KSB STAAL 40 AKD, STAAL 100 AKGS-A, STAAL 100 ZTS, STAAL 40 AKKS, STAAL 100 AKK Operating Manual

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STAAL 40 AKD/AKDS, STAAL 100 AKD/AKDS, AKG-A/AKGS-A, ZTS, STAAL 40 AKK/AKKS, STAAL 100 AKK/AKKS, AKR/AKRS, ZRS, VTS, UGS

Operating Manual

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Legal information/Copyright

Operating Manual

Original operating manual

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.

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Contents

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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

2.3.1 Prevention of foreseeable misuse.......................................................................................................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 ..............................................................................................................................................9

2.7 Safety information for the operator/user.......................................................................................................9

2.8 Safety information for maintenance, inspection and installation ................................................................9

2.9 Unauthorised modes of operation..................................................................................................................9

3 Transport/Temporary Storage/Disposal............................................................................................. 11

3.1 Checking the condition upon delivery..........................................................................................................11

3.2 Transport.........................................................................................................................................................11

3.3 Storage/preservation......................................................................................................................................12

3.4 Return to supplier...........................................................................................................................................13

3.5 Disposal ...........................................................................................................................................................13

4 Valve Description ................................................................................................................................. 14

4.1 General description ........................................................................................................................................14

4.2 Marking...........................................................................................................................................................14

4.3 Gate Valves .....................................................................................................................................................14

4.3.1 Function of gate valves with bolted bonnet....................................................................................14

4.3.2 Function of gate valves with pressure seal bonnet .........................................................................15

4.3.3 Gate Valves to DIN/EN with Bolted Bonnet .....................................................................................16

4.3.4 Gate Valves to DIN/EN in Pressure Seal Design ................................................................................23

4.4 Body Pressure Relief Valve.............................................................................................................................29

4.4.1 UGS .....................................................................................................................................................29

4.5 Swing check valves .........................................................................................................................................33

4.5.1 Function of swing check valves with bolted cover ..........................................................................33

4.5.2 Function of swing check valves with pressure seal cover ................................................................33

4.5.3 Swing Check Valves with Bolted Cover ............................................................................................34

4.5.4 Swing check valves with pressure seal cover....................................................................................39

4.6 Line Blind Valve ..............................................................................................................................................45

4.6.1 VTS ......................................................................................................................................................45

4.7 Scope of supply...............................................................................................................................................48

4.8 Dimensions and weights ................................................................................................................................48

5 Installation at Site................................................................................................................................ 49

5.1 General information/Safety regulations .......................................................................................................49

5.2 Installation position and location..................................................................................................................50

5.3 Welding into the pipeline..............................................................................................................................51

5.4 Valves with actuator.......................................................................................................................................52

5.5 Insulation ........................................................................................................................................................53

5.6 Body pressure relief valve ..............................................................................................................................54

6 Commissioning/Start-up/Shutdown................................................................................................... 57

6.1 Commissioning/Start-up.................................................................................................................................57

6.1.1 Prerequisites for commissioning/start-up .........................................................................................57

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6.1.2 Valve actuation ..................................................................................................................................59

6.1.3 Information on the mechanical components...................................................................................60

6.2 Shutdown........................................................................................................................................................62

6.2.1 Measures to be taken for shutdown ................................................................................................62

6.2.2 Servicing/Maintenance ......................................................................................................................62

7 Servicing/Maintenance........................................................................................................................ 64

7.1 Safety regulations...........................................................................................................................................64

8 Trouble-shooting.................................................................................................................................. 65

9 EU Declaration of Conformity............................................................................................................. 66

9.1 EU Declaration of Conformity for STAAL40, STAAL100, AKG-A/AKGS-A, AKR/AKRS, ZTS, ZRS, VTS ......66

Index ..................................................................................................................................................... 67

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Glossary

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Glossary

Pressure Equipment Directive (PED)

The 2014/68/EU 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.

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1 General

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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 your nearest KSB sales organisation responsible 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

Information on Kv and zeta values

General assembly drawing

Sectional drawing of the valve

Sub-supplier product literature3)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

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.

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2 Safety

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2 Safety

DANGER

All the information contained in this section refers to hazardous situations. In addition to the present general safety information the action-related safety

information given in the other sections must be observed.

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 operating manual contains general installation, operating and maintenance instructions that must be observed to ensure safe operation of the system 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 understood by the responsible specialist

personnel/operators prior to installation and commissioning. The contents of this operating manual must be available to the specialist personnel

at the site at all times. Information and markings attached directly to the product 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 ▪ Body material

The operator is responsible for ensuring compliance with all local regulations not taken into account in this operating manual.

The design, manufacture and the testing of the valve are subject to a QM system to DINENISO9001 as well as the current European Pressure Equipment Directive. European Pressure Equipment Directive (PED) Compliance with these requirements, however, is based on normal, predominantly static loading.

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Bear in mind that 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. Refer to the relevant sales documentation for applicable limitations.

This operating manual does not take into account:

▪ Any eventualities or incidents occurring 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.

2.3 Intended use

▪ Only operate valves which are in perfect technical condition. ▪ Do not operate the valve in partially assembled condition. ▪ Only use the valve for fluids specified in the product literature. Take the material

variant into account.

▪ Only operate the valve within the operating limits described in the other

applicable documents.

▪ The valve's design and rating are based on predominantly static loading in

accordance with the codes applied. Consult the manufacturer if the valve is subjected to dynamic loads or any other additional influences.

▪ Consult the manufacturer about any other modes of operation not described in

the product literature.

▪ Do not use the valve as a foothold.

2.3.1 Prevention of foreseeable misuse

▪ Never exceed the permissible application and operating limits specified in the

product literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this 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 these operating instructions 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

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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 regulations 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.

▪ Fit protective equipment (e.g. contact guards) supplied by the operator for hot,

cold or moving parts, and check that the equipment functions properly.

▪ Do not remove any protective equipment (e.g. 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/components authorised by the

manufacturer. The use of other parts/components 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. ▪ Protect the valve body and body bonnet/cover from any impacts. ▪ As soon as the work has been completed, re-install and re-activate any safety-

relevant devices and protective devices. Before returning the product to service, observe all instructions on commissioning. (ðSection6.1,Page57)

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. (ðSection2.3,Page8)

Shut-off valves are not suitable for regulating volume flow.

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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

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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 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

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.

If properly stored indoors, the equipment is protected for a maximum of 12 months.

NOTE

For actuated valves, also observe the actuator's operating manual.

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3.4 Return to supplier

1. Drain the valve as described in the manual.

2. Flush and clean the valve, particularly if it has been used for handling noxious, explosive, hot or other hazardous fluids.

3. If the valve has handled fluids whose residues could lead to corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen also neutralise the valve and blow through with anhydrous inert gas to ensure drying.

4. When returning valves used for handling Fluids in Group1 always complete and enclose a certificate of decontamination. Indicate any safety measures and decontamination measures taken.

NOTE

If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination

3.5 Disposal

WARNING

Fluids handled, consumables and supplies which are hot 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 local 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 and/or max. permissible pressure/

temperature

PN ... / ... bar / ...

°C Manufacturer KSB Type series/model and/or order number NORI... Year of construction 20..

Material .......

Flow direction arrow →

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 2014/68/EU.

Fluids in Groups 1 and 2

Class PN DN

≤25 32 40 50 65 80 100 125 150 ≥200 10 16 25

≥

≥40

150

300

Fluid groups In accordance with Article13 Para.1 of Pressure Equipment Directive 2014/68/EU,

Group 1 comprises all fluids posing physical or health hazards, e.g. 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 Gate Valves

4.3.1 Function of gate valves with bolted bonnet

The valve consists of the pressure-retaining parts, i.e. body 100 and yoke 166, and the functional unit.

Body 100 and yoke 166 are connected by studs 902.1 or grub screws 904 and nuts

920.1, and the joint is sealed off by joint ring 411.1.

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The functional unit consists mainly of wedge holder 367, flexibly mounted wedge discs 360 and stem 200. The actuating element is either a handwheel 961 or an actuator.

The seating faces of body 100 and wedge discs 360 are hard-faced. Gland packing 461, which seals off stem 200, is tightened via gland follower 452 by means of studs

902.3 or hinged bolts and nuts 920.2.

4.3.2 Function of gate valves with pressure seal bonnet

Gate valves with wedge discs 360 consist of body 100 with welded stellited seat rings 515, wedge discs 360 with stellited seating faces, bonnet 139 with gland packing 461 and yoke 166 with the actuating element.

Shut-off is performed by two wedge discs 360 pressed against seat rings 515; they are flexibly mounted in wedge holder 367 and supported by replaceable thrust inserts 553 via pins 563.

Wedge holder 367 is screwed onto stem 200. A retainer prevents wedge discs 360 from twisting in wedge holder 367. To prevent twisting of the obturator components, the wedge holder is guided in the body by lateral guide ribs 752. The valve is equipped with a pressure seal bonnet.

The pressure inside body 100 presses bonnet 139 against joint ring 411.1, which is supported by compression ring 501. The studs 902.2 and hexagon nuts 920.6, which are supported by thrust plate 414 ensure that bonnet 139 is held in position against joint ring 411.1, even if there is no pressure inside body 100.

For fitting a body pressure relief valve (ðSection4.4.1,Page29) (see type series booklet 7300.1) a 22/14x74mm connection branch 131.2 is welded to body 100. The connection branch is closed upon delivery.

Body pressure relief valves, if ordered, are supplied unassembled, i.e. attached loosely to the gate valve.

Instead of fitting a body pressure relief valve, the operator may also provide a means of pressure balancing between the body's middle section and the gate valve's pressurised connection branch, e.g.:

▪ a pressure balancing hole in the seat ring or ▪ an external balancing line.

In this case the gate valve can be used for one flow direction only. If gate valves and swing check valves in pressure seal design (bonnet 139) are fitted in

close proximity to one another, meaning that the trapped liquid could heat up if the valves are closed, the operator must fit a body pressure relief valve.

