersection 7 Commissioning.

3.7 Unauthorized Modification andManufacturing of Spare Parts

The equipment shall not be altered or modified in any way priorto consultation with the manufacturer. Genuine spare partsand accessories authorized by the manufacturer will ensureoperational safety. The manufacturer cannot be heldresponsible for damage resulting from the use of non-genuineparts or accessories or changes in these parts.

3.8 Inadmissible Modes of OperationOperational safety and reliability of the valve supplied is onlywarranted for its designated use as defined in section 2�General� of the operating instructions. The limits stated in thetechnical documentation must not be exceeded under anycircumstances.

4 Transport & Interim Storage4.1 TransportThe valves in the as-supplied condition are ready foroperation.

ATTENTION For transport and storage, the valves mustalways be maintained in the closed position and theconnection ends must be plugged using suitable means (e.g.covers, plastic sheets, etc.) to prevent damage to the seats.

ATTENTION To prevent damage, do not suspend the valveby its handwheel, stem or the actuator.

Valves with actuators should be suspended by the connectionends or the yoke arms depending on the center of gravity.

For valve weights, please refer to Annexure No.1.

After delivery or prior to installation, the valve should bechecked for damage during transit.

4.2 Interim StorageThe valves must be stored in such a way that correct operationis assured even after prolonged storage. This comprises:

� Storing in the closed position (to protect the seats fromdamage).

� Suitable measures against contamination, moisture, frostand corrosion (e.g. by using plastic sheets or end covers).

5 Description / Related DocumentsThe sectional drawings shown on page no. 5 are examples forthe general design of our valves. For drawings and otherinformation pertaining to a specific valve series, please refer tothe relevant type leaflets.

5.1 MarkingThe valves are marked to PED 97/23/EC and ASME B16.34.

In particular the marking contains at least following:� Manufacturer� Year of production� Valve type model or order no.� NPS (DN)� Pressure class� Material

By attaching a CE-marking to the valve the conformity with theEurop. Pressure Equipment Directive 97/23/EC is explained.

Class PN DN≤25 32 40 50 65 80 100 125 150 ≥200

15010

15016

≥30025

≥300≥40

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5.2 Drawings / Documents

5.2.1 Sectional Drawings Gate valves

Type Size Class Type leaflet no.

GTC 150-600 2� � 12� 150-600 7244.1

GTC 900-2500 2� � 12� 900-2500 7241.1

GTF 800-1500 1/2� � 2� 800-2500 7240.1

GTC 150-600 GTC 900-2500GTF 800-1500

5.2.2 Sectional Drawings Globe valves

Type Size Class Type leaflet no.

GLC 150-600 2� � 10� 150-600 7245.1

GLC 900-2500 2� � 8� 900-2500 7242.1

GLF 800-1500 1/2� � 2� 800-2500 7240.1

GLC 150-600 GLC 900-2500GLF 800-2500

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5.2.3 Sectional Drawings Check valves

Type Size Class Type leaflet no.

SCC 150-600 2� � 12� 150-600 7246.1

SCC 900-2500 2� � 12� 900-2500 7243.1

PCF 800-2500 1/2� � 2� 800-2500 7240.1

SCC 150-600 SCC 900-2500PCF 800-2500

5.3 List of ComponentsPart No. Discription100 Body139 Yoke160 Cover166 Bonnet200 Stem350 Disc360/361 Wedge367 Wedge Holder411 Gasket452 Gland Flange456 Gland Bush461 Gland Packing500 Spacer Ring501 Thrust Ring515 Seat Ring450 Back seat bushing544 Stem Nut562 Grub screws563 Hinge pin570 Hinge arm636 Grease Nipple900 Gland Bolt901 Hex Bolt902/902.1 Stud902.2 Hex Nut920.1 Hex. Nut920.2 Hex. Nut933 Cotter Pin961 Handwheel966 Bonnet retainer ring

5.4 Functioning Principle

5.4.1 Cast Gate, Globe and Swing check valvesAll cast valves have been designed according to the followingstandards and specifications :

ASME B16.34, API 600, BS 1873, BS 1868

5.4.1.1 Gate valves (Class 150, 300, 600)The valve consists mainly of body (100), bonnet (166) as wellas wedge (361) and stem (200) and the actuating unit.

