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Gate Valve
ECOLINE GT 40
Operating Manual
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Legal information/Copyright
Operating Manual ECOLINE GT 40
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or
processed for any other purpose, nor otherwise transmitted, published or made available to a third party without
the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft, Frankenthal 08.06.2016
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Contents
Glossary ......................................................................................................................................... 5
1 General .......................................................................................................................................... 6
1.1 Principles .........................................................................................................................................................6
1.2 Target group ...................................................................................................................................................6
1.3 Other applicable documents ..........................................................................................................................6
1.4 Symbols ...........................................................................................................................................................6
2 Safety ............................................................................................................................................. 7
2.1 Key to safety symbols/markings .....................................................................................................................7
2.2 General ............................................................................................................................................................7
2.3 Intended use ...................................................................................................................................................8
2.4 Personnel qualification and training .............................................................................................................8
2.5 Consequences and risks caused by non-compliance with this manual .......................................................8
2.6 Safety awareness ............................................................................................................................................8
2.7 Safety information for the operator/user .....................................................................................................8
2.8 Safety information for maintenance, inspection and installation ..............................................................9
2.9 Unauthorised modes of operation ................................................................................................................9
3 Transport/Temporary Storage/Disposal ..................................................................................... 10
3.1 Checking the condition upon delivery ........................................................................................................10
3.2 Transport .......................................................................................................................................................10
3.3 Storage/preservation ....................................................................................................................................11
3.4 Return to supplier .........................................................................................................................................12
3.5 Disposal .........................................................................................................................................................12
4 Valve Description ........................................................................................................................ 13
4.1 General description ......................................................................................................................................13
4.2 Marking .........................................................................................................................................................13
4.3 Operating data .............................................................................................................................................13
4.4 Fluids handled ...............................................................................................................................................14
4.5 Design details ................................................................................................................................................14
4.6 Pressure/temperature ratings ......................................................................................................................14
4.7 Materials .......................................................................................................................................................15
4.8 Function ........................................................................................................................................................17
4.9 Scope of supply .............................................................................................................................................17
4.10 Dimensions and weights ..............................................................................................................................17
5 Installation at Site ....................................................................................................................... 18
5.1 General information/Safety regulations .....................................................................................................18
5.2 Installation position and location ................................................................................................................19
5.3 Welding into the pipeline ............................................................................................................................19
5.4 Valves with actuator .....................................................................................................................................20
Contents
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5.5 Insulation ......................................................................................................................................................21
6 Commissioning/Start-up/Shutdown ........................................................................................... 22
6.1 Commissioning/start-up ...............................................................................................................................22
6.2 Shutdown ......................................................................................................................................................25
7 Servicing/Maintenance ............................................................................................................... 26
7.1 Safety regulations .........................................................................................................................................26
7.2 Maintenance .................................................................................................................................................26
8 EC Declaration of Conformity ECOLINE GT 40 .......................................................................... 28
Index ............................................................................................................................................ 29
Contents
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Glossary
PED
The 97/23/EC or 2014/68/EU directive, also
known as the Pressure Equipment Directive,
sets out the requirements to be met by pressure
equipment intended to be placed on the
market in the European economic area.
Technical literature
Refer to the product catalogue for the
technical literature on our products at
www.ksb.com.
Glossary
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1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
In the event of damage, immediately contact the KSB sales organisation responsible
in order to maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Type series booklet Description of the valve
Flow characteristics
1)
Information on Kv and zeta values
General assembly drawing
2)
Sectional drawing of the valve
Sub-supplier product literature
3)
Operating manuals and other product literature
for the accessories
Observe the relevant manufacturer's product literature for the accessories.
1.4 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1)
If any
2)
If inclusion in the scope of supply has been agreed; otherwise refer to the type series booklet.
3)
If inclusion in the scope of supply has been agreed.
1 General
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2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
!
DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!
WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe valve operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and fully understood by the specialist personnel/
operators responsible prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Instructions and information attached directly to the valve must always be complied
with and kept in a perfectly legible condition at all times. This applies to, for
example: flow direction arrow, manufacturer, type designation, nominal pressure,
nominal size, year of construction and material.