Gland packing 461, which seals off stem 200, is tightened via gland follower 452 by means of studs 902.3 and nuts 920.1. Stem 200 is moved in axial direction by the rotating threaded bush 544, which is fitted with cylindrical roller bearings 323. Stem 200 lifts off wedge discs 360 or presses them against seat rings 515.

Threaded bush 544 is positioned in the yoke head by intermediate flange 729 and hexagon socket head cap screws 914.1. Handwheel 961 sits on threaded bush 544, to which it is joined via key 940. It is secured by circlip 932.

The stop nut 920.3 fitted on stem 200 serves as a travel stop in closing direction. It prevents jamming of the wedge assembly in the seat and is secured by parallel pin

562.3.

Fig.2: Parallel discs

Unlike wedge gate valve designs, slide gate valves feature two parallel discs 368, which are flexibly mounted in disc holder 367. The discs are supported by replaceable disc springs 950.1 via parallel pins 562.1, which press them against seat rings 515.

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4.3.3 Gate Valves to DIN/EN with Bolted Bonnet

4.3.3.1 STAAL 40 AKD/AKDS

4.3.3.1.1 Operating data

Table5: Operating properties

Characteristic Value

Nominal pressure PN 10 - 40 Nominal size DN 50 - 600 Max. permissible pressure [bar] 40 Min. permissible temperature [°C] ≥-10 Max. permissible temperature [°C] ≤+450

Selection as per pressure/temperature ratings (ðSection4.3.3.1.4,Page17)

4.3.3.1.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.3.3.1.3 Design details

Design

▪ Body of forged or welded steel construction ▪ Bolted bonnet ▪ Non-rotating stem with external screw ▪ Split wedge ▪ Standard position indicator ≤ DN200 ▪ Yoke head suitable for mounting electric actuators (DINISO5210) ▪ The valves satisfy the safety requirements of AnnexI of the European Pressure

Equipment Directive2014/68/EU (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 (≥ DN250) ▪ Stem protecting tube with position switch (≥ DN250) ▪ Position switch(es) mounted on yoke (≤DN200) ▪ Bypass ▪ Drain branch ▪ Barrier water connection ▪ Electric actuators

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▪ Actuator installation kit ▪ Seat/disc interface made of wear-resistant and corrosion-proof Stellite ▪ Stem made of 1.4122 ▪ TA-Luft-compliant model (with or without spring loading) for applications to

VDI2440 at temperatures ≤ 250°C and > 250°C (400°C maximum)

▪ Other flange designs or butt weld end designs ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /

Pressure Vessel Regulations – or to customer specification

▪ ≥ DN 700 on request

4.3.3.1.4 Pressure/temperature ratings

Table6: Permissible operating pressure [bar] (to EN 1092-1)

PN Material [°C]

100 150 200 250 300 350 400 450

10 P250GH / P265GH 10,0 9,2 8,8 8,3 7,6 6,9 6,4 5,9 3,2 16 16,0 14,8 14,0 13,3 12,1 11,0 10,2 9,5 5,2 25 25,0 23,2 22,0 20,8 19,0 17,2 16,0 14,8 8,2 40 40,0 37,1 35,2 33,3 30,4 27,6 25,7 23,8 13,1

4) Operating pressures in accordance with DIN 2401 are also permissible.

5) RT: room temperature (-10°C to +50°C)

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4.3.3.1.5 Materials

PN 10 - 40

DN 50 - 200

PN 40

DN 250 - 600

AKD AKDS AKD AKDS

Table7: Parts list

Part No. Description Material Material number Note

100 Body P 250 GH 1.0460 -

P265GH 1.0425 ≥ DN 250

131.1 Connection branch P 235 GH 1.0345 P265GH 1.0425 ≥ DN 500

165 Bonnet P 250GH 1.0460 166 Yoke GP 240 GH+N 1.0619+N -

P265GH 1.0425 ≥ DN 250

200

Stem X 20 Cr 13+QT800 1.4021+QT800 -

323

Thrust bearing Steel - -

360

Wedge discs GP 240 GH+N 1.0619+N -

P265GH 1.0425 ≥ DN 250

367

Disc/wedge holder P 250 GH 1.0460 -

P265GH 1.0425 ≥ DN 250

Seat/disc interface

Body X20CrMo171 1.4115 17% chrome steel Wedge discs X8CrTi18 1.4502

411

Joint ring CrNi steel/graphite - 452 Gland follower P250GH/P265GH 1.0460 / 1.0425 461

Gland packing Pure graphite - 544

Threaded bush 46S20+C 1.0727+C DN 50-200, nitrocarburised

11SMn30+C 1.0715+C ≥ DN 250, nitrided 579 Stop S235JR - 723 Flange P 250 GH 1.0460 902 Stud 25CrMo4 1.7218 920 Hexagon nut C35E 1.1181 961 Handwheel EN-GJL-250 5.1301 DN 50-200

Steel - ≥ DN 250

6) Recommended spare parts

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4.3.3.2 STAAL 100 AKD/AKDS

4.3.3.2.1 Operating data

Table8: Operating properties

Characteristic Value

Nominal pressure PN 63 - 100 Nominal size DN 50 - 500 Max. permissible pressure [bar] 100 Min. permissible temperature [°C] ≥-10 Max. permissible temperature [°C] ≤+530

Selection as per pressure/temperature ratings (ðSection4.3.3.2.4,Page20)

4.3.3.2.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.3.3.2.3 Design details

Design

▪ Body of forged or welded steel construction ▪ Bolted bonnet ▪ Non-rotating stem with external screw ▪ Split 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 2014/68/EU(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.

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Variants

▪ Stem protecting tube ▪ Stem protecting tube with position indicator ▪ Limit switch(es) ▪ Bypass ▪ Drain branch ▪ Hard-faced back seat ▪ Threaded bush free from non-ferrous metals ▪ Electric actuators ▪ Pneumatic actuators ▪ Spur gear ▪ Bevel gear ▪ Actuating bush for remote actuation ▪ Other flange designs or butt weld end designs ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /

Pressure Vessel Regulations – or to customer specification

▪ Die-forged model for DN300/250 on request. ▪ DN 500 and above on request

4.3.3.2.4 Pressure/temperature ratings

Table9: Permissible operating pressure [bar] (to EN 1092-1)

PN Material [°C]

Designation Number RT8)100 150 200 250 300 350 400 450 460 470 480 490 500 510 520 530

63 P250GH 1.0460 63,0 58,5 55,5 52,5 48,0 43,5 40,5 37,5 20,7 - - - - - - - -

P265GH 1.0425 63,0 58,5 55,5 52,5 48,0 43,5 40,5 37,5 20,7 - - - - - - - 16Mo3 1.5415 63,0 63,0 63,0 63,0 61,5 54,0 51,0 47,1 43,5 40,3 37,2 34,1 31,0 27,9 - - 13CrMo4-5 1.7335 63,0 63,0 63,0 63,0 63,0 63,0 60,0 56,7 53,1 50,5 47,9 45,4 42,8 41,1 34,8 28,2 23,4

100 P250GH 1.0460 100,0 92,8 88,0 83,3 76,1 69,0 64,2 59,5 32,8 - - - - - - - -

P265GH 1.0425 100,0 92,8 88,0 83,3 76,1 69,0 64,2 59,5 32,8 - - - - - - - 16Mo3 1.5415 100,0 100,0 100,0 100,0 100,0 97,6 80,9 74,7 69,0 64,0 59,1 54,2 49,2 44,2 - - 13CrMo4-5 1.7335 100,0 100,0 100,0 100,0 100,0 100,0 95,2 90,0 84,2 80,2 76,1 72,0 68,0 65,2 55,2 44,7 37,1

7) Operating pressures in accordance with DIN 2401 are also permissible.

8) RT: room temperature (-10°C to +50°C)

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4.3.3.2.5 Materials

DN 50/50-250/250 DN 300/300-500/500

AKD AKD

AKDS AKDS

Table10: Parts list DN 50/50-250/250

Part No. Description Temperature

[°C]

Material Material number Note

100 Body ≤ 450 P 250 GH 1.0460 Body die-forged and

welded

≤ 530 13CrMo4-5 1.7335

723 Flange ≤ 450 P 250 GH 1.0460 -

≤ 530 13CrMo4-5 1.7335

131.1 Connection

branch

≤ 450 P 250 GH 1.0460 Material can be matched to

pipeline material

≤ 530 13CrMo4-5 1.7335

360

Wedge discs ≤ 450 P 250 GH 1.0460 -

≤ 530 13CrMo4-5 1.7335

367

Disc/wedge holder ≤ 450 P 250 GH 1.0460 -

≤ 530 13CrMo4-5 1.7335

166 Yoke ≤ 450 P 250 GH 1.0460 -

9) Recommended spare parts

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Part No. Description Temperature

[°C]

Material Material number Note

166 Yoke ≤ 530 13CrMo4-5 1.7335 Seat/disc

interface

Body ≤ 450 X20CrMo17-1 1.4115 Hard-faced Wedge discs ≤ 530 Stellite

200

Stem ≤ 530 X39CrMo17-1 1.4122 -

411

Joint ring 1.4541/graphite - Serrated gasket 452 Gland follower P250GH 1.0460 457

Neck ring G-X70CrMo292 1.4136 -

461.1/.2

Gland packing Graphite - Compression-moulded

rings (confined)

544

Threaded bush CuZn35Ni2 2.0540 On axial needle bearing

902.1 Stud 21CrMoV5-7 1.7709 -

920.1 Hexagon nut 25CrMo4 1.7218 961 Handwheel GG-25 0.6025 Non-rising

Table11: Parts list DN 300/300-500/500

Part No. Description Temperature

[°C]