Stem seal area : The gland packing (461) which seals thestem (200) is tightened by gland bolts (900) and nuts (920.2)on the gland flange (452). The bonnet (166) is equipped with aback seat bushing (450) which seals the valve while stem is inuppermost position.

Flow seal area : The hard faced seat rings (515) are weldedinto the body (100) or swaged (Class 150). The seal faces ofthe wedge (360) are hard faced. The wedge (360) isconnected to the stem (200) by a �T �joint. The wedge is guidedby lateral rails in the body (100).

Bonnet seal area: Body (100) and bonnet (166) areconnected to each other by through bolts (902) and nuts(920.1). Tightness is assured by means of the gasket (411).

5.4.1.2 Gate valves (class 900, 1500, 2500)The valve consists mainly of body (100), bonnet (166), yoke(139) as well as split wedge (350), wedge holder and stem(200) and the actuating unit.

Stem seal area: The gland packing (461) which seals thestem (200) is tightened by the studs (902.2) and nuts (920.2)on the gland flange (452). The bonnet (166) is equipped withan integral, hard faced back seat, which seals the valve whilestem is in uppermost position.

Flow seal area : The seat rings (515) are welded into the body(100). The split wedge unit consists of two hard faced discs(350) which can pivot on the wedge holder (367).The discs aresupported by replaceable thrust inserts. The discs aresecured from turning by a retaining element at the bottom ofthe stem (200). The split wedge unit is screwed on the stem(200) (locked by means of cylindrical pins) and guided bylateral rails in the body (100).

Bonnet seal area : The valve is equipped with a pressure sealbonnet. The bonnet (166) is pressed against the gasket (411)by the pressure in the valve body (100). The gasket issupported by the spacer ring (500) and the segmental thrustring (501) which is seated in a groove of the body (100). Thegasket is precompressed between disc thrust plate andbonnet (166) by means of the studs (902.1) and nuts (920.1).For optional over pressure safety device see �Pressure ReliefArrangement�

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Pressure Relief Arrangement:

External pipe connectingbonnet cavity and upstream side

Internal relief through seat ring

Bore through seat ring

Relief through external pipe Relief through safety valve

Bodysafetyvalve

Bi-directionalFlow direction

Flow direction

Important note: A pressure relief of the body is necessary if, with the gate valve closed, there is a danger of trapped liquid becoming overheated,thus creating an unacceptable pressure increase inside the valve. KSB standard valve is not provided with safety device.Pressure relief arrangement can be provided in any of the above options. When ordering please state whether a pressure reliefis required and by which method. For pressure relief through safety valve a connection branch is provided in our valve. For spring loaded body safety valve; refer leaflet number 7300.1

5.4.1.3 Globe valves (class 150, 300, 600)The valve consists mainly of body (100), bonnet (166) as wellas disc (350) and stem (200) and the actuating unit.

Stem seal area : The gland packing (461) which seals thestem (200) is tightened by gland bolts (900) and nuts (920.2)on the gland flange (452). The bonnet (166) is equipped with aback seat bushing (450), which seals the valve while stem is inuppermost position.

Flow seal area : The hard faced seat ring (515) is welded intothe body (100). The seat face of the flat disc is hard faced.

Bonnet seal area : Body (100) and bonnet (166) areconnected to each other by through bolts (902) and nuts(920.1). Sealing is assured by means of the gasket (411)encapsulated between the flanges.

5.4.1.4 Globe valves (class 900, 1500, 2500)The valve consists mainly of body (100), bonnet (166), yoke(139) as well as disc (350) and stem (200) and the actuatingunit.