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this manual.
The design, manufacture and the testing of the valves are subject to a QM system to
DIN EN ISO 9001 as well as the European Pressure Equipment Directive 97/23/EC.
Compliance with these requirements, however, is based on normal, predominantly
static loading.
Valves exposed to creep-rupture conditions have a limited service life and have to
meet the applicable regulations stipulated in the technical codes.
In the case of customised special variants, further restrictions may apply with regard
to the operating mode and service life. Please refer to the relevant sales literature for
this information.
This operating manual does not take into account:
▪ Any eventualities or incidents which may occur during installation performed by
the customer, operation and maintenance.
▪ Local regulations; the operator must ensure that such regulations are strictly
observed by all, including the personnel called in for installation.
!
DANGER
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2.3 Intended use
▪ Only operate valves which are in perfect technical condition.
▪ Do not operate partially assembled valves.
▪ The valve must only handle the fluids specified in the product literature.
▪ Only operate the valve within the permissible operating range specified for
pressure and temperature.
▪ Consult the manufacturer about any other modes of operation not described in
the product literature.
Prevention of foreseeable misuse
▪ Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪ Observe all safety information and instructions in this operating manual.
2.4 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the product this manual refers to and be fully aware of the interaction
between the valve and the system.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Hands-on training at the valve must always be supervised by specialist technical
personnel.
2.5 Consequences and risks caused by non-compliance with this manual
▪ Non-compliance with this operating manual will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
▪ Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable standards, directives and laws
2.7 Safety information for the operator/user
Actuator-operated valves are intended for use in areas which cannot be accessed by
unauthorised persons. Operation of these valves in areas which can be accessed by
unauthorised persons is only permitted if appropriate protective devices are fitted at
the site. This must be ensured by the operator.
▪ The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
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▪ Do not remove any contact guards during operation.
▪ Provide the personnel with protective equipment and make sure it is used.
▪ Contain leakages (e.g. at the stem seal) of hazardous fluids (e.g. explosive, toxic,
hot) so as to avoid any danger to persons and the environment. Adhere to all
relevant laws.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2.8 Safety information for maintenance, inspection and installation
▪ Modifications or alterations of the valve require the manufacturer's prior
consent.
▪ Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪ The operator ensures that maintenance, inspection and installation is performed
by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.
▪ Carry out work on the valve during standstill only.
▪ The valve body must have cooled down to ambient temperature.
▪ The pressure in the valve body must have been released and the valve must have
been drained.
▪ When taking the valve out of service always adhere to the procedure described
in the manual.
▪ Decontaminate valves which handle fluids posing a health hazard.
▪ As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning.
2.9 Unauthorised modes of operation
Never operate the valve outside the limits stated in the data sheet and in this
operating manual.
The warranty relating to the operating reliability and safety of the valve supplied is
only valid if the valve is used in accordance with its intended use. (⇨ Section 2.3 Page
8)
Shut-off valves are not suitable for regulating volume flow.
Gate valves are used in such a way that they are either fully open or fully closed. An
intermediate position (throttling function) is not permitted.
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3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
Always close the valve manually before transporting it. The valve is delivered ready
for operation and its line connection ports may still be closed with caps, if applicable.
Original spare parts are only ready for operation following assembly/installation and
subsequent shell and leak testing of the valve.
DANGER
The valve could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Only transport the valve in the specified position.
▷ Never suspend the valve from its handwheel.
▷ Pay attention to the weight data and the centre of gravity.
▷ Observe the applicable local accident prevention regulations.
▷ Use suitable, permitted lifting accessories.
▷ Transport devices (if any) on the actuator may not be suitable for being
attached to a suspension arrangement in order to transport the valve/actuator
assembly. Refer to the actuator operating manual for the permissible loads.
To transport the valve, suspend it from the lifting tackle as illustrated.
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Fig. 1: Transporting the valve
3.3
Storage/preservation
A single coat of alkyd/acrylic enamel, blue RAL 5002, is applied at the factory to
protect the external surfaces. The flange faces have been coated with an anticorrosive which can easily be removed.