Material Material number Note

100 Body ≤ 450 P265GH 1.0425 Body of welded steel

construction

≤ 500 16Mo3 1.5415 ≤ 530 13CrMo4-5 1.7335

723 Flange ≤ 450 P 250 GH/P 265GH1.0460/1.0425 -

≤ 500 16Mo3 1.5415 ≤ 530 13CrMo4-5 1.7335 -

131.1 Connection

branch

≤ 450 ≤ 500 ≤ 530

P265GH 16Mo3 13CrMo4-5

1.0425

1.5415

1.7335

Material can be matched to pipeline material

360

Wedge discs 367

Disc/wedge holder 166 Yoke Seat/disc

interface

Body ≤ 450 X20CrMo17-1 1.4115 Hard-faced

≤ 530 Stellite -

Wedge discs ≤ 450 X8CrTi18 1.4502

≤ 530 Stellite -

200

Stem ≤ 530 X39CrMo17-1 1.4122 411

Joint ring ≤ 530 1.4541/graphite - Serrated gasket 452 Gland follower P 250 GH/P 265GH1.0460/1.0425 -

461

Gland packing Graphite - Compression-moulded

rings (confined)

544

Threaded bush CuZn35Ni2 2.0540 On axial bearing 900 Screw ≤ 450 25CrMo4 1.7218 -

≤ 530 21CrMoV5-7 1.7709 -

920 Hexagon nut ≤ 450 25CrMo4 1.7218 -

≤ 530 25CrMo4 1.7218 -

961 Handwheel ≤ 530 Steel - Non-rising

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4.3.4 Gate Valves to DIN/EN in Pressure Seal Design

4.3.4.1 AKG-A/AKGS-A

4.3.4.1.1 Operating data

Table12: Operating properties

Characteristic Value

Nominal pressure PN 63 - 160 Nominal size DN 80/80-300/250 Max. permissible pressure [bar] 160 Min. permissible temperature [°C] ≥-10 Max. permissible temperature [°C] ≤+550

Selection as per pressure/temperature ratings (ðSection4.3.4.1.4,Page24)

4.3.4.1.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.3.4.1.3 Design details

Design

▪ Pressure seal design ▪ Non-rotating stem ▪ Split 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 2014/68/EU(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.

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Variants

▪ Body made of forged steel ▪ Position indicator ▪ Limit switch(es) ▪ Drain branch ▪ Hard-faced back seat ▪ Disc spring supported yoke head ▪ Parallel discs ▪ Bypass ▪ Spur gear ▪ Bevel gear ▪ Electric actuators ▪ Pneumatic actuators ▪ Actuating bush for remote actuation ▪ Other flange designs ▪ Other butt weld end versions ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /

Pressure Vessel Regulations – or to customer specification

4.3.4.1.4 Pressure/temperature ratings

Flanged ends, type AKG-A

Table13: Permissible operating pressures [bar]

10)

(to EN 1092-1)

11)

Material [°C]

Designation Number RT

12)

100 150 200 250 300 350 400 450 460 470 480 490 500 510 520 530 540 550

P250GH 1.0460 63,0 58,5 55,5 52,5 48,0 43,5 40,5 37,5 20,7 - - - - - - - - - 13CrMo4-5 1.7335 63,0 63,0 63,0 63,0 63,0 63,0 60,0 56,7 53,1 50,5 47,9 45,4 42,8 41,1 34,8 28,2 23,4 18,3 14,7

100

P250GH 1.0460 100,0 92,8 88,0 83,3 76,1 69,0 64,2 59,5 32,8 - - - - - - - - - 13CrMo4-5 1.7335 100,0 100,0 100,0 100,0 100,0 100,0 95,2 90,0 84,2 80,2 76,1 72,0 68,0 65,2 55,2 44,7 37,1 29,0 23,3

160

P250GH 1.0460 160,0 148,5 140,9 133,3 121,9 110,4 102,8 95,2 52,5 - - - - - - - - - 13CrMo4-5 1.7335 160,0 160,0 160,0 160,0 160,0 160,0 152,3 144,0 134,8 128,3 121,8 115,3 108,8 104,3 88,3 71,6 59,4 46,4 37,3

Butt weld ends, unmachined, type AKGS-A

Table14: Permissible operating pressures [bar]

10)

Material [°C]

Designation Number Up to

120

200 250 300 350 400 425 450 475 500 510 520 530 540 550

160

P250GH 1.0460 160 160 140 120 100 80 72 60 - - - - - - 13CrMo4-5 1.7335 160 160 160 160 160 150 147 145 140 118 100 80 67 52 42

10) The valves are suitable for temperatures down to -10 °C.

11) Operating pressures in accordance with DIN2401 are also permissible.

12) RT: room temperature (-10°C to +50°C)

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4.3.4.1.5 Materials

AKG-A AKGS-A

Table15: Parts list DN 50/50-250/200

Part No. Description Temperature

[°C]

Material Material number Note

100 Body ≤ 450 P 250 GH 1.0460 Body die-forged and welded

≤ 550 13CrMo4-5 1.7335

723 Flange ≤ 450 P 250 GH 1.0460 -

≤ 550 13CrMo4-5 1.7335 -

131.1 Connection branch ≤ 450 P 250 GH 1.0460 Material can be matched to

pipeline material

≤ 550 13CrMo4-5 1.7335

139 Bonnet ≤ 450 P 250 GH 1.0460 -

≤ 550 13CrMo4-5 1.7335

360

13)

Wedge discs ≤ 450 P 250 GH 1.0460 -

≤ 550 13CrMo4-5 1.7335

367

13)

Disc/wedge holder ≤ 450 P 250 GH 1.0460 -

≤ 550 13CrMo4-5 1.7335

162 Yoke bonnet ≤ 550 C22N 1.0402 Welded design

131.2 Connection branch 13CrMo4-5 1.7335 Seat/disc

interface

Body ≤ 450 Hard-faced 1.4115 Hard-faced Wedge discs ≤ 550 Stellite hard-

faced

200

13)

Stem ≤ 550 X39CrMo17-1 1.4122 -

411.1

13)

Joint ring Pure graphite - 452 Gland follower 13CrMo4-5 1.7335 461

13)

Gland packing Pure graphite - With packing end rings 501 Segmental ring 13CrMo4-5 1.7335 544

13)

Threaded bush CuZn35Ni2 2.0540 On cylindrical roller bearings 961

13)

Handwheel EN-GJL-250 5.1301 ≥DN150 made of steel

(welded)

13) Recommended spare parts

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4.3.4.2 ZTS

4.3.4.2.1 Operating data

Table16: Operating properties

Characteristic Value

Design pressure [bar] ~ 600 Nominal size DN 50 - 800 Max. permissible pressure [bar] ~ 600 Min. permissible temperature [°C] ≥-10 Max. permissible temperature [°C] ≤+650

Selection as per pressure/temperature ratings (ðSection4.3.4.2.4,Page27)

4.3.4.2.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.3.4.2.3 Design details

Design

▪ Body made of forged steel ▪ Pressure seal design ▪ Non-rotating stem ▪ Split wedge ▪ Yoke head suitable for mounting electric and pneumatic actuators (DINISO5210) ▪ Seat/disc interface made of wear-resistant and corrosion-proof Stellite ▪ The valves satisfy the safety requirements of Annex I of the European Pressure

Equipment Directive 2014/68/EU(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.

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Variants

▪ Flanged ends ▪ Bypass ▪ Drain branch ▪ Parallel discs (type GTS) ▪ Pressure relief connections (3-branch system) ▪ Balancing hole in seat ring ▪ Hard-faced back seat ▪ Lantern ring in gland packing ▪ Disc spring supported threaded bush ▪ Packing combination for high-temperature applications ▪ Pressure seal joint ring capped with stainless steel ▪ Position indicator ▪ Limit switch(es) ▪ Spur gear ▪ Bevel gear ▪ Electric actuators ▪ Pneumatic actuators ▪ Actuating bush for remote actuation ▪ Threaded bush free from non-ferrous metals ▪ Locking device ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /

Pressure Vessel Regulations – or to customer specification

4.3.4.2.4 Pressure/temperature ratings

Subseries B

14)

Table17: Permissible operating pressure [bar]

15)

Material Subseries

16)

[°C]

20 300 350 400 425 450 475 500 510 520 530 540 550 560 570 580 590 600

16Mo3

1.5415

B 100 86 81 75 72 69 57 44 - - - - - - - - - -

13CrMo4-5

1.7335

B 100 100 95 90 87 84 74 65 55 45 37 - - - - - - -

10CrMo9-10

1.7380/ 11CrMo9-10

1.7383

B 100 100 98 93 90 88 76 64 56 49 43 37 32 - - - - -

X10CrMoVNb9-1

1.4903

B 100 100 100 100 100 100 100 100 100 100 96 87 79 71 64 57 50 45

Subseries C, D, E and F

Table18: Permissible operating pressure [bar]

15)17)

Material Subseries

16)

[°C]

100

150

200

250

300

350

400

425

450

475

500

510

520

530

540

550

560

570

580

590

600

610

620

630

640

650

P250GH

1.0460

C 212 202 181 161 141 126 105 85 76 66 - - - - - - - - - - - - - - - - D 323 308 277 246 215 192 161 130 115 100 - - - - - - - - - - - - - - - - E 426 407 366 325 284 254 213 172 152 132 - - - - - - - - - - - - - - - - -

14) DN 350-800

15) The valves are suitable for temperatures down to -10 °C.

16) The subseries determines the maximum operating pressure per temperature. The gate valve is designed and marked for the actual design data specified in the purchase order.

17) The test pressure is defined in accordance with the provisions of the technical codes PED2014/68/EC; DINEN12516-2 and EN12266-1.