Stem seal area : The gland packing (461) which seals thestem (200) is tightened by the studs (902.2) and nuts (920.2)on the gland flange (452). The bonnet (166) is equipped withan integral, hard faced back seat, which seals the valve whilestem is in uppermost position.

Flow seal area : The seat rings (515) are welded into the body(100). The seal face of the tapered disc (350) and the seat ringare hard faced.

Bonnet seal area : The valve is equipped with a pressure sealbonnet. The bonnet (166) is pressed against the gasket (411)by the pressure in the valve body (100). The gasket issupported by the spacer ring (500) and the segmental thrustring (501) which is seated in a groove of the body (100).

The gasket is precompressed between disc thrust plate andbonnet (166) by means of the studs (902.1) and nuts (920.1).

5.4.1.5 Swing check valves (class 150, 300, 600):The valve consists mainly of body (100), cover (160) as well asthe disc (350).

Flow seal area : The hard faced seat ring (515) is welded intothe body (100). The disc (350) is hard faced. lt is connected toa hinge arm (570) by means of a nut (920.2) and pin. The nut issecured by a cotter pin (anti-rotation device). The hinge arm ismounted to the body by means of an inside hinge pin (563).

Bonnet seal area : Body (100) and cover (161) are connectedto each other through bolts (902) and nuts (920.1). Sealing isassured by means of a gasket (411) encapsulated betweenthe flanges.

5.4.1.6 Swing check valves (class 900, 1500, 2500)The valve consists mainly of body (100), bonnet (166) as wellas the disc (350).

Flow seal area : The seat ring (515) is welded into the body(100). The sealing faces of the disc (350) and the seat ring(515) are hard faced. The disc is connected with a hinge armby means of a nut (920.2) and a pin. The nut is secured by acotter pin (anti-rotation device). The hinge arm is mounted tothe body by means of an inside hinge pin (563).

Bonnet seal area : The valve is equipped with a pressure sealbonnet. The bonnet (166) is pressed against the gasket (411)by the pressure in the valve body (100). The gasket issupported by the spacer ring (500) and the segment thrust ring(501) which is seated in a groove on the body (100). Thegasket is precompressed between disc thrust plate andbonnet (166) by means of the studs (902.1) and nuts (920.1).

5.4.2 Forged gate, globe and non-return valves (class 800-2500)

All forged valves have been designed according to thefollowing standards and specifications: ASME B16.34, API602, BS 5352.

Forged valves mainly consist of body, bonnet and the closingas well as the actuating unit (only gate and globe valves).

Stem seal area : The gland packing of gate and globe valveswhich seals the stem is tightened by the studs and nuts on thegland flange. The bonnet is equipped with an integral backseat, which seals the valve while the stem is in uppermostposition.

Flow seal area : The hard faced seat rings of gate valves areswaged into the body. The solid wedge is connected to thestem by a �T� joint. The integral seal faces of the body of globeand non-return valves are hard faced. The disc of non-returnvalves is spring loaded.

Bonnet seal area (with gasket) : The bonnet/yoke of class800 valves is bolted to the body with gasket encapsulated inbetween. In the case of class 1500 & 2500 the bonnet isthreaded and seal welded to the body.

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6 Installation6.1 General

ATTENTION To avoid leakage, deformation or rupture of thebody, the piping should be laid out in such a way that no thrustor bending forces act on the valve bodies (100) when they areinstalled and operational.

ATTENTION Remove only the covers from the connectionends just before installation. The sealing faces of the flangesmust be clean and undamaged.

The gaskets at the connecting flanges must beprecisely entered. Use only joints and gaskets of approvedmaterials. All holes provided in the flanges must be used forthe flange connection.

When painting the pipes, do not apply paint to bolts andstem (200). lf construction work is still in progress, the valvesmust be protected against dust, sand and building materialetc. (cover by suitable means).