The inner surfaces are protected with a fully synthetic silicone-free anti-corrosive
(water hazard class 1) for long-term preservation.
If properly stored indoors, the equipment is protected for a maximum of 12 months.
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storing the valve:
CAUTION
Incorrect storage
Damage to the valve due to dirt, corrosion, moisture and/or frost!
▷ Store the valve in a dust- and vibration-free, frost-proof room where the
atmospheric humidity is as constant as possible (use suitable caps or film for
protection).
▷ Close the valve using little force and store in the closed position.
▷ Protect the valve from contact with solvents, lubricants, fuels or other
chemicals.
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NOTE
For actuated valves, also observe the actuator's operating manual.
3.4 Return to supplier
1. Drain the valve as described in the manual.
2. Always flush and clean the valve, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the fluids handled by the system leave residues which might lead to corrosion
damage when coming into contact with atmospheric humidity, or which might
ignite when coming into contact with oxygen, the valve must also be
neutralised and blown through with anhydrous inert gas for drying purposes.
4. When returning valves used for handling Fluids in Group 1 always complete and
enclose a certificate of decontamination.
Always indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
KSB web site at: www.ksb.com/certificate_of_decontamination
3.5 Disposal
WARNING
Fluids, consumables and supplies which are hot and/or pose a health hazard
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the valve.
Collect greases and other lubricants during dismantling.
2. Separate and sort the valve materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with current regulations or in another
controlled manner.
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4 Valve Description
4.1 General description
The sectional drawings below provide examples of the general design/configuration
of the valve. For additional and more detailed information, refer to the respective
type series booklet.
4.2 Marking
Table 4: General marking
Nominal size DN ...
Nominal pressure class or max. permissible pressure/temperature PN ... / ... bar / ...
°C
Manufacturer KSB
Type series/model or order number ECOLINE...
Year of construction 20..
Material .......
Traceability of the material .......
CE marking PED
Identification number of the notified body 0036
Customer's marking e.g. plant/
system No., etc.
The CE marking on the valve indicates that it is in conformity with the European
Pressure Equipment Directive 97/23/EC.
Class PN DN
≤25 32 40 50 65 80 100 125 150 ≥200
10
16
25
≥
≥40
150
300
Group 1 comprises fluids defined as
▪ Explosive
▪ Extremely flammable
▪ Highly flammable
▪ Flammable: The maximum allowable temperature is above flashpoint
▪ Very toxic
▪ Toxic
▪ Oxidising
Group 2 comprises all other fluids not referred to in Group 1.
4.3 Operating data
Table 5: Operating properties
Characteristic Value
Nominal pressure PN 10-40
Nominal size DN 50 - 600
Max. permissible pressure 40 bar
Min. permissible temperature -10 °C
Max. permissible temperature +400 °C
Selection as per pressure/temperature ratings (⇨ Section 4.6 Page 14)
Fluids in Groups 1 and 2
Fluid groups
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4.4 Fluids handled
▪ Water
▪ Steam
▪ Other non-aggressive fluids such as gas or oil on request.
4.5 Design details
Design
Valves to type series booklet 7367.1
▪ Bolted bonnet
▪ Non-rotating stem with external screw
▪ Back seat
▪ Flexible wedge
▪ Yoke head suitable for mounting electric and pneumatic actuators (DIN ISO 5210)
▪ The valves satisfy the safety requirements of Annex I of the European Pressure
Equipment Directive 97/23/EC (PED) for fluids in Groups 1 and 2.
▪ The valves do not have a potential internal source of ignition and can be used in
potentially explosive atmospheres, Group II, category 2 (zones 1+21) and
category 3 (zones 2+22) to ATEX 2014/34/EU.
Variants
▪ Stem protecting tube
▪ Stem protecting tube with position indicator
▪ Stem protecting tube with position switch
▪ Bypass
▪ Installation kit for electric actuators to EN ISO 5210 Type A
▪ Spur gear
▪ Bevel gear
▪ Electric actuators
▪ Seat/disc interface made of wear-resistant and corrosion-proof Stellite
▪ TA-Luft-compliant model for applications to VDI 2440 up to 400 °C (max.)