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Material Subseries

16)

[°C]

100

150

200

250

300

350

400

425

450

475

500

510

520

530

540

550

560

570

580

590

600

610

620

630

640

650

P250GH

1.0460

F 521 496 446 397 347 310 260 210 186 160 - - - - - - - - - - - - - - - - -

15NiCuMoNb5

1.6368

C 367 367 367 367 367 356 341 327 314 242 - - - - - - - - - - - - - - - - CS

18)

445 445 445 445 445 430 415 400 380 300 - - - - - - - - - - - - - - - - -

19)

558 558 558 558 558 539 518 498 476 374 - - - - - - - - - - - - - - - - -

E 738 738 738 738 738 711 685 658 629 495 - - - - - - - - - - - - - - - - -

16Mo3

1.5415

C 268 237 214 192 177 151 147 141 140 136 134 94 66 52 42 - - - - - - - - - - - D 408 361 326 292 269 231 223 215 211 207 205 143 100 79 63 - - - - - - - - - - - E 539 478 432 386 356 304 294 284 279 275 269 189 132 104 83 - - - - - - - - - - - F 657 583 527 471 434 372 359 347 341 335 329 231 162 128 102 - - - - - - - - - - - -

13CrMo4-5

1.7335

C 268 243 228 213 202 187 177 167 162 157 155 138 118 95 79 61 49 - - - - - - - - - D 408 369 346 323 308 284 269 254 246 238 235 211 178 145 119 93 75 - - - - - - - - - E 539 488 457 427 407 376 355 335 325 315 310 277 236 191 158 124 100 - - - - - - - - - F 657 596 558 521 496 459 434 409 397 385 378 341 288 233 193 151 121 - - - - - - - - - -

10CrMo9-10

1.7380/ 11CrMo9-10

1.7383

C 268 248 232 217 213 202 187 177 173 167 162 136 119 104 91 79 69 58 51 - - - - - - - D 408 377 354 331 323 308 284 269 262 254 246 207 181 158 138 119 104 89 78 - - - - - - - E 539 498 467 437 427 407 376 355 345 335 325 275 239 210 183 158 138 117 103 - - - - - - - F 657 608 570 533 521 496 459 434 422 409 397 335 292 255 223 193 168 144 126 - - - - - - - -

X10CrMoVNb9-1

1.4903

C - - - - - - - - - - - - - 245 225 204 185 166 148 131 116 102 89 78 67 59 50 D - - - - - - - - - - - - - 324 296 270 244 214 195 174 154 135 117 103 87 77 67 E - - - - - - - - - - - - - 470 429 391 353 316 283 251 221 197 170 148 126 112 96 F - - - - - - - - - - - - - 514 472 428 387 347 311 275 244 215 186 162 139 122 105

X10CrWMoVNb9-2

1.4901

C - - - - - - - - - - - - - - - - - - - 134 120 107 94 82 71 61 53 D - - - - - - - - - - - - - - - - - - - 201 180 160 142 123 106 92 79 E - - - - - - - - - - - - - - - - - - - 262 234 208 184 160 138 120 103 F - - - - - - - - - - - - - - - - - - - 314 281 250 221 192 166 144 124

4.3.4.2.5 Materials

DN 50/50 - 200/175 DN 200/200 - 500/450

with connection branch extensions without connection branch

extensions

18) Weights, dimensions and differential pressures on request.

19) Special CD subseries version on request. Depending on the nominal size, permissible operating pressures up to the subseriesD pressure/temperature ratings are possible (subject to differential pressure limitations compared to subseriesD, however).

20) Recommended spare parts

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Table19: Parts list

Part No. Description Materials for operating temperatures [°C] up to

450 530 550 570 600 650

101 Lower body section P250 GH

1.0460

15NiCuMoNb5

1.6368

16Mo3

1.5415

13CrMo4-5

1.7335

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb9-1

1.4903

X10CrWMoVNb 9-2

1.4901

102 Upper body section 108 Main body

131.1 Connection branch 139 Bonnet 10CrMo9-10

1.7380/

11CrMo9-10

1.7383

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

501

20)

Segmental ring

360

20)

Wedge discs hard-faced with Stellite6

368

20)

Parallel discs hard-faced with Stellite6

515 Seat ring

hard-faced with Stellite6

13CrMo4-5

1.7335

13CrMo4-5

1.7335

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

131.2 Connection branch 13CrMo4-5

1.7335

11CrMo9-10

1.7383

X10CrMoVNb9-1

1.4903

166 Yoke 13CrMo4-5

1.7335

11CrMo9-10

1.7383

X10CrMoVNb9-1

1.4903

200

20)

Stem X39CrMo17-1

1.4122

X22CrMoV11-1

1.4923

X22CrMoV11-1

1.4923

X5NiCrTi2615

1.4980

367

20)

Disc/wedge holder 13CrMo4-5

1.7335

15NiCuMoNb5

1.6368

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb9-1

1.4903

411.1

20)

Joint ring Pure graphite, capped with stainless steel

452 Gland follower 13CrMo4-5

1.7335

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

461

20)

Gland packing Pure graphite/stainless steel capped packing end rings

544

20)

Threaded bush Copper base alloys

961 Handwheel Steel

4.4 Body Pressure Relief Valve

4.4.1 UGS

4.4.1.1 Operating data

Table20: Operating properties

Characteristic Value

Nominal pressure ≥ PN 40 Nominal size DN 15 Max. permissible pressure 25 - 750bar

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4.4.1.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.4.1.3 Design details

Design

▪ Body made of forged steel ▪ Stainless steel valve disc (UGS and UGSV) ▪ Adjustable, needle bearing supported spring assembly (UGS and UGSV) ▪ Blow-off pressure is set via screw-type body ▪ Stellited seat ▪ Lead-sealed screw prevents unauthorised manipulation of set blow-off pressure ▪ The valves satisfy the safety requirements of Annex I of the European Pressure

Equipment Directive 2014/68/EU(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

▪ Bursting disc (UGSV and UGSVA) ▪ Blocking device ▪ With lockable shut-off valve

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4.4.1.4 Materials

UGS: without bursting disc, spring-loaded

UGSV: with bursting disc, spring-loaded

UGSVA: with bursting disc, without spring loading

To be used in combination with

lockable globe valve only .

1) Lead-sealed 2) Paint dot

3) Name plate for bursting disc

Table21: Parts list

Part No. Description Material Material number Note

32-2 Axial needle bearing Steel - 160 Cover P250GH 1.0460 350 Valve disc X39CrMo17-1 1.4122 500 Ring X6CrNiTi18-10 1.4541 520 Sleeve 13CrMo4-5 1.7335 Stellited

550.1 Disc X20Cr13 1.4021 -

550.2 Bursting disc 316 SS - 574 Rod X39CrMo17-1 1.4122 731 Pipe union P250GH 1.0460 Stellited

13CrMo4-5 1.7335 10CrMo9-10/

11CrMo9-10

1.7380

1.7383

X10CrMoVNb9-1 1.4903 734 Screw-type body 9 SMn28 k - 900 Screw 5.8 - 901 Hexagon head bolt 8.8 - -

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Part No. Description Material Material number Note

920 Hexagon nut 8 - 950 Disc spring Inconel 718 - -

4.4.1.5 Heating up of trapped liquids

The heating up of trapped liquids primarily occurs inside gate valves. If liquid remains in the body after pressure testing, for instance, or if condensate

develops due to certain operating conditions, there is a risk of an impermissible pressure increase if the body is heated up by hot water or steam in one or both the connected pipes. The potential pressure increase depends both on the temperature and the extent to which the body is filled with liquid and may reach impermissible values very quickly.

The problem of trapped liquids heating up inside the valve is particularly dangerous on gate valves with a pressure seal bonnet as the bonnet seal becomes tighter with rising pressure. The pressure may reach several times the operating pressure.

On gate valves with a bolted bonnet, an impermissible increase in pressure will be relieved through leaks developing at the bonnet gasket.

Gate valves with a pressure seal bonnet, by contrast, must be fitted with body pressure relief valves if excessive heating of trapped liquids is potentially a problem. The body pressure relief valve ensures that the body is protected against excessive loads and deformation under all operating conditions, thus avoiding incidents which may compromise safety.

The likelihood of trapped liquid heating up varies depending on the system and must be individually assessed for each gate valve by the purchaser. It is therefore necessary to order the body pressure relief valve and the gate valve separately.

4.4.1.6 Function

Body pressure relief valves are available in three different designs:

▪ Spring-loaded body pressure relief valve (UGS) ▪ Spring-loaded body pressure relief valve with bursting disc (UGSV) ▪ Non-spring-loaded designs with bursting disc in combination with a lockable

globe valve (UGSVA).

Spring-loaded body

pressure relief valve (UGS)

Stainless steel valve disc 350 is pressed onto the stellited seat of pipe union 731 by means of adjustable spring assembly 950 via disc 550.1 and rod 574, ensuring tight closure.

The required pre-loading of disc springs 950 is adjusted via screw-type body 734, supported by needle bearing 32-2. Screw-type body 734 is locked in position by means of screw 900.

The blow-off pressure is always set at the supplying factory and stamped on the body pressure relief valve. It is determined by the respective valve type, the operating data and the max. permissible body load.

Every body pressure relief valve is tested and lead-sealed. Removal of the lead seal will result in forfeiture of any warranty claims.

Setting and testing are performed on the basis of work instructions or parts list specifications using special testing equipment. Re-setting can only be performed at the supplying factory.

Spring-loaded body

pressure relief valve with

bursting disc (UGSV)

The body pressure relief valve with pre-fitted bursting disc basically consists of two assemblies:

▪ Bursting disc with fastening elements ▪ Downstream spring-loaded body pressure relief valve

Bursting disc 550.2 is clamped between pipe union 731 and sleeve 520 and sealed by means of intermediate ring 500.

It is combined with the downstream spring-loaded body pressure relief valve described above.

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If bursting disc 550.2 bursts as a result of excessive pressure inside the gate valve, the space between bursting disc 550.2 and the body pressure relief valve's seat is also subjected to this excessive pressure. This causes valve disc 350 to lift off its seat and the body pressure relief valve to blow off.

Excess pressure is relieved and the body is thus protected against excessive loads. After blowing off, the body pressure relief valve closes again.

Despite the damaged bursting disc, operation of the gate valve with the body pressure relief valve can be continued until the next maintenance inspection is due. The bursting disc must then be renewed.

A paint dot at the point where the rod (574) passes through the screw-type body (734) serves as a visual indicator. It indicates that the body pressure relief valve has tripped and the bursting disc must have burst. When the body pressure relief valve trips, this paint dot will burst open.

The paint dot must therefore be checked at regular intervals. The paint dot does not affect the body pressure relief valve's functioning.