Do not use valve handwheels as footholds!

Valves and pipes used for high (> 50 deg. C) or low (< 0 deg. C) temperatures must either be fitted with a protectiveinsulation, or there must be warning signs installed showingthat it is dangerous to touch these valves.

Valves with external moving elements must be fitted withprotective covers, or other suitable measures must be taken toprevent accidents.

lf a valve is used as end-valve in a pipe, this valveshould be protected against unauthorized or unintentionalopening to prevent personal injury or damage to property.

6.2 Installation positionThe valve bodies are marked with an arrow indicating the flowdirection. Valves should always be installed in such a way thatthe actual flow direction of the medium matches the arrow onthe body.

6.2.1 Gate valvesFlow may pass a gate valve in either direction (see page 7�Body Pressure Relief Arrangement�). When installing a gatevalve in a horizontal pipe, the stem should be vertical, i.e. thehandwheel or actuator is on top. Inclined or horizontal stemposition (e.g. in a vertical pipe) is also possible, in this case,however, the actuator must be supported by some suitablemeans.

6.2.2 Swing check valvesSwing check valves should preferably be installed inhorizontal pipes. When installing in vertical pipes, make surethat the flow direction is upwards, so that in unpressurizedcondition, the disc will be closed by its weight.

6.2.3 Globe valvesFlow may pass a globe valve in either direction if not indicatedotherwise. Installing a globe valve in a horizontal stem position(e.g. in a vertical pipe) is also possible, in this case, however,the actuator must be supported by some suitable means.

6.3 Welding InstructionsResponsibility for welding the connecting pipes lies with thepiping installation contractor.

ATTENTION When welding valves into the piping or whenwelding pipes after the valves have been installed, the weldermust make sure that no foreign particles, e.g. weld beads,enter the valve body and remain there, because these willcause damage to the valve seats or the stem.

On valves with socket weld ends, the insertion depth as perTechnical Rules must be complied with. A gap between thepipe end and the base of the socket will prevent inadmissibletensions in the weld.

ATTENTION During the welding process, the valve must beopened enough to ensure that there is no contact between thesealing elements; otherwise there is a risk of unintentionalwelding of the seat faces.

ATTENTION Do not attach the welding cable (opposite pole)to movable parts of the valve, otherwise these parts may bescorched.

6.4 Actuated Valves

ATTENTION Read the instruction manual of the actuator before installation.

Electrical cables may only be connected by qualifiedpersonnel.

The applicable electrical regulations (e.g. VDE), alsofor equipment in hazardous locations, must be observed.

All electrical equipment such as actuator, switchboard,magnetic valve drive, limit switch etc. must be installed infloodproof dry locations.

Voltage and frequency must match the valves stated on thename plate.

7 Commissioning / Decommissioning7.1 Commissioning

7.1.1 GeneralPrior to commissioning the valve, the pressure, temperatureand material data stated on the valve should be compared tothe actual operating conditions in the piping system to checkwhether the valve can withstand the loads occurring in theSystem.

Possible pressure surges (water hammer) must notexceed the highest admissible pressure of the valve.Adequate precautions should be taken.

In new pipe systems and especially after repair work, thesystem should be flushed with the valves fully open to removesolids, e.g. weld beads, which may damage the seats.

Venting the valve by undoing the bonnet/cover bolting orremoving the gland packing is dangerous and therefore notpermitted.

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7.1.2 OperationThe valves are closed by turning the handwheel in theclockwise direction (top view) and opened in thecounterclockwise direction. (Valve closing and opening torquevalues are listed in Annexure 2).

ATTENTION Valves with handwheels may only be actuatedby hand. As the valve can be damaged by applying excessiveforces, it is not allowed to use additional levers when movingthe handwheel.

7.1.3 Functional CheckThe following functions should be checked:

Before commissioning, the shut-off function of the valvesshould be checked by repeated opening and closing.