▪ Other flange designs
▪ Other butt weld end versions
4.6
Pressure/temperature ratings
Table 6: Permissible operating pressures in bar at temperatures in °C (to EN 1092-1)
4)
Nominal
pressure
Material
RT
5)
100 150 200 250 300 350 400
10 GP 240 GH 10,0 9,2 8,8 8,3 7,6 6,9 6,4 5,9
16 16,0 14,8 14,0 13,3 12,1 11,0 10,2 9,5
25 25,0 23,2 22,0 20,8 19,0 17,2 16,0 14,8
40 40,0 37,1 35,2 33,3 30,4 27,6 25,7 23,8
4)
Operating pressures to DIN 2401 are also permissible
5)
RT: room temperature (-10 ℃ to +50 ℃)
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Table 7: Test pressures
Nominal pressure Shell and leak test (body) Leak test (back seat) Leak test (seat)
With water With air
P 10, P 11
6)
API 598
P 12
7)
PN [bar] [bar] [bar]
10 15 11 6
16 24 17,6 6
25 38 27,5 6
40 60 44 6
4.7 Materials
Model with flanged ends
PN 10-25
DN 50-300
PN 40
DN 50-300
515
904
961
921
514
544
166
920.2
456
452
900
461.1
563
940
500
450
411
920.1
160
200
361
902.1
100
636
902.2
920.3
461.2
515
904
514
636
544
166
920.2
456
452
900
461.1
563
940
500
450
411
920.1
160
200
361
902.1
100
961
921
902.2
920.3
461.2
PN 10-25
DN 350-600
PN 40
DN 350-400
6)
DIN EN 12266-1 (P 10, P 11)
7)
DIN EN 12266-1 (P 12, leakage rate A)
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Model with butt weld ends
PN 10-25
DN 50-300
PN 40
DN 50-300
PN 10-25
DN 350-600
PN 40
DN 350-400
Table 8: Parts list
Part No. Description Material Material number Note
100 Body GP 240 GH 1.0619
131 Connection branch P 265 GH 1.0425
160 Bonnet GP 240 GH 1.0619
166 Yoke A 216 WCB
Equivalent DIN material:
GP 240 GH
200 Stem A 182 F6A
Equivalent DIN material:
X 10 Cr 13
361 Flexible wedge A 216 WCB
Equivalent DIN material:
GP 240 GH
Seat/disc
interface
Body Stellite 6
Wedge discs 13 % Cr
411 Joint ring SS316-Graphit
450 Back seat A 276 410
Equivalent DIN material:
X 12 Cr 13
452 Gland follower A 216 WCB
Equivalent DIN material:
GP 240 GH
456 Gland bush A 276 410
Equivalent DIN material:
X 12 Cr 13
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Part No. Description Material Material number Note
461.1 Packing ring Graphite
461.2 Graphite
Packing end rings
500 Neck ring A 276 410
≥ DN 400
514 Yoke bush A 29 M 1035
Equivalent DIN material:
C 35
515 Seat ring A 105
P 250 GH
544 Threaded bush A 439 D-2
Free from non-ferrous
metals
563 Grooved pin A 29 M 1035
Equivalent DIN material:
C 35
636 Lubricating nipple SS304
900 Eyebolt A 307-B
Equivalent DIN material:
St 50.11
902.1/.2 Stud A 193 B7
Equivalent DIN material:
24 CrMo 5
904 Grub screw
920.1/.2/.3 Hexagon nut A 194 2H
Equivalent DIN material:
C 35
921 Slotted round nut A 29 M 1035
Equivalent DIN material:
C 35
940 Key A 29 M 1035
Equivalent DIN material:
C 35
961 Handwheel QT400-18
≤ DN 350, nodular cast iron
A 29 M 1020
> DN 350
Equivalent DIN material:
C 22
4.8 Function
The valves consist of the pressure-retaining parts, i.e. body (100) and yoke (166), and
the functional unit.
The body (100) and yoke (166) are connected by studs (902.1) and hexagon nuts
(920.1), and the joint is sealed off by the joint ring (411).