NOTE

Rupture of the bursting disc always indicates an impermissible pressure increase. Before replacing the bursting disc, investigate the cause of this malfunction to rule out any negative effects on the proper functioning of the valve.

Non-spring-loaded design

with bursting disc (UGSVA)

WARNING

Fluid escaping following rupture of bursting disc

Burns/scalding and damage/hazard to the environment!

▷ Take appropriate measures, e.g. fence off area.

Under normal operating conditions, the globe valve is locked in the open position. If the globe valve is closed, the pressure relief function is not available.

The globe valve must be capable of reducing the amount of fluid escaping after the bursting has ruptured, e.g. while the system is being shut down.

4.5 Swing check valves

4.5.1 Function of swing check valves with bolted cover

Swing check valves consist of forged body 100 with hard-faced seating faces. Fluid flow is shut off by hard-faced valve disc 746, which is flexibly mounted on hanger arm 570. This connection is secured with a nut and a locking pin.

Body 100 is joined to cover 161 by studs 902.1 and sealed to atmosphere by joint ring

411.1. The disc assembly is pivot-mounted on hinge 230 welded to cover 161 or on hinge pin 210 mounted in the body.

4.5.2 Function of swing check valves with pressure seal cover

The swing check valve is equipped with a pressure seal cover. The pressure inside body 100 presses bonnet 139 against joint ring 411.1; the latter is supported by segmental ring 501, which rests in a groove inside the body, via compression ring

500. Studs 902.2 and hexagon nuts 920.6, which are supported by cover 161, ensure that bonnet 139 is held in place against joint ring 411.1, even if there is no pressure inside body 100.

Hinge pin 210 held by bearing bushes 545 acts as a pivotal point for hanger arm 570 with valve disc 746. Together with plate 198, the hanger arm forms a complete assembly that is inserted into body 100 and clamped and locked in place in a circumferential groove inside the body by locking plates 196.

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4.5.3 Swing Check Valves with Bolted Cover

4.5.3.1 STAAL 40 AKK/AKKS

4.5.3.1.1 Operating data

Table22: Operating properties

Characteristic Value

Nominal pressure PN 10 - 40 Nominal size DN 80 - 400 Max. permissible pressure [bar] 40 Min. permissible temperature [°C] ≥-10 Max. permissible temperature [°C] ≤+450

Selection as per pressure/temperature ratings (ðSection4.5.3.1.4,Page35)

4.5.3.1.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.5.3.1.3 Design details

Design

▪ Body of forged or welded steel construction ▪ Bolted cover ▪ Internally mounted hinge pin ▪ The valves satisfy the safety requirements of Annex I of the European Pressure

Equipment Directive 2014/68/EU(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

▪ Extended hinge pin from DN 250 (for lever and weight operation) ▪ Other flange designs ▪ Other butt weld end versions ▪ Drain branch ▪ Seat/disc interface made of wear-resistant and corrosion-proof Stellite ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /

Pressure Vessel Regulations – or to customer specification

▪ DN 500 and above on request

21) Operating pressures in accordance with DIN2401 are also permissible.

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4.5.3.1.4 Pressure/temperature ratings

Table23: Permissible operating pressure [bar] (to EN 1092-1)

21)

PN Material [°C]

22)

100 150 200 250 300 350 400 450

10 P235GH / P265GH 10,0 9,2 8,8 8,3 7,6 6,9 6,4 5,9 3,2 16 16,0 14,8 14,0 13,3 12,1 11,0 10,2 9,5 5,2 25 25,0 23,2 22,0 20,8 19,0 17,2 16,0 14,8 8,2 40 40,0 37,1 35,2 33,3 30,4 27,6 25,7 23,8 13,1

4.5.3.1.5 Materials

AKK AKKS

Table24: Parts list

Part No. Description Material Material number Note

100 Body P 235 GH 1.0345 -

P265GH 1.0425 -

131.1 Connection branch P 235 GH 1.0305 161 Body cover P265GH 1.0425 210

23)

Hinge pin X 20 Cr 13 1.4021 -

Seat/disc interface

Body X20CrMo171 1.4115 17% chrome steel Valve disc X8CrTi18 1.4502

411

23)

Joint ring Pure graphite - -

570

23)

Hanger arm P265GH 1.0425 723 Flange P 250 GH 1.0460 746

23)

Valve disc P265GH 1.0425 900 Screw 25CrMo4 1.7218 920 Hexagon nut C35E 1.1181 -

22) RT: room temperature (-10 °C to +50 °C)

23) Recommended spare parts

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4.5.3.2 STAAL 100 AKK/AKKS

4.5.3.2.1 Operating data

Table25: Operating properties

Characteristic Value

Nominal pressure PN 63 - 100 Nominal size DN 80 - 400 Max. permissible pressure [bar] 100 Min. permissible temperature [°C] ≥-10 Max. permissible temperature [°C] ≤+530

Selection as per pressure/temperature ratings (ðSection4.5.3.2.4,Page37)

4.5.3.2.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.5.3.2.3 Design details

Design

▪ Body of forged or welded steel construction ▪ Bolted cover ▪ Internally mounted hinge pin ▪ The valves satisfy the safety requirements of Annex I of the European Pressure

Equipment Directive 2014/68/EU(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

▪ Extended hinge pin from DN 250 (for lever and weight operation) ▪ Other flange designs ▪ Other butt weld end versions ▪ Drain branch ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /

Pressure Vessel Regulations – or to customer specification

▪ DN 50 and DN 65 on request ▪ DN 400 and above on request.

25) RT: room temperature (-10°C to +50°C)

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4.5.3.2.4 Pressure/temperature ratings

Table26: Permissible operating pressure [bar] (to EN1092-1)

25)

Material [°C]

Designation Number RT

25)

100 150 200 250 300 350 400 450 460 470 480 490 500 510 520 530

P250GH 1.0460 63,0 58,5 55,5 52,5 48,0 43,5 40,5 37,5 20,7 - - - - - - - P265GH 1.0425 63,0 58,5 55,5 52,5 48,0 43,5 40,5 37,5 20,7 - - - - - - - 16Mo3 1.5415 63,0 63,0 63,0 63,0 61,5 54,0 51,0 47,1 43,5 40,3 37,2 34,1 31,0 27,9 - - 13CrMo4-5 1.7335 63,0 63,0 63,0 63,0 63,0 63,0 60,0 56,7 53,1 50,5 47,9 45,4 42,8 41,1 34,8 28,2 23,4

100

P250GH 1.0460 100,0 92,8 88,0 83,3 76,1 69,0 64,2 59,5 32,8 - - - - - - - P265GH 1.0425 100,0 92,8 88,0 83,3 76,1 69,0 64,2 59,5 32,8 - - - - - - - 16Mo3 1.5415 100,0 100,0 100,0 100,0 100,0 97,6 80,9 74,7 69,0 64,0 59,1 54,2 49,2 44,2 - - 13CrMo4-5 1.7335 100,0 100,0 100,0 100,0 100,0 100,0 95,2 90,0 84,2 80,2 76,1 72,0 68,0 65,2 55,2 44,7 37,1

4.5.3.2.5 Materials

DN 80/80-250/250 DN 300/300-400/400

AKK AKK

AKKS AKKS

Table27: Parts list DN 80/80-250/250

Part No. Description Temperature

[°C]

Material Material number Note

100 Body ≤ 450 P 250 GH 1.0460 Body die-forged and welded

≤ 530 13CrMo4-5 1.7335

723 Flange ≤ 450 P 250 GH 1.0460 -

≤ 530 13CrMo4-5 1.7335

131.1 Connection branch ≤ 450 P 250 GH 1.0460 Material can be matched to

pipeline material.

≤ 530 13CrMo4-5 1.7335

161 Body cover ≤ 450 P 250 GH 1.0460 -

≤ 530 13CrMo4-5 1.7335

746

26)

Valve disc ≤ 450 P 250 GH 1.0460 -

≤ 530 13CrMo4-5 1.7335

Seat/disc interface

Body ≤ 450 X20CrMo17-1 1.4115 Hard-faced

24) Operating pressures in accordance with DIN2401 are also permissible.

26) Recommended spare parts

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Part No. Description Temperature

[°C]

Material Material number Note

Seat/disc interface

Body ≤ 530 Stellite - Hard-faced Valve disc ≤ 530 X15CrNiMn18-81.4370

411

26)

Joint ring ≤ 530 1.4541/graphite - Serrated gasket

570

26)

Hanger arm 13CrMo4-5 1.7335 -

210 Hinge pin X39CrMo17-1 1.4122 -

902.1 Stud 21CrMoV5-7 1.7709 -

920.1 Hexagon nut 25CrMo4 1.7218 -

Table28: Parts list DN 300/300-400/400

Part No. Description Temperature

[°C]

Material Material number Note

100 Body ≤ 450 P265GH 1.0425 Body of welded steel

construction

≤ 500 16Mo3 1.5415 ≤ 530 13CrMo4-5 1.7335

723 Flange ≤ 450 P 250 GH/P 265GH1.0460/1.0425 -

≤ 500 16Mo3 1.5415 ≤ 530 13CrMo4-5 1.7335 -

131.1 Connection branch ≤ 450 P265GH 1.0425 Material can be matched to

pipeline material. ≤ 500 16Mo3 1.5415 ≤ 530 13CrMo4-5 1.7335 -

161 Body cover ≤ 450 P265GH 1.0425 -

≤ 500 16Mo3 1.5415 ≤ 530 13CrMo4-5 1.7335 -

746

27)

Valve disc ≤ 450 P 250 GH/P 265GH1.0460/1.0425 -

≤ 500 16Mo3 1.5415 ≤ 530 13CrMo4-5 1.7335 -

Seat/disc interface

Body ≤ 450 X20CrMo17-1 1.4115 Hard-faced

≤ 530 Stellite -

Valve disc ≤ 450 X8CrTi18 1.4502

≤ 530 Stellite -

411

27)

Joint ring ≤ 530 1.4541/graphite - Serrated gasket

570

27)

