Flowserve ZK210 User Manual
ZK 210 GB
Installation Instructions 810691-00
Control Valve with ZK Radial Stage Nozzle
Contents
Page
Important Notes
Usage for the Intended Purpose.............................................................................................. 3
Safety Note.............................................................................................................................. 3
Warning ................................................................................................................................... 4
Ratings Pursuant to Article 9 of the Pressure Equipment Directive ......................................... 4
Explanatory Notes
Scope of Supply ...................................................................................................................... 5
Description............................................................................................................................... 5
Function............................................................................................................................... 6, 7
Technical Data......................................................................................................................... 8
Pressure/Temperature Rating ................................................................................................. 8
Material.................................................................................................................................... 9
Corrosion Resistance .............................................................................................................. 9
Nominal Sizes.......................................................................................................................... 9
Connections............................................................................................................................. 9
Operation................................................................................................................................. 9
Capacity Charts ..................................................................................................................... 10
Kvs Values and Actuator Selection Data ................................................................................ 10
Operating Procedure
Installation ....................................................................................................................... 11, 12
Commissioning ...................................................................................................................... 12
Operation............................................................................................................................... 13
Maintenance .................................................................................................................... 13, 14
Repairs
Repair.................................................................................................................................... 15
Spare Parts............................................................................................................................ 15
2
Important Notes
Usage for the Intended Purpose
The control valve, series ZK 210, is intended solely for cutting off and/or regulating the flow of
fluids consisting of water, steam, or steam condensate.
Its use is permissible only within the allowable limits of pressure and temperature and only if
the chemical and corrosive influences on the pressure equipment are taken into account.
Before installation and operation, a check must be performed to ascertain that the valve is
resistant to the medium in the operational conditions that will exist.
Opening of the valve body and/or structural changes may be performed only if the
manufacturer's written permission is obtained.
Any type of use differing from the usage described above must be considered as improper.
The resulting risk will have to be borne by the user alone. The manufacturer hereby expressly
rejects any claims for any resulting damage.
Safety Note
The control valve ZK 210 must not be installed, removed, commissioned, operated or
maintained by anyone other than qualified staff.
"Qualified staff" are persons who are familiar with the procedures for installation, removal,
commissioning, operation and maintenance of the product, and who have qualifications
appropriate for their work, for example staff who have received the following:
Training as specialists.
Training or instruction in the use of appropriate safety procedures in accordance with the
standards of safety engineering.
Training or instruction in first aid and in accident prevention regulations.
For installation, removal, commissioning, operation and maintenance, every person who
works with the control valve must have read and understood the complete installation
instructions. Furthermore, responsibilities must have been defined clearly and unambiguously
and must be adhered to.
In addition to these installation instructions, the documents issued by the manufacturers of
the actuators, and in particular the safety information contained in these documents, must be
observed.
Usage of the control valve ZK 210 for the intended purpose includes compliance with the
rules and notes in these installation instructions for installation, removal, commissioning,
operation and maintenance.
The operating company must ensure that, whenever the control valve ZK 210 is being
operated, it is in perfect condition.
Working methods that jeopardise safety must not be used.
3
Important Notes
Warning
Danger
If the control valve is used in an inexpert or improper manner by unqualified
staff, it can cause danger to life and limb for the user or for third parties,
possibly resulting in death.
During operation, the control valve ZK 210 is under pressure. In this condition,
screws, nuts or bolts must not be slackened. Hot water or steam could flow out
and could cause severe scalding over the entire body.
During operation, the valve might be hot. If the valve is touched when in the
operational condition, severe burns are possible. It must be ensured that,
when handwheels are being operated, the operator wears gloves.
Any installation or removal work may only be performed when the equipment
is at zero pressure and has cooled down. When such work is to be done, the
pressure in the pipes upstream and downstream of the valve must have been
reduced to zero and the valve must have cooled down sufficiently. It must be
ensured that, during the work, the system section in which pressure has been
reduced to zero cannot be accidentally put back into operation. The shut-off
valves needed for this purpose must be separately secured and marked.
In addition, it must be ensured that the actuators of the valve are not in the
connected state. The connection to the energy supply (electric, pneumatic,
hydraulic) must be disconnected and must be secured to prevent it from being
operated accidentally. One or more warning notices, for example containing
the text "DO NOT SWITCH ON", must be displayed in a clearly visible manner
at each operating element.
(continued)
Ratings Pursuant to Article 9 of the Pressure Equipment Directive
Gaseous Liquid
Fluid
1212
Use
Category
Nominal size of connection, DN
CE marking
The control valve may only be used in accordance with the above-mentioned ratings pursuant
to Article 9 of the Pressure Equipment Directive. Any other type of use must be considered as
improper.
No Yes No Yes
Exception
according
to Art.3.3
25 32 – 100
No Yes Yes ---
IIIIV(safety
≥125
equipment)
---
4
Explanatory Notes
Scope of Supply
Control valve ZK 210 with or without an attached actuator, according to the order
Installation instructions for the control valve
Parts list with drawing
Operation instructions for the actuator
Acceptance certificates according to the order
Description
The control valve ZK 210 is used to reduce large differential pressures. It is used mainly in
industrial plants and power stations in which ease of maintenance and high resistance to
wear are required.
The valve consists of the valve body, a yoke suitable for the various actuators, and a ZK
radial stage nozzle with valve plug integrated in the valve body to act at the control element.
Depending on requirements, the bodies are designed as straight-through (ZK210-D/..) or
angle versions (ZK210-E/..).
The control valve can be operated by means of various actuators, e.g. electric rotary
actuators, pneumatic actuators or by means of a handwheel.
Special equipment is available, such as sampling valves, a sealing-fluid connection and selftightening stuffing boxes.
If the operating conditions of the plant change, the Kvs value and the characteristic curve of
the control valves can be adapted to suit the new conditions by turning of the sleeve insert of
the ZK radial stage nozzle, without having to remove the valve.
Control valve ZK 210-D/14 DN 25 with
handwheel
Control valve ZK 210-E/14 DN 80 with electric
rotary actuator
5
Explanatory Notes
(continued)
Function
Every control valve is equipped with a ZK radial stage nozzle .
This is a system comprising several sleeves nesting within one another and containing radial
orifices drilled in them. By rotation of the sleeves, the orifices are shifted relative to one
another, thus forming a large number of throttling points in parallel, with turbulence chambers
(expansion chambers) in between.
The throughput through the ZK radial stage nozzle is set by means of the valve plug.
Depending on its position, this valve plug opens up the individual orifices partially or
completely, thus producing different flow rates.
As a result of this design, the pressure drop is reduced in steps and the medium flowing
through is split up into many partial flows. This ensures high resistance to wear and reduces
the noise level.
On the valve plug, there is a control edge which is separate from the seat surface and closes
the orifices of the sleeve insert before the valve plug comes to rest completely against the
seat ring. As a result, wear is prevented on the surfaces of the seat. Because of the multiple,
step-by-step expansion in the turbulence chambers, the pressure drop in the region of the
seat is minimised.
Setting slots Control edge
Orifices of sleeve
insert (sleeves
not shifted)
Seat
Orifices
Flash chambers
(sleeves shifted)
Control valve ZK 210: 3-stage radial nozzle,∆p
100 bar
max
6
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