The functional unit mainly consists of a flexible wedge (361), the stem (200) and the
actuating element, i.e. the handwheel (961) or actuator.
The seating faces of the body (100) and of the flexible wedge (361) are hard-faced.
The gland packing (461), which seals off the stem (200), is tightened via the gland
follower (452) by means of the eyebolts (900) and the hexagon nuts (920.2).
4.9 Scope of supply
▪ Valve
▪ Operating manual for each packaging unit
4.10 Dimensions and weights
For dimensions and weights please refer to the type series booklet.
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5 Installation at Site
5.1 General information/Safety regulations
The operator ensures that maintenance, inspection and installation is performed by
authorised, qualified specialist personnel who are thoroughly familiar with the
manual.
Responsibility for positioning and installing the valve lies with the consultant,
construction company or operator/user. Planning and installation errors may impair
the reliable function of the valve and pose a substantial safety hazard.
DANGER
Dead-end valve
High-pressure hazard!
Risk of burns!
▷ Protect the valve against unauthorised or unintentional opening.
WARNING
Cold/hot piping and/or valve
Risk of thermal injury!
▷ Insulate the valve.
▷ Attach warning signs.
WARNING
Exposed rotating parts
Risk of injury!
▷ Do not touch rotating parts.
▷ When the equipment is in operation, perform any work with utmost caution.
▷ Take suitable precautions, e.g. provide safety covers.
WARNING
Impermissible loads resulting from operating conditions and/or valve-mounted
components, e.g. actuators
Leakage from or rupture of the valve body!
▷ Provide adequate support.
▷ Additional loads, e.g. traffic, wind or earthquakes are not taken into account
for standard variants; these require a separate design.
CAUTION
Condensation water forming in air-conditioning, cooling and refrigerating systems
Ice forming!
Actuating element blockage!
Damage due to corrosion!
▷ Insulate the valve to prevent diffusion.
CAUTION
Improper installation
Damage to the valve!
▷ Remove the caps prior to installation.
▷ Clean the mating flange faces.
▷ Protect the body and bonnet/cover from any impacts.
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CAUTION
Outdoor installation
Damage due to corrosion!
▷ Protect the valve appropriately against moisture.
CAUTION
Painting of pipes
Impairment of the valve's function and loss of information!
▷ Protect stem and plastic components prior to applying paint.
▷ Protect printed name plates prior to applying paint.
CAUTION
Impermissible load
Damage to the actuating element!
▷ Do not use the valve as a foothold.
NOTE
Only use fasteners (e.g. to DIN EN 1515-4) and flange gaskets (e.g. to DIN EN 1514)
made of materials approved for the respective valve size. Always use all flange bolt
holes provided when connecting the valve to the piping. Refer to the type series
booklet for details on flange connections.
NOTE
For the valves to reach the documented Kv values, the flow direction must
correspond to the flow direction arrow.
NOTE
The mating flange faces must be clean and undamaged and the gaskets on the
mating flanges must be properly centred.
NOTE
Use an appropriate tool to evenly tighten the bolts crosswise, applying the
permissible torques.
5.2 Installation position and location
Any installation position can be chosen for gate valves. For gate valves installed in
horizontal pipes a vertical stem position is recommended (handwheel or actuator on
top). Installation with the stem in a horizontal or inclined position (e.g. in a vertical
pipe) is permitted; in this case, however, the actuator must be adequately supported.
Make sure that the non-rising handwheel can be operated and that there is sufficient
clearance available for the rising stem.
The position and flow direction must be in accordance with the manufacturer’s data.
The valve must not be fitted downstream of tees and level or three-dimensional
double bends.
5.3 Welding into the pipeline
Responsibility for welding the valve into the piping and for any heat treatment
required lies with the commissioned construction company or the plant operator.
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CAUTION
Weld beads, scale and other impurities
Damage to the valve!
▷ Take suitable measures to protect the valve against impurities.
▷ Remove any impurities from the piping.
▷ If necessary, install a strainer.
CAUTION
Incorrect earthing during welding work on the piping
Damage to the valve (scorching)!
▷ Open the valve during welding.