Hanger arm ≤ 450 P 250 GH/P 265GH1.0460/1.0425 -

≤ 530 16Mo3 1.5415 ≤ 530 13CrMo4-5 1.7335 -

210

27)

Hinge pin ≤ 450 X20Cr13 1.4021 -

≤ 530 X39CrMo17-1 1.4122 -

900 Screw ≤ 450 25CrMo4 1.7218 -

≤ 530 21CrMoV5-7 1.7709 -

920 Hexagon nut ≤ 450 25CrMo4 1.7218 -

≤ 530 25CrMo4 1.7218 -

27) Recommended spare parts

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4.5.4 Swing check valves with pressure seal cover

4.5.4.1 AKR/AKRS

4.5.4.1.1 Operating data

Table29: Operating properties

Characteristic Value

Nominal pressure PN 63 - 160 Nominal size DN 80/80-300/250 Max. permissible pressure [bar] 160 Min. permissible temperature [°C] ≥-10 Max. permissible temperature [°C] ≤+550

Selection as per pressure/temperature ratings (ðSection4.5.4.1.4,Page40)

4.5.4.1.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.5.4.1.3 Design details

Design

▪ Body of forged or welded steel construction ▪ Pressure seal design ▪ Internally mounted hinge pin ▪ The valves satisfy the safety requirements of Annex I of the European Pressure

Equipment Directive 2014/68/EU(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

▪ Other flange designs ▪ Other butt weld end versions ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /

Pressure Vessel Regulations – or to customer specification

30) RT: room temperature (-10°C to +50°C)

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4.5.4.1.4 Pressure/temperature ratings

Flanged ends, type AKR (to EN1092-1)

29)

Table30: Permissible operating pressures [bar]

30)

Material [°C]

Designation Number RT

30)

100 150 200 250 300 350 400 450 460 470 480 490 500 510 520 530 540 550

100

160

Butt weld ends, machined, type AKRS

28)

Table31: Permissible operating pressures [bar]

29)

PN Material [°C]

Designation Number Up to

120

200 250 300 350 400 425 450 475 500 510 520 530 540 550

63/160 P250GH 1.0460 160 160 140 120 100 80 72 60 - - - - - - -

13CrMo4-5 1.7335 160 160 160 160 160 150 147 145 140 118 100 80 67 52 42

4.5.4.1.5 Materials

AKR AKRS

Table32: Parts list

Part No. Description Temperature

[°C]

Material Material number Note

100 Body ≤ 450°C P 250GH 1.0460 Body die-forged and welded

≤ 550°C 13CrMo4-5 1.7335

723 Flange ≤ 450°C P 250GH 1.0460 -

≤ 550°C 13CrMo4-5 1.7335

131.1 Connection branch ≤ 450°C P 250GH 1.0460 Material can be matched to pipeline material.

≤ 550°C 13CrMo4-5 1.7335

746

31)

Valve disc ≤ 450°C P 250GH 1.0460 -

≤ 550°C 13CrMo4-5 1.7335

139 Bonnet ≤ 450°C P 250GH 1.0460 -

≤ 550°C 13CrMo4-5 1.7335

Seat/disc interface

Body ≤ 450°C Hard-faced 1.4115 Hard-faced

≤ 550°C Stellite hard-

faced

28) Operating pressures in accordance with DIN2401 are also permissible.

29) The valves are suitable for temperatures down to -10 °C.

31) Recommended spare parts

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Part No. Description Temperature

[°C]

Material Material number Note

Seat/disc interface

Valve disc ≤ 550°C Stainless steel

hard-faced

1.4370 Hard-faced

411

31)

Joint ring ≤ 550°C Pure graphite - 501 Segmental ring 13CrMo4-5 1.7335 570 Hanger arm 13CrMo4-5 1.7335 -

4.5.4.2 ZRS

4.5.4.2.1 Operating data

Table33: Operating properties

Characteristic Value

Design pressure [bar] ~ 600 Nominal size DN 50/50-500/450 Max. permissible pressure [bar] ~ 600 Min. permissible temperature [°C] ≥-10 Max. permissible temperature [°C] ≤+650

Larger nominal sizes on request. Selection as per pressure/temperature ratings (ðSection4.5.4.2.4,Page43)

4.5.4.2.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.5.4.2.3 Design details

Design

▪ Body made of forged steel ▪ Pressure seal design ▪ Internally mounted hinge pin ▪ Seat/disc interface made of wear-resistant and corrosion-proof Stellite ▪ The valves satisfy the safety requirements of Annex I of the European Pressure

Equipment Directive 2014/68/EU(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.

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Variants

▪ Flanged ends ▪ Minimum flow connections ▪ Other butt weld end versions ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /

Pressure Vessel Regulations – or to customer specification

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4.5.4.2.4 Pressure/temperature ratings

Table34: Permissible operating pressure [bar]

32)33)

Material Subseries

34)

[°C]

100

150

200

250

300

350

400

425

450

475

500

510

520

530

540

550

560

570

580

590

600

610

620

630

640

650

P250GH

1.0460

C 212 202 181 161 141 126 105 85 76 66 - - - - - - - - - - - - - - - - D 323 308 277 246 215 192 161 130 115 100 - - - - - - - - - - - - - - - - E 426 407 366 325 284 254 213 172 152 132 - - - - - - - - - - - - - - - - F 521 496 446 397 347 310 260 210 186 160 - - - - - - - - - - - - - - - - -

15NiCuMoNb5

1.6368

C 367 367 367 367 367 356 341 327 314 242 - - - - - - - - - - - - - - - - CS

35)

445 445 445 445 445 430 415 400 380 300 - - - - - - - - - - - - - - - - -

36)

558 558 558 558 558 539 518 498 476 374 - - - - - - - - - - - - - - - - -

E 738 738 738 738 738 711 685 658 629 495 - - - - - - - - - - - - - - - - -

16Mo3

1.5415

13CrMo4-5

1.7335

10CrMo9-10

1.7380/ 11CrMo9-10

1.7383

X10CrMoVNb9-1

1.4903

X10CrWMoVNb9-2

1.4901

32) The valves are suitable for temperatures down to -10 °C.

33) The test pressure is defined in accordance with the provisions of the technical codes PED2014/68/EC; DINEN12516-2 and EN12266-1.

34) The subseries defines the maximum operating pressure possible for the respective temperature. The swing check valve is selected and marked according to the actual design data specified in the order.

35) Weights, dimensions and differential pressures on request.

36) Special design subseries CD on request. Depending on the nominal size, permissible operating pressures up to the maximum pressure and temperature of subseries D are possible (however, with restrictions regarding the differential pressure for subseries D).

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4.5.4.2.5 Materials

DN 50/50 - 200/175 DN 200/200 - 500/450

with connection branch extensions without connection branch

extensions

Table35: Parts list

Part No. Description Materials for operating temperatures [°C] up to

450 530 550 570 600 650

101 Lower body section P 250 GH

1.0460

15NiCuMoNb5

1.6368

16 Mo 3

1.5415

13 CrMo 4-5

1.7335

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb 9-1

1.4903

X10CrWMoVNb 9-2

1.4901

102 Upper body section 108 Main body

131.1 Connection branch 139 Bonnet 10CrMo9-10

1.7380/

11CrMo9-10

1.7383

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

501

37)

Segmental ring

746

37)

Valve disc hard-faced

1.7380 NP 1.6368 H21 1.7380 NP 1.4903 H21

515 Seat ring

hard-faced

13 CrMo 4-5

1.7335 H21

1.6368 H6 13 CrMo 4-5

1.7335 H21

10CrMo9-10

1.7380 H6/

11CrMo9-10

1.7383 H6

1.4903 H6

196 Locking plate 13 CrMo 4-5

1.7335

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb 9-1

1.4903

198 Plate 13 CrMo 4-5

1.7335

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb 9-1

1.4903

210

37)

Hinge pin X39CrMo17-1

1.4122

X20CrMoV11-1

1.4922

411.1

37)

Joint ring Pure graphite

570

37)

Hanger arm 13 CrMo 4-5

1.7335

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb 9-1

1.4903

37) Recommended spare parts

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4.6 Line Blind Valve

4.6.1 VTS

4.6.1.1 Operating data

Table36: Operating properties

Characteristic Value

Design pressure [bar] ~ 600 Nominal size DN 200 - 500 Max. permissible pressure [bar] ~ 600 Min. permissible temperature [°C] ≥-10 Max. permissible temperature [°C] ≤+650

Selection as per pressure/temperature ratings (ðSection4.6.1.4,Page46)

4.6.1.2 Fluids handled

▪ Water ▪ Steam ▪ Other non-aggressive fluids such as gas or oil on request.

4.6.1.3 Design details

Design

▪ Body made of forged steel ▪ Pressure seal design ▪ Position indicator ▪ The valves satisfy the safety requirements of Annex I of the European Pressure

Equipment Directive 2014/68/EU(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

▪ Limit switch(es) ▪ Flanged ends ▪ Extended nozzles ▪ Blow-out attachment ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler /

Pressure Vessel Regulations – or to customer specification

Page 46

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4.6.1.4 Pressure/temperature ratings

Table37: Permissible operating pressure [bar]

38)39)

Material Subseries [°C]

100

150

200

250

300

350

400

425

450

475

500

510

520

530

540

550

560

570

580

590

600

610

620

630

640

650

P250GH

1.0460

15NiCuMoNb5

1.6368

C 429 407 394 380 367 356 341 327 314 242 - - - - - - - - - - - - - - - - D 660 618 598 578 558 539 518 498 476 374 - - - - - - - - - - - - - - - - E 869 814 789 764 738 711 685 658 629 495 - - - - - - - - - - - - - - - - -

16Mo3

1.5415

13CrMo4-5

1.7335

10CrMo9-10

1.7380/ 11CrMo9-10

1.7383

X10CrMoVNb9-1

1.4903

X10CrWMoVNb9-2

1.4901

4.6.1.5 Materials

Fig.3: VTS

Table38: Parts list

Part No. Description Materials for operating temperatures [°C] up to

450 530 550 570 600 650

100 Body

hard-faced with 17%Cr steel

P 250 GH

1.0460

15NiCuMoNb5

1.6368

16 Mo 3

1.5415

13 CrMo 4-5

1.7335

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb 9-1

1.4903

X10CrWMoVNb 9-2

1.4901

134 Blow-out attachment 16 Mo 3

1.5415

38) The valves are suitable for temperatures down to -10°C.