The gland packing (461) should be checked when it issubjected to the full operating pressure and temperature forthe first time. lf necessary, retighten the nuts (920.2) at thegland flange (452) evenly and carefully.

On valves in pressure seal design, the nuts (920.4/920.6) ofthe studs (902.2) pre-loading the bonnet (139) and the jointring (411) must always be tightened under operatingconditions such that leakage at the cover/bonnet, which mightbe caused by the bonnet (139) sinking as a result of lowpressure inside the body, is avoided.

The bonnet / cover bolting 902.1/920.1 with the joint ring(411.1) shall be gradually tightened crosswise, evenly and inclockwise direction after the first loading or heating up of thevalves and in the event of leakage at the joint ring (411.1). Fortightening torques please contact the manufacturer, ifnecessary.

ATTENTION Open the gate or globe valve by one or two turnsof the handwheel prior to retightening the nuts 920.1 to preventjamming of the seat.

Retightening of the nuts (920.1) of the cover bolting especiallyapplies to valves used in heat transfer systems to DIN 4754.

7.1.4 Actuated Gate ValvesOn valves with electric/pneumatic/hydraulic actuators, thestrokes/forces must be limited.

Electric actuators should be wired as follows:

Gate valve �CLOSE� travel-dependent

Gate valve �OPEN� travel-dependent

For pneumatic/hydraulic actuators, the control pressuresspecified in the order shall be complied with. Non-observancemay damage the actuator.

7.2 DecommissioningDuring extended shutdown periods, liquids liable to changetheir condition due to polymerization, crystallization,solidification etc. must be drained from the piping system. Ifnecessary, the piping system should be flushed with thevalves fully open.

8 Maintenance / Repair

8.1 Safety InstructionsMaintenance and repair work may only be carried out byskilled and qualified personnel.

For all maintenance and repair work, the safety instructionslisted below and also the general notes in section 3 must beobserved.

Always use suitable spare parts and tools, even inemergencies, otherwise correct operation of the valves cannot be assured.

8.1.1 Dismantling of valvesBefore removing the complete valve from the pipe, or beforerepair or maintenance work on the valve itself, i.e.

� before removing the pipe connection flanges� before removing cover/yoke or pressure seal bonnet from

the body� before removing/unscrewing vent or drain plugs� before removing the gland cover to replace packing rings� before removing an actuator bolted directly to the yoke head

the entire valve must be unpressurized and must havecooled down sufficiently so that the temperature of themedium in all the valve chambers is lower than thevaporization point of the medium, to prevent scalding.

Dismantling a pressurized valves will cause danger tolife and limb!

lf toxic or highly inflammable substances or liquids whoseresidues may cause corrosion by interaction with the airhumidity were handled by the valve, then the valve should bedrained and flushed or vented.

lf necessary, wear safety clothing and a face guard/mask.

Depending on the installation position, any liquid remaining inthe valve may have to be removed.

Prior to possible transport, the valves must be flushed anddrained carefully.

lf you have any questions please contact your KSB SalesOffice.

8.1.2 Removing Actuators

lf actuators powered by an external source of energy(electric, pneumatic, hydraulic) need to be removed from thevalves or dismantled, the energy supply must be shut downprior to starting any repair work and the instructions in thesections 3, 8.1 and the operating instructions of the actuatormust be observed.

Actuators with integrated spring mechanism containpre-loaded springs. They shall only be dismantled withextreme care, using the requisite locking devices.

Caution : Springs under tension!

lf you have any questions please contact your KSB SalesOffice.

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8.2 MaintenanceOur valves are largely maintenance free, materials of slidingparts were selected to keep wear to a minimum. To ensurereliable operation and to reduce repair costs, all valves �especially those which are seldom operated or where accessis difficult � should be checked periodically.

The user is responsible for defining appropriate intervals forchecks and maintenance, depending on the application of thevalve.