▷ Never earth the electric welding equipment on the valve's functional parts.
CAUTION
Non-compliance with the max. permissible application temperature
Damage to the valve!
▷ Complete the weld seam in several steps to ensure that the temperature in the
middle of the body does not exceed the max. permissible application
temperature.
NOTE
For valves with socket weld ends, comply with the insertion depth given in the
applicable technical code. A gap between the pipe end and the base of the weld
socket prevents impermissible stress on the weld.
5.4 Valves with actuator
Install valves with transmission gear and/or actuators with the stem in the vertical
position. If this requirement cannot be met, adequately support the actuator on site
or consult KSB.
Mounted actuators are factory-set and ready for operation. Changes to these
settings, e.g. changes to the set switching points of the limit positions, may impair
the valve's function and result in damage to the actuator, valve or the system.
DANGER
Unqualified personnel performing work on valves with actuator
Danger of death from electric shock!
▷ Ensure that the connection to the power supply and the process control system
is performed by a trained electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.
DANGER
Work on valves with energy storage, e.g. spring mechanisms or compressed air
storage
Danger to life resulting from incorrect assembly
▷ Ensure that work on the actuator is performed by qualified specialist personnel.
▷ Mount/remove the actuator in accordance with the operating manual.
NOTE
If the valves are fitted with actuators, ensure that the actuator's operating manual
is also observed.
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On valves with electric, pneumatic or hydraulic actuators, the actuator strokes/forces
must be limited.
Electric actuators are ready for operation and wired as follows:
▪ Valve "CLOSED": travel-dependent
▪ Valve "OPEN": travel-dependent
The wiring diagrams are located in the terminal boxes.
For pneumatic or hydraulic actuators, the control pressures specified in the order
confirmation must be observed. Non-observance may damage the actuator.
If required, consult the manufacturer for closing and opening torques or actuating
forces.
5.5 Insulation
NOTE
Any insulation fitted on the valve must not impair the valve's function. The sealing
areas at the cover/bonnet joint and at the stem passage (gland packing) must be
directly accessible and visible.
Electric actuators
Pneumatic/hydraulic
actuators
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6 Commissioning/Start-up/Shutdown
6.1 Commissioning/start-up
6.1.1 Prerequisites for commissioning/start-up
Before commissioning/start-up of the valve, ensure that the following requirements
are met:
▪ The material, pressure and temperature data on the valve complies with the
operating conditions of the piping. (⇨ Section 4 Page 13) .
▪ The material's chemical resistance and stability under load have been checked.
The nominal pressure classes only apply at room temperature. For values for higher
temperatures, refer to the pressure/temperature ratings tables. (⇨ Section 4 Page
13) . Using the valve in conditions deviating from those specified will lead to
overload which the valves cannot withstand.
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the valve!
▷ Remove any impurities from the piping.
▷ If necessary, install a strainer.
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Remove the valve's flange covers before installing it in the piping.
3. Check that the inside of the valve is free from any foreign objects. Remove any
foreign objects.
4. If required, install a strainer in the piping.
DANGER
Surge pressure/water hammer potentially occurring at high temperatures
Danger to life caused by burns and scalds!
▷ The max. permissible valve pressure must not be exceeded (⇨ Section 4 Page
13) .
▷ Use valves made of nodular cast iron or steel.
▷ Operator shall provide general safety measures for the system.
CAUTION
Aggressive flushing and pickling agents
Damage to the valve!
▷ Match the cleaning operation mode and duration of flushing and pickling to
the body and seal materials used.
▷ Responsibility for the compatibility of the pickling media used and the pickling
procedure itself lies with the pickling company.
1. Check the shut-off function of the installed valve prior to commissioning/startup by opening and closing it several times.
2. Check the gland packing (461) for leakage when it is subjected to full operating
pressure and operating temperature for the first time.
3. If the gland follower (452) is loose, evenly re-tighten the nuts (920.2).
4. Check the bonnet/cover bolting (902.1/920.1) and the joint ring (411) for
tightness after the valve has been subjected to load conditions or heated up for
the first time.