39) The test pressure is defined in accordance with the provisions of the technical codes PED2014/68/EU; DINEN12516-2 and EN12266-1.

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Part No. Description Materials for operating temperatures [°C] up to

450 530 550 570 600 650

139 Bonnet P 250 GH

1.0460

15NiCuMoNb5

1.6368

16 Mo 3

1.5415

13 CrMo 4-5

1.7335

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb 9-1

1.4903

X10CrWMoVNb 9-2

1.4901

198 Plate 16 Mo 3

1.5415

368

40)

Blind plate hard-faced with CrNi steel

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

15NiCuMoNb5

1.6368

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb 9-1

1.4903

X10CrWMoVNb 9-2

1.4901

411.1 Joint ring Pure graphite, capped with stainless steel 501 Segmental ring 10CrMo9-10

1.7380/

11CrMo9-10

1.7383

15NiCuMoNb5

1.6368

10CrMo9-10

1.7380/

11CrMo9-10

1.7383

X10CrMoVNb 9-1

1.4903

X10CrWMoVNb 9-2

1.4901

Typical applications

Free passage (blind plate removed) Closed passage (blind plate fitted)

40) Recommended spare parts

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4.6.1.6 Function

The line blind valve consists of body 100, bonnet 139 and blind plate 368 which shuts off fluid flow in body 100. The seating faces of body 100 and blind plate 368 are hard-faced. Blind plate 368 rests against plate 198 in the body seat via threaded pin 563 and nut 920.2.

The line blind valve is equipped with a pressure seal cover. The pressure inside the body presses bonnet 139 against joint ring 411.1, which is supported by segmental ring 501 via compression ring 500. Hexagon nuts 920.2, which are supported by cover 160 via studs 902.1, can be used to pre-load the pressure seal cover and to re-tighten it at system pressure.

4.7 Scope of supply

▪ Valve ▪ One valve operating manual per packaging unit

4.8 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.

The consultant, construction company or operator are responsible for positioning and installing the valves. Planning errors and installation errors may impair the reliable function of the valves and pose a substantial safety hazard.

DANGER

Dead-end valve

High-pressure hazard! Risk of burns!

▷ Protect the valve against unauthorised and/or unintentional opening.

WARNING

Cold/hot piping and/or valve

Risk of thermal injury!

▷ Insulate the valve. ▷ Fit 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 valve-mounted components, e.g. actuators

Leakage from or rupture of the valve body!

▷ Lay the piping in such a way that detrimental thrust and bending forces are

kept away from the valve body.

▷ Additional loads, e.g. traffic, wind or earthquakes are not taken into account

for standard variants; these require a separate design.

▷ Provide adequate support.

CAUTION

Condensation forming in air-conditioning systems, cooling systems and refrigerating systems

Ice forming! Actuating element blockage! Damage due to corrosion!

▷ Insulate the valve to prevent diffusion.

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CAUTION

Improper installation

Damage to the valve!

▷ Protect the body and body bonnet/cover from any impacts.

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

Gate valves For gate valves installed in horizontal pipes a vertical stem position is recommended

(handwheel or actuator on top, see position (a) shown below). Installation with the stem in an inclined or horizontal position, e.g. as in vertical pipes (positions b, c, g, h), is permitted. In this case, however, the actuator must be adequately supported at the site. Avoid any installation positions with the actuator hanging downward (positions d, e, f – risk of dirt ingress into the packing area via the back seat).

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(a)

(b)

(h)

(g)

(c)

(f)

(d)

(e)

Fig.4: Gate valve installation positions

Swing check valves Preferably install swing check valves in horizontal pipes. When installing them in

vertical pipes, make sure that the flow direction is upward. In the unpressurised condition, the valve disc will then be closed by its own weight.

Line blind valve Line blind valves are mainly used for pressure testing the boiler or a run of piping in

a plant. For this purpose, the line blind valve must be installed in such a way that the boiler pressure presses blind plate 368 against the body seat. When the shut-off elements are not fitted, flow may pass through the valve in either direction.

When blind plate 368 is fitted, the protruding parallel pin 562.1 must point upwards. This ensures that bonnet 139 can only be fitted with pointer 572 positioned perpendicular to the flow direction. This indicates that the flow passage is closed.

When installing the line blind valve without the shut-off elements (normal operating condition), make sure bonnet 139 is fitted so that the pointer is oriented in flow direction. This indicates that the fluid passage is open.

Installation location 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.

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)!

▷ Fully open the valve during welding. If the valve is equipped with a back seat,

run the obturator to an intermediate position.

▷ Never earth the electric welding equipment on the valve's functional parts.

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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.

ü The valve is installed in accordance with the appropriate pipeline isometry. ü Comply with the welding processes, filler metals and welding data laid down in

the welding plan.

1. Run the valve disc to the middle position prior to welding.

2. Verify that the butt weld ends are clean and undamaged.

3. Weld the valve into the piping in such a way that the valve/pipe welds are not subjected to stresses, strains or torsion. During the welding process, ensure constancy of the gap to the pipeline without radial offset.

4. When installing the valve with the stem in a horizontal position, adequately support the weight of the actuator or gearbox.

5.4 Valves with actuator

Installation position and location (ðSection5.2,Page50) 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.

On valves with electric, pneumatic or hydraulic actuators, the actuator strokes/forces must be limited.

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Electric actuators Electric actuators are factory-set ready for operation and wired as follows:

▪ Valve "CLOSED": travel-dependent ▪ Valve "OPEN": travel-dependent

The wiring diagrams are located in the terminal boxes.

Pneumatic/hydraulic

actuators

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.

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5.6 Body pressure relief valve

Spring-loaded body

pressure relief valve (UGS)

DANGER

Valve blowing off downwards or upwards

High-pressure hazard! Leakage of hot and/or toxic fluids! Risk of burns!

▷ UGS and UGSV blow off downwards. ▷ UGSVA blows off upwards. ▷ Suitable measures must be taken to mark the hazardous area. ▷ Secure the hazardous area by fitting appropriate protective devices.

CAUTION

Incorrect installation of the body pressure relief valve

Damage to the valve!

▷ Do not weld the body pressure relief valve directly to connection branch 131.2;

connect it via pipe 710 in a vertical, upright position.

▷ Observe a distance of at least 200 mm outside the insulation when fitting the

body pressure relief valve.

NOTE

Use the body pressure relief valve only for the purpose of protecting the valve body, never to protect piping systems, etc.

A body pressure relief valve is necessary if, with the gate valve closed, there is a danger of the liquid trapped inside the valve body heating up and causing an unacceptable pressure increase inside the valve. A warning sign is affixed to the yoke arm near the name plate.

② 731

710 131.2

100 ③

①

Fig.5: UGS/UGSV body pressure relief valve on gate valve in pressure seal design

① 200mm minimum

distance

② Body pressure relief valve for both

flow directions

③ Insulation 100 Body

131.2 Connection branch 710 Pipe, not included in KSB’s scope of supply

731 Pipe union

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All gate valves with pressure seal bonnet manufactured by KSB are factory-supplied with a closed connection branch 131.2 with connection dimensions Ø22 / Ø14.1 (suitable for pipe Ø21.3x3.6).

④

⑤

131.2

(ø 12,3)

ø 22

ø 14,1

ø 10

30°

Fig.6: Closed connection branch for body pressure relief valve

④ Welding groove ⑤ When connecting to pipe 710, cut here

and bevel the face to obtain a welding groove.

131.2 Connection branch

To allow the installation to be matched to the structural requirements, the body pressure relief valve is supplied with the gate valve, but not fitted.

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.

Prior to welding, open closed connection branch 131.2 by sawing off the branch end (the branch length should be 70mm) and bevel the face to obtain a welding groove.

CAUTION

Tripping of body pressure relief valve during commissioning

Damage to the seating faces due to foreign particles!

▷ Lock the body pressure relief valve in the closed position: The valve disc can be

pressed into the closed position via the rod by means of cover 160 fitted to screw-type body 734, thus ensuring tight closure.

▷ Tapped holes are provided in screw-type body 734 for this purpose. The

relevant parts can be ordered at the supplying factory.

▷ The blocking device must be removed after the pressure test has been

completed.

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Blocking device

Spring-loaded body

pressure relief valve with

bursting disc (UGSV)

The body pressure relief valve with bursting disc is supplied fully assembled, i.e. equipped with the bursting disc.

The installation is performed as described above.

Non-spring-loaded design

with bursting disc (UGSVA)

Always operate the UGSVA variant in combination with a lockable globe valve. Never replace the bursting disc during operation. To do so, the pressure in the gate valve must have been released.

The installation is performed as described above.

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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. (ðSection4,Page14) .

▪ 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. (ðSection4,Page14) . 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 or scalds!

▷ The max. permissible valve pressure must not be exceeded

(ðSection4,Page14) .

▷ Use valves made of nodular cast iron or steel. ▷ Operator shall provide general safety measures for the system.

CAUTION

Steam hammer potentially occurring at high temperatures

Damage to the valve!

▷ Drain the valve body completely. ▷ Specify drainage requirements in the purchase order. ▷ Unless otherwise agreed, drain branches shall be used exclusively for draining

the valve body.

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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.

Functional check The following functions must be checked:

1. Check the shut-off function of the installed valve prior to commissioning/startup by opening and closing it several times.

2. Check gland packing 461 for leakage when it is subjected to full operating pressure and operating temperature for the first time.

3. If gland follower 452 is loose, evenly re-tighten nuts 920.1/920.2.

4. Always tighten nuts 920.4/920.6 of the studs 902.2 pre-loading bonnet 139 and joint ring 411 under operating conditions to ensure that leakage at the pressure seal bonnet/cover, which might be caused by bonnet 139 sinking as pressure inside body 100 decreases, is avoided.