The service life of non-maintenance-free valves can beextended by:

� lubricating movable parts such as stem (200) and glandbolts (not for oxygen valves) using suitable lubricants (toDIN 51825 / equivalent)

� timely changing of the packing rings� timely replacing of the cover gasket (411)

The safety instructions in sections 3, 8.1 and the notes insection 9 must be observed.

8.3 Valve ReassemblyValve reassembly shall be effected in reverse order todismantling.

To maintain functional reliability, new gaskets and glandpackings shall be used whenever the valve is reassembled.

After reassembly and prior to commissioning / start-up, thevalves shall be subjected to a leak test in accordance with DIN 3230, Part 3, or API 598 and ASME B16.34 Section 8.

9 Troubleshooting9.1 GeneralAll repair and service work must be carried out by qualifiedpersonnel using suitable tools and genuine spare parts.

We recommend to have this work performed by our servicepersonnel.

The safety instructions in sections 3 and 8 must be observed.

9.2 Faults & Remedies

� Leakage at the seat

Possible causes:

� contaminations/solids in the medium� erosion, corrosion, abrasion� excessive loads from pipeline forces or thermal stresses

> Remachine the seat on wedge/disc and body using suitableregrinding equipment after dismantling the valve. Regrindingor replapping should be continued until the seats show asmooth and even ring.

� Leakage at the cover gasketPossible causes:

� gasket has settled as a result of high temperaturefluctuations

� impermissible pressure loads� poor maintenance� poor gasket resistance to temperature and fluid handled

� Cover Flange> Replace the gasket (411.1) after removing the cover bolting (902/920.1). Clean thesurfaces carefully before inserting a new gasket.

� Pressure seal bonnet/cover> Tighten the nuts (920.4/920.6) as indicated in section 7.1.3

> Replace the gasket (411.1)after removing the pressure seal bonnet/cover. Clean thesealing surfaces carefully before inserting a new gasket.

� Leakage on the Stuffing Box> Retighten the stuffing box with the nuts (920.1) at the glandflange (452). Make sure that the friction forces at the stem donot increase too much.

> Replace the packing rings of the gland packing (461):Unscrew the nuts (920.2) and lift gland flange (452) and glandbush (436). Clean the stuffing box chamber thoroughly beforeinserting new packing rings. Split packing rings should beinserted in such a way that the cut edges are offset by 120° �180°. Tighten the gland nut to a level at which no gland leak isseen. Avoid overtightening the pland packing.

Do not replace packing while the valve is pressurized.The back seat bushing is not intended to maintain a sealduring packing replacement.

ATTENTION On asbestos-free gaskets, no additionalsealing agents may be used. When using anti-adhesivecoatings, use only sealing agents explicity recommended bythe manufacturer of the sealing material.

lf you have any questions please contact your KSB SalesOffice.

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10 Valve weight (in kg)

I. CAST VALVES

SIZE CLASSGATE GLOBE CHECK

SIZE CLASSRF BW RF BW RF BW

150 15 12 19 14 16 11300 28 25 27 19 22 17

2�600 32 27 35 35 28 23

2�900 � 30 � 47 � 301500 � 45 � 75 � 352500 � 65 � 85 � 45150 25 22 35 35 35 32300 45 40 48 43 41 36

3�600 60 46 65 65 55 47

3�900 � 40 � 65 � 371500 � 45 � 130 � 452500 � 80 � 160 � 55150 40 35 55 50 47 42300 65 55 70 60 63 48

4�600 105 90 105 105 97 70

4�900 � 55 � 153 � 601500 � 75 � 180 � 1002500 � 95 � 230 � 128150 70 65 115 85 80 65300 135 110 135 120 120 100

6�600 210 160 210 160 160 130

6�900 � 120 � 200 � 1171500 � 200 � 275 � 2102500 � 325 � 325 � 170150 120 100 140 125 125 105300 220 185 295 250 265 225

8�600 365 280 530 490 310 235

8�900 � 310 � 260 � 2001500 � 350 � � � 4002500 � 470 � � � 420150 200 180 265 235 220 190300 375 315 375 305 280 235

10�600 600 520 780 710 490 440

10�900 � 375 � � � 3751500 � 520 � � � 6202500 � 1000 � � � 690150 280 245 � � 345 300300 470 390 � � 390 350

12�600 820 660 � � 640 575

12�900 � 680 � � � 5601500 � 950 � � � 7072500 � 1250 � � � 860

II. FORGED VALVES

TYPE CLASS ENDSSIZE (�)

TYPE CLASS ENDS0.5 0.75 1 1.5 2

800 SW 2 2.5 3 6.5 10

GATE 1500 SW 2 3 4.5 12.5 132500 SW � � � � �800 SW 1.5 2 3 6.5 10.5

GLOBE 1500 SW 2 4.5 6 11 12.52500 SW 2 4.5 6.5 11.5 13800 SW 1 1.5 2 5 9

CHECK 1500 SW 1 2 3 7.5 92500 SW 2 2.5 3 8 9.5

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11 Do�s and Dont�s

DO�S DONT�S

Read instruction manual carefully before and afterinstallation.

Do not allow unauthorised person for installation andservice.

Check valves should be mounted with the openingtowards the flow in vertical lines.

In vertical pipe lines check valves should not bemounted with opening in the downward direction.

flow direction flow direction

Arrow mark direction should be matched with the flowdirection.

While storing the valve should be in fully closed posi-tion and covered with end covers.

Adequate support for the pipe is to be ensured to avoidpossible extra strain on valve body.

Do not over torque for full close.

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DO:

1. Observe safety instructions

2. Employ skilled, trained and experienced personnel to handle the valve

3. Align the pipe correctly in position before mounting a valve on line

4. Use a correct type of flange gasket

5. Ensure the correct direction of flow on the valve

6. Ensure the valve is unpressurised before any work is carried out

7. Decontaminate the valve in contact with hazardous fluids

8. Lubricate the valves periodically

9. Protect the threads with a metal/leather jacket if the working conditions are abrasive

10. Allow clearance for raising stem type valve to open fully

11. Flush the valves in fully opened condition to remove foreign material like Welding Flux, Spatter, Slag,Dust, etc. to avoid damage of seats

12. Check shut off function by repeatedly opening and closing before commissioning

13. Check the frequency and voltage of actuators to match with the line voltage and frequency

14. If gasket is observed, tighten gasket bolts crosswise evenly in a clock wise direction

15. After attaining the full operating pressure and temperature, check and if necessary, tighten the gland nut

16. When a gate valve is fully opened, screw it down 1/4 turn to prevent sticking

17. During storage position the valve such that the stem is upright

18. For Globe valve follow the instructions carefully for direction of installation

DON�T:

1. Don�t expose the valves to dust, sand, building matl, etc during storage

2. Don�t use unauthorised spares

3. Don�t remove end protective covers before installation

4. Don�t use valve handwheel as foot holds

5. Don�t exceed the limits stated in technical documentation

6. Don�t store the valve in open condition

7. Don�t attempt to dismantle a pressurised valve or valve with high temperature

8. Don�t use a valve to pull an unsupported and badly aligned pipes into position

9. Don�t leave a gate valve in crack open condition

10. Don�t use a gate valve for throttling

11. Don�t force a gate valve closed with a wrench

12. Don�t use globe valves with flat disc for start-up and vent application

13. Once the valve is installed and commissioned do not tamper the torque & limit switches in case of valvewith electrical actuator

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KSB AktiengesellschaftBahnhofplatz 1 • 91257 Pegnitz (Germany)Tel.: +49 (92 41) 71 0 • fax: +49 (92 41) 71 17 95 • e-mail: valves@ksb.com • www.ksb.com