5. To avoid stress or distortion, open the valve by approx. two full counterclockwise handwheel turns.
Functional check
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6. If the bonnet/cover bolting (902.1/920.1) has loosened, evenly re-tighten it
crosswise.
NOTE
Re-tightening the bonnet/cover bolting is particularly important for valves operated
at temperatures exceeding 200 °C.
On valves with electric, pneumatic or hydraulic actuators, the actuator strokes/forces
must be limited.
DANGER
Unqualified personnel performing work on valves with actuator
Danger of death from electric shock!
▷ Ensure that the connection to the power supply and the process control system
is performed by a trained electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
NOTE
If the valves are fitted with actuators, ensure that the actuator's operating manual
is also observed.
1. Check the available mains voltage against the data on the name plate of the
actuator.
2. Select an appropriate start-up method.
Electric actuators are ready for operation and wired as follows:
▪ Valve "CLOSED": travel-dependent
▪ Valve "OPEN": travel-dependent
The wiring diagrams are located in the terminal boxes.
For pneumatic or hydraulic actuators, the control pressures specified in the order
confirmation must be observed. Non-observance may damage the actuator.
If required, consult the manufacturer for closing and opening torques or actuating
forces.
Shut-off valves are not suitable for regulating volume flow. Gate valves are used in
such a way that they are either fully open or fully closed. An intermediate position
(throttling function) is not permitted.
6.1.2
Valve actuation
NOTE
Viewed from above, the valve is closed by turning the handwheel in clockwise
direction, and opened by turning the handwheel in counter-clockwise direction.
Direction symbols are found on the top of the handwheel.
CAUTION
Excessively long idle periods
Damage to the valve!
▷ Check the function by opening and closing the valve at least once or twice a
year.
Actuated valves
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CAUTION
Use of levers
Damage to the valve as a result of excessive forces!
▷ Only actuate handwheel-operated valves by hand.
▷ Levers may only be used in exceptional cases and in compliance with the
following tables.
▷ Do not use levers in the area of the position indicator.
6.1.3 Information on the mechanical components
6.1.3.1 Moving parts
The valve/actuator combination comprises moving parts which are not fully enclosed.
Depending on the type and design, these include the following:
▪ Stem
▪ Stop
▪ Position switches
▪ Coupling
▪ Other force-transmitting equipment
Depending on the actuator type and design, further moving parts may be present,
e.g. emergency handwheels turning along with the actuator.
Valve commissioning/start-up is not permitted until both valve ends have been
connected to the pipeline and any risk of injuries can be ruled out.
6.1.3.2
Electric actuator overtravel
Depending on the mass to be accelerated, electric actuators may be subject to a
corresponding overtravel effect. Take into account this overtravel effect when setting
the actuator.
NOTE
If the valves are fitted with actuators, ensure that the actuator's operating manual
is also observed.
6.1.3.3 Self-locking function
As standard, the trapezoidal stem thread is self-locking. For special designs, e.g.
multiple threads, the self-locking function is taken over by the actuator assembly.
The self-locking effect may be reduced over time due to wear.
6.1.3.4 Uncontrolled movements
In the following cases, the valve's position may change in an uncontrolled manner
due to the system's pressure with resultant effects on the plant:
▪ Control failure
▪ Signal error
▪ Power supply failure during operation
▪ Incorrect actuator setting
▪ De-activation of the position switches in the actuator
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6.2 Shutdown
6.2.1 Measures to be taken for shutdown
During prolonged shutdown periods, ensure that the following conditions are met:
1. Drain fluids which change their physical condition due to changes in
concentration, polymerisation, crystallisation, solidification, etc. from the
piping.
2. If required, flush the piping with the valves fully opened.
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7 Servicing/Maintenance
7.1 Safety regulations
The operator ensures that maintenance, inspection and installation is performed by
authorised, qualified specialist personnel who are thoroughly familiar with the
manual.
DANGER
Valve under pressure
High-pressure hazard!
Leakage of hot and/or toxic fluids!
Risk of burns!
▷ The valve and its surrounding system must be depressurised prior to any
maintenance and installation work.
▷ If the bellows are defective or fluid escapes, ensure the valve is depressurised.
▷ Ensure the valve is depressurised before removing any drain, opening or vent
plugs.
▷ Allow the valve to cool down so that the temperature is below the fluid's
vaporisation temperature in all areas in contact with the fluid in order to
effectively prevent any risk of scalding.
▷ Never vent the valve by removing the bonnet/cover bolting or gland packing.
▷ Use appropriate spare parts and tools, even in emergencies.
WARNING
Fluids, consumables and supplies which are hot and/or pose a health hazard
Risk of injury!
▷ Observe all relevant laws.
▷ When draining the fluid take appropriate measures to protect persons and the
environment.
▷ Decontaminate valves used for handling fluids posing a health hazard.
NOTE
Before removing the valve from the piping, ensure that the pipe has been taken
out of service and released for repair/maintenance work.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the valve with a minimum of maintenance
expenditure and work.
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. For contact details please refer to the enclosed "Addresses"
booklet or visit "www.ksb.com/contact" on the Internet.
Never use force when dismantling and reassembling the valve.
7.2 Maintenance
This valve has been designed to be largely maintenance-free. The materials of the
sliding parts have been selected for minimum wear.
NOTE
The user is responsible for defining appropriate intervals for checks and
maintenance, depending on the application of the valve.
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NOTE
If several valves are serviced at the same time, take appropriate measures to
prevent the dismantled parts from getting mixed up.
The service life can be extended by taking the following measures:
▪ Checking the function by opening and closing the valve at least once or twice a
year
▪ Lubricating the moving parts such as stem (200) and gland bolts using
appropriate lubricants (e.g. lubricants suitable for high temperatures)
▪ Adding or replacing packing rings in the gland packing (461) in time
▪ Re-tightening or replacing the bonnet/cover gasket (411) in time
After reassembly and prior to commissioning/start-up, the valves must be subjected
to shell and leak testing to DIN EN 12266-1.
Testing overhauled valves
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8 EC Declaration of Conformity ECOLINE GT 40
Herewith we, KSB Valves (Changzhou) Co., Ltd.
No. 68 Huanbao Four Road, Environment Protection Industrial
Park,
Xinbei District,
Changzhou City
Jiangsu Province
P. R. China
declare that the product:
Gate valve
ECOLINE GT 40 PN 10-40 DN 50 - 600
satisfies the safety requirements laid down in the Pressure Equipment Directive 97/23/EC (until 18 July 2016) and
2014/68/EU (from 19 July 2016).
Codes applied:
AD 2000-Merkblatt HP 0 / A 4 and EN ISO 3834-2
Suitable for:
Fluids in Groups 1 and 2
Conformity assessment procedure:
Module H
Name and address of the notified body responsible for approval and surveillance:
TÜV SÜD Industrie Service GmbH
Westendstraße 199
80686 München (Germany)
Identification number of the notified body:
0036
This Declaration of Conformity also confirms the conformity of the casting suppliers for ECOLINE GT 40 with the
requirements of Pressure Equipment Directive 97/23/EC (until 18 July 2016) and 2014/68/EU (from 19 July 2016) and
"AD 2000-Merkblatt HP 0" regarding the materials used for the pressure-retaining parts.
Jason Ji
Head of Quality Management
This document has been prepared electronically and is valid without a signature.
8 EC Declaration of Conformity ECOLINE GT 40
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Index
A
Applications 8
C
CE marking 13
Commissioning/start-up 22
D
Disposal 12
F
Fluids in Group 1 13
Fluids in Group 2 13
Function 17
I
Intended use 8
M
Maintenance 26
Marking 13
Materials 16
Misuse 8
O
Operating data 13
Other applicable documents 6
P
Pressure Equipment Directive 97/23/EC 13
Pressure/temperature ratings 14
R
Return to supplier 12
S
Safety 7
Safety awareness 8
Scope of supply 17
Shutdown 25
Storage 11
T
Transport 10
W
Welding into the pipeline 19
Index
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7367.8/03-EN
KSB Aktiengesellschaft
Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 • Fax +49 6233 86-3476
E-Mail: valves@ksb.com • www.ksb.com
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