5. Check the joint between the body and the bonnet/cover established by bolting

902.1/904/920.1 and joint ring 411.1 for tightness after the valve has been subjected to load conditions or heated up for the first time.

6. To avoid stress or distortion, open the valve by approx. two full counterclockwise handwheel turns.

7. If bonnet/cover bolting 902.1/904/920.1 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.

Valves with actuators 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.

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Electric actuators are factory-set 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.

Line blind valve The line blind valve is supplied in pre-assembled condition. After the pressure test the

shut-off elements (368 and 198) are dismantled in the following sequence:

DANGER

Valve under pressure

High-pressure hazard! Leakage of hot and/or toxic fluids! Risk of burns!

▷ Make sure that there is no system pressure on the inlet or outlet side of the

valve!

▷ 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.

▷ Use appropriate spare parts and tools, even in emergencies.

1. Undo hexagon nut 920.1 and lift out cover 160.

2. Push bonnet 139 downwards and take segmental ring 501 out of the groove.

3. Lift out bonnet 139 complete with parts 500 and 411.

4. Loosen nut 920.2 and lift out shut-off assembly 368 and 198 connected by threaded pin 563. Eyebolts 900 facilitate this step.

When re-installing shut-off elements 368 and 198 for another pressure test, it is essential to do so in the reverse sequence of dismantling.

WARNING

Incorrect installation of the flow direction pointer

Leakage of hot and/or toxic fluids! Damage to the system!

▷ Flow passage open = Pointer in flow direction ▷ Flow passage closed = Pointer perpendicular to the flow direction ▷ Having removed the shut-off assembly after the pressure test, make sure that

the bonnet is reassembled with the pointer pointing into the direction of flow.

When installing the pressure seal bonnet/cover ensure that parallel pin 562.1 is aligned with the hole in bonnet 139.

Gate valves 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.

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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.

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.

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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.

6.2.2 Servicing/Maintenance

The 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.

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 twice a year ▪ Lubricating the moving parts such as stem 200 and gland bolts (not for oxygen

valves) using appropriate lubricants (e.g. lubricants suitable for high temperatures)

▪ Adding or replacing packing rings in gland packing 461 in time ▪ Re-tightening or replacing the bonnet/cover gasket 411.1 in time

Testing overhauled valves After reassembly and prior to commissioning/start-up, the valves must be subjected

to shell testing and leak testing to DINEN12266-1.

Body pressure relief valve

DANGER

Gate valve is not closed.

High-pressure hazard! Leakage of hot and/or toxic fluids! Risk of burns!

▷ Close the gate valve. ▷ Perform work with utmost care, making sure that all safety measures are

complied with.

Leakages at the seat caused by foreign objects between the body seat and valve disc can be removed by briefly lifting rod 574 and allowing valve disc 350 to snap back onto the seat. This is done by inserting two screw drivers on opposite sides into the rod's groove.

If leakage cannot be eliminated, this indicates that the seating faces are damaged. If this is the case, the body pressure relief valve needs to be replaced the next time that the system is shut down.

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CAUTION

Bursting discs are not marked

Risk of mixing up bursting discs!

▷ Always select the bursting disc according to the name plate in its packaging. ▷ Do not mix up bursting discs.

CAUTION

Incorrect installation position of bursting disc

Damage to the valve!

▷ Observe the installation position. ▷ The concave curvature must face the pressure side.

NOTE

Bursting discs are safety elements and must be handled with utmost care.

If the bursting disc needs replacing, the following steps must be observed:

ü Make sure the gate valve is not pressurised.

1. Remove sleeve 520 from pipe union 731.

2. Remove defective bursting disc 550.2. Do not damage the lead seal of the spring-loaded body pressure relief valve.

3. Clean the sealing surfaces and ring 500.

4. Carefully take a new bursting disc 550.2 out of its packaging.

5. Insert bursting disc 550.2 into pipe union 731.

6. Place ring 500 onto the bursting disc.

7. Screw the complete body pressure relief valve into pipe union 731 and tighten using a torque wrench. PN ≤ 160: tightening torque 130 Nm PN > 160: tightening torque as required

8. Remove the old name plate and replace with the new one.

9. Renew the paint dot at the point where rod 574 passes through screw-type body 734.

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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

Risk of injury! 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 and 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.

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8 Trouble-shooting

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8 Trouble-shooting

WARNING

Improper remedial work on the valve

Risk of injury!

▷ For any work performed in order to remedy faults on the valve observe the

relevant information given in this operating manual and/or the product literature provided by the accessories manufacturers.

If problems occur that are not described in the following table, consultation with the KSB customer service is required.

Table39: Trouble-shooting

Problem Possible cause Remedy

Leakage at the seat ▪ Contaminations or solids in the

fluid

▪ Erosion, corrosion or abrasion ▪ Excessive loads from pipeline

forces or thermal stresses

1. Dismantle bonnet/cover bolting

902.1/920.1.

2. Rework the seating faces of valve disc and body using a suitable reseating tool.

3. Continue re-seating until the seating faces exhibit a consistently smooth and even ring.

Leakage at the gland packing Unevenly tightened gland packing 1. Re-tighten hexagon nuts 920/920.2

as specified in the manual.

Defective gland packing 1. Undo hexagon nuts 920/920.2.

2. Lift gland follower 452.

3. Clean the gland packing chamber.

4. Insert split packing rings in such a manner that the cut ends of the rings are offset by between 120° and 180°.

Leakage at bonnet/body joint or cover/body joint (bolted bonnet/ cover design)

Unevenly tightened bonnet/cover bolts

1. Re-tighten bonnet/cover bolting

902.1/920.1 as specified in the manual.

Defective bonnet/cover gasket 1. Dismantle bonnet/cover bolting

902.1/920.1.

2. Clean sealing surfaces.

3. Replace joint ring 411.

The tightening torques must be observed.

Leakage at the bonnet/body joint or cover/body joint (for pressure seal design)

Unevenly tightened hexagon head bolts

1. Re-tighten hexagon head bolts

901.1/920.1 as specified in the manual.

Defective joint ring 1. Remove pressure seal bonnet/cover.

2. Clean sealing surfaces.

3. Replace joint ring 411.1.

The tightening torques must be observed.

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9 EU Declaration of Conformity

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9 EU Declaration of Conformity

9.1 EU Declaration of Conformity for STAAL40, STAAL100, AKG-A/AKGS-A, AKR/AKRS, ZTS, ZRS, VTS

Herewith we, KSB SE & Co. KGaA

Bahnhofplatz 1

91257 Pegnitz

Registered office: Frankenthal (Pfalz)

Germany

declare that the product:

Gate valves

STAAL40 AKD/AKDS PN10 - 40 DN50 - 1400 STAAL100 AKD/AKDS PN63 - 100 DN50 - 800 AKG-A/AKGS-A PN63 - 160 DN 80 - 300 ZTS Pmax. = 600 bar DN50 - 800

Swing check valves

STAAL 40 AKK/AKKS PN10 - 40 DN80 - 400 STAAL 100 AKK/AKKS PN63 - 100 DN80 - 400 AKR/AKRS PN63 - 160 DN80 - 300 ZRS Pmax. = 600 bar DN 50 - 800

Line blind valve

VTS Pmax. = 600 bar DN200 - 500

Body pressure relief valve

UGS/UGSV/UGSVA ≥ PN40 DN 15

satisfies the safety requirements laid down in the Pressure Equipment Directive 2014/68/EU.

Codes applied:

AD2000 code of the German Pressure Vessel Society

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

For models with by-pass, the assembly's conformity with the Pressure Equipment Directive 2014/68/EU is confirmed.

The EU Declaration of Conformity was issued in/on:

Frankenthal, 1 February 2018

Wolfgang Glaub Dr. Christopher Lange Vice President Integrated Management Germany Head of Corporate Unit Valves

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Index

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Index

CE marking14 Commissioning57

Design16, 19, 23, 26, 34, 36, 41, 45 Design details

AKG-A/AKGS-A23 AKR/AKRS39 STAAL 100 AKD/AKDS19 STAAL 100 AKK/AKKS36 STAAL 40 AKD/AKDS16 STAAL 40 AKK/AKKS34 VTS45 ZRS41 ZTS26

Disposal13

Event of damage6

Faults

Causes and remedies65 Fluids in Group 114 Fluids in Group 214

Function

AKG-A/AKGS-A15

AKR/AKRS33

STAAL 100 AKK/AKKS33

STAAL 40 AKK/AKKS33

UGS32

VTS48

ZRS33

ZTS15

Intended use8

Key to safety symbols/markings7

Maintenance62, 64 Marking14

Materials

AKG-A/AKGS-A25

AKR/AKRS40

STAAL 100 AKD/AKDS21

STAAL 100 AKK/AKKS37

STAAL 40 AKD/AKDS18

STAAL 40 AKK/AKKS35

UGS31

VTS46

ZRS44

ZTS29

Operating data

AKG-A/AKGS-A23 AKR/AKRS39 STAAL 100 AKD/AKDS19 STAAL 100 AKK/AKKS36 STAAL 40 AKD/AKDS16 STAAL 40 AKK/AKKS34 VTS45 ZRS41

ZTS26 Operating limits8 Other applicable documents6

Personnel8 Pressure Equipment Directive 2014/68/EU14

Pressure/temperature ratings

AKG-A/AKGS-A24

AKR/AKRS40

STAAL 100 AKD/AKDS20

STAAL 100 AKK/AKKS37

STAAL 40 AKD/AKDS17

STAAL 40 AKK/AKKS35

VTS46

ZRS43

ZTS27

Qualification8

Return to supplier13

Safety7 Safety awareness9 Scope of supply48 Shutdown62 Storage12

Transport11

Warnings7 Warranty claims6

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KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com

0570.81/16-EN

KSB STAAL 40 AKD, STAAL 100 AKGS-A, STAAL 100 ZTS, STAAL 40 AKKS, STAAL 100 AKK Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual