Spirax Sarco KE71, KE71B1, KE73, KE71B4, KE73B4 Installation And Maintenance Instructions Manual

...

Download

3010052/4

IM-S24-15

CH Issue 4

K and L Series

Two-port Control Valves

Installation and Maintenance Instructions

1. Safety information

IM-S24-15 CH Issue 4

Printed in the UK

2. General product information

3. Installation and commissioning

4. Maintenance

5. Spare parts

1. Safety information

Sa f e ope r ation of th e se pr o ducts can o n l y be g uara n t eed i f the y are p r oper l y in stal led, co mmis sion ed, use d and mai n tai n ed by qua l ifi e d p e rso n nel (s e e Section 1.11) in compliance with the operating instructions. General installation and safety instructions for pipeline and plant construction, as well as the proper use of tools and safety equipment must also be complied with.

Safety note - Handling precautions

PTFE

Within its working temperature range PTFE is a completely iner t material, but when heated to its sintering temperature it gives rise to gaseous decomposition products or fumes which can produce unpleasant ef fects if inhaled. The inhalation of these fumes is easily prevented by applying local exhaust ventilation to atmosphere as near to their source as possible. Smoking should be prohibited in workshops where PTFE is handled because tobacco contaminated with PTFE will during burning give rise to polymer fumes. It is therefore impor tant to avoid contamination of clothing, especially the pockets, with PTFE and to maintain a reasonable standard or personal cleanliness by washing hands and removing any PTFE particles lodged under the fingernails.

LAMINATED GASKETS

The metal foil sheet used to reinforce gaskets is very thin and sharp. Care should be taken when handling to avoid the possibility of cuts or lacerations to fingers or hands.

1.1 Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet, check that the product is suitable for the intended use / application. The products listed on pages 3, 4 and 5 comply with the requirements of the European Pressure Equipment Directive 97/23/EC, carry the mark when so required and fall within the Pressure Equipment Directive categories stated.

i) The products have been specifically designed for use on steam, air or condensate

which are in Group 2 of the above mentioned Pressure Equipment Directive. It can also be used on propane or methane gases which are in Group 1 of the above mentioned Pressure Equipment Directive. The products’ use on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted to confirm the suitability of the product for the application being considered.

ii) Check material suitability, pressure and temperature and their maximum and

minimum values. If the maximum operating limits of the product are lower than those of the system in which it is being fitted, or if malf unction of the product could result in a dangerous overpressure or overtemperature occurrence, ensure a safety dev ice is incl uded in the system to prevent such over-limit situati ons.

iii) Determine the correct installation situation and direction of fluid flow.

iv) Spirax Sarco products are not intended to withstand external stresses that may

be induced by any system to which they are fitted. It is the responsibility of the installer to consider these stresses and take adequate precautions to minimise them.

v) Remove protection covers from all connections before installation.

IM-S24-15 CH Issue 4

KE valves

Group 1 Group 2 Group 1 Group 2

DN15 - DN25 SEP SEP SEP SEP

DN32 2 SEP SEP SEP

KE43 PN40

DN65 - DN100 2 1 2 SEP

DN15 - DN25 SEP SEP SEP SEP

DN32 2 SEP SEP SEP KE43B1 PN40

DN65 - DN100 2 1 2 SEP

DN15 - DN25 SEP SEP SEP SEP

DN32 2 SEP SEP SEP

KE43B4 PN40

DN65 - DN100 2 1 2 SEP

KE61 PN40 DN15 - DN25 SEP SEP SEP SEP

DN15 - DN25 SEP SEP SEP SEP

DN32 2 SEP SEP SEP

KE63 PN40

DN65 - DN100 2 1 2 SEP

DN15 - DN25 SEP SEP SEP SEP

KE71 PN25 DN32 - DN40 1 SEP SEP SEP

DN50 2 1 SEP SEP

DN15 - DN25 SEP SEP SEP SEP

KE71B1 PN25 DN32 - DN40 1 SEP SEP SEP

DN50 2 1 SEP SEP

DN15 - DN25 SEP SEP SEP SEP

KE71B4 PN25 DN32 - DN40 1 SEP SEP SEP

DN50 2 1 SEP SEP

DN15 - DN25 SEP SEP SEP SEP

DN32 - DN40 1 SEP SEP SEP

KE73 PN25

DN100 2 1 2 SEP

DN15 - DN25 SEP SEP SEP SEP

DN32 - DN40 1 SEP SEP SEP

KE73B1 PN25

DN100 2 1 2 SEP

DN15 - DN25 SEP SEP SEP SEP

KE73B4 PN25 DN50 - DN80 2 1 SEP SEP

DN100 2 1 2 SEP

Product

Gases Gases Liquids Liquids

DN40 - DN5 0 2 1 SEP SEP

DN50 - DN80 2 1 SEP SEP

DN32 - DN40 1 SEP SEP SEP

IM-S24-15 CH Issue 4

KEA valves

Group 1 Group 2 Group 1 Group 2

DN15 - DN25 SEP SEP SEP SEP

DN32 2 SEP SEP SEP KE A41 ANSI 300

DN50 2 1 2 SEP

DN15 - DN25 SEP SEP SEP SEP

DN40 - DN50 1 SEP SEP SEP

ANSI 150 DN65 - DN100 2 1 SEP SEP

DN150 2 1 2 SEP

DN20 0 3 2 2 SEP

KEA4 3

DN40 2 1 SEP SEP

DN150 - DN200 3 2 2 SEP

DN15 - DN25 SEP SEP SEP SEP

DN32 2 SEP SEP SEP

KEA61 ANSI 300

DN50 2 1 2 SEP

DN15 - DN25 SEP SEP SEP SEP

DN40 - DN50 1 SEP SEP SEP

ANSI 150 DN65 - DN100 2 1 SEP SEP

DN150 2 1 2 SEP

DN20 0 3 2 2 SEP

KEA63

DN40 2 1 SEP SEP

DN150 - DN200 3 2 2 SEP

DN15 - DN25 SEP SEP SEP SEP

KEA71 ANSI 250

DN15 - DN25 SEP SEP SEP SEP

DN40 - DN65 1 SEP SEP SEP

DN150 - DN200 2 1 2 SEP

KEA73

DN40 - DN50 2 1 SEP SEP

DN150 - DN200 3 2 2 SEP

Product

DN15 - DN25 SEP SEP SEP SEP

ANSI 300

DN15 - DN25 SEP SEP SEP SEP

ANSI 300

ANSI 125

DN15 - DN25 SEP SEP SEP SEP

ANSI 250

Gases Gases Liquids Liquids

DN40 2 1 SEP SEP

DN50 - DN100 2 1 2 SEP

DN40 2 1 SEP SEP

DN50 - DN100 2 1 2 SEP

DN32 - DN50 2 2 2 SEP

DN80 - DN100 2 1 SEP SEP

DN65 - DN100 2 1 2 SEP

IM-S24-15 CH Issue 4

LE valves

Group 1 Group 2 Group 1 Group 2

LE31 PN16 DN15 - DN50 - SEP - SEP

LE31B1 PN16 DN15 - DN50 - SEP - SEP

LE33 PN16

DN65 - DN100 - 1 - SEP

LE33B1 PN16

DN65 - DN100 - 1 - SEP

Product

DN15 - DN50 - SEP - SEP

Gases Gases Liquids Liquids

LEA valves

Group 1 Group 2 Group 1 Group 2

LEA31 ANSI 125 DN15 - DN50 - SEP - SEP

LEA33 ANSI 125

DN80 - DN100 - 1 - SEP

Product

Gases Gases Liquids Liquids

DN25 - DN65 - SEP - SEP

1.2 Access

Ensu re safe acc ess a nd if ne ces sary a s afe w ork ing plat for m (su ita bly g uar ded ) before attempting to work on the product. Arrange suitable lifting gear if required.

1.3 Lighting

Ensure adequate lighting, particularly where detailed or intricate work is requi red.

1.4 Hazardous liquids or gases in the pipeline

Co nsi der wh at is i n t he pip elin e o r w hat may ha ve bee n in th e p ipe line at so me prev iou s t ime . C ons ide r: flamm abl e m ate ria ls, su bst ances ha zar dou s t o h eal th, extremes of temperature.

1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxyg en (e.g. tanks, pits), dangerous g ases, extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed action (e.g. c losing isol at ion valves, e lectrical iso la tion) put a ny other part o f the system or any personnel at risk? Dange rs mig ht inc lud e i sol ati on of ven ts or pro tec tive devic es or the re nde rin g ineffective of controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system shocks.

1.7 Pressure systems

Ensu re that any press ure is isola ted a nd sa fe ly ve nted to at mosph er ic pr essur e. Con si der double isolatio n (double block and b le ed) and the locking o r labelling of clos ed valv es. D o not assu me th at th e sys tem h as de press ur ised even when the pressure gauge indicates zero.

IM-S24-15 CH Issue 4

1.8 Temperature

Allow time for temperature to normalise after isolation to avoid the danger of burns and consider whether protective clothing (including safety glasses) is required.

PTFE SEALS

If seals made from PTFE have been subjected to a temperature approaching 260°C (500°F) or higher, they will give off toxic fumes, which if inhaled are likely to cause temporary discomfort. It is essential for a no smoking rule to be enforced in all areas where PTFE is stored, handled or processed as persons inhaling the fumes from burning tabacco contaminated with PTFE particles can develop ‘polymer fume fever’.

1.9 Tools and consumables

Before starting work ensure that you have suitable tools and / or consumables available. Use only genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consider whether you and /or others in the vicinity require any protective clothing to protect against the hazards of, for example, chemicals, high / low temperature, radiation, noise, falling objects, and dangers to eyes and face.

1.11 Permits to work

Al l w ork mus t b e c arri ed out or be supe rvi sed by a s uit a bly co mpet ent pe rson . Inst all ati on and op erating per son nel sh oul d b e tra ine d i n t he cor rect use of th e product according to the Installation and Maintenance Instructions. Where a formal ‘permit to work’ system is in force it must be complied with. Where there is no such system, it is recommended that a responsible person should know wha t work is going o n and, where ne ce ssary, arrange to have an assist an t whose primary responsibility is safety. Post ‘warning notices’ if necessary.

1.12 Handling

Manual handling of large and /or heavy products may present a risk of injury. Lifting, pushing, pulling, carrying or supporting a load by bo dil y f orc e c an cau se inj ury particularly to the back. You are advised to assess the risks taking into account the task, the individual, the load and the working environment and use the appropriate handling method depending on the circumstances of the work being done.

1.13 Residual hazards

In nor ma l use t he exte rnal su rface o f the p ro duct ma y be ve ry hot. If use d at th e maximum permitted operating conditions the surface temperature of some products may reach temperatures of 350°C (662°F). Many products are not self-draining. Take due care when dismantling or removing the product from an installation (refer to ‘Maintenance instructions’).

1.14 Freezing

Prov is ion m ust b e mad e to prote ct pr oduct s whi ch ar e not s elf-d raini ng ag ainst frost dama ge in env ironments where they may be exposed to temperatures below freezing point.

IM-S24-15 CH Issue 4

1.15 Disposal

Un less othe r wise sta t ed i n the Ins t alla t ion a nd M aint e nanc e Ins truc t ions , thi s pr odu c t i s re cycl able and no eco l ogi cal haza rd i s a n tic i pat ed w ith its dis p osa l providing due care is taken. However, if the valve is fitted with a Viton or PTFE seat, sp e c ial c a re mu s t be t a ken t o avoi d poten t i al h e a lth h a z ards a ssoci a t ed w i t h decomposition / burning of these seats.

PTFE:

- Can only be disposed of by approved methods, not incineration.

- Keep P TFE was te in a separa te cont ainer, do not mix it with ot her rub bish, a nd consign it to a landfill site.

1.16 Returning products

Cu s t o m e r s a n d s t o c k i s t s a r e r e m i n d e d t h a t u n d e r E C H e a l t h , S a f et y a n d En viro n men t Law , wh e n re turn i ng p rodu c ts t o Sp i rax Sarc o th e y mu st p r ovid e information on any ha zards and the precau tions to be taken du e to cont amination r e s i d u e s o r m e ch a n i c a l d a m a g e w h i c h m a y pr e s e n t a h e a l th , s a f e t y o r envi r o n m e n tal r i s k . Thi s i n f o rma t i o n m ust b e p r o vid e d i n w rit i n g i n clud i n g Health and Safety data sheets relating to any substances identified as hazardous or potentially hazardous.

IM-S24-15 CH Issue 4

2. General product information

The K and L series control valve range consists of; two-por t single seat globe valves with cage-retained seats conforming to either EN 1092 or ANSI/ASTM specification. These valves are available in three body materials: SG iron, cast steel or stainless steel (with the exception of the L series, which is available in cast iron only) in sizes DN15 to DN100 (½" to 4").

2.1 Pressure / temperature limits - KE and LE valves

KE43, KE61 and KE63 PN40

Body design conditions

LE31, LE31B1, LE33 and LE33B1 PN16

KE43 40 bar g @ 120°C

Maximum design pressure

KE43B1, KE61B1, KE63B1, KE71B1 and KE73B1 16 bar g @ 110°C

LE31, LE31B1, LE33 and LE33B1 16 bar g @ 110°C

KE43, KE61 and KE63 400°C

Maximum design temperature

LE31, LE31B1, LE33 and LE33B1 300°C

Minimum design temperature

LE31, LE31B1, LE33 and LE33B1 -10°C

Standard packing PTFE chevron 250°C

PTFE soft seat (G) 200°C

High temperature packing (H) LE Valves 300°C

Maximum operating temperature

Extended bonnet (E) with graphite packing 300°C

Bellows (B1) 300°C

Designed for a maximum cold

hydraul ic test pressure of:

Warning for valves fitted with bellows - Remove bellows before hydraulic testing is done

Maximum differential pressures: See relevant actuator Technical Information sheet

KE71 and KE73 PN25

KE43B1, KE61B1, KE63B1, KE71B1 and KE73B1 PN16

KE61 and KE63 40 bar g @ 50°C

KE71 and KE73 25 bar g @ 110°C

KE71 and KE73 350°C

KE43B1, KE61B1, KE63B1, KE71B1 and KE73B1 300°C

KE43B1, KE61B1, KE63B1, KE71B1 and KE73B1 -10°C

KE61 and KE63 -10°C

High temperature packing (H) 400°C

Extended bonnet (E) with PTFE chevron 250°C

KE43 60 bar g

KE61 and KE63 60 bar g

KE71 and KE73 38 bar g

LE31 and LE33 24 bar g

Key to charts on page 9:

The product must not be used in this region.

High temperature packing is required for use in this region.

High temperature bolting and packing is required for use in this region.

A - A Note: Valves ﬁtted with PN16 bellows (B1) are limited to the maximum bellows rating of 16 bar.

IM-S24-15 CH Issue 4

















    





















   





















   

















   

   

















       

KE43, KE43B1 and KE43B4 (cast steel)

KE61 and KE63 (stainless steel )

KE71 and KE71B1, KE73 and KE73B1 (SG iron)

Steam saturation curve

Steam saturation

Temperature °C Temperature °C

Temperature °C

curve

Steam saturation curve

Pressure bar g

LE31 and LE33 (cast iron)

Temperature °C

LE31B1 and LE3 3B1 ( cast iron)

Temperature °C

IM-S24-15 CH Issue 4

Steam saturation curve

Pressure bar g

Steam saturation curve

Pressure bar g

2.2 Pressure / temperature limits - ANSI KEA and LEA valves

KEA41 and KEA43 ANSI 150 or ANSI 300

Body design conditions

LEA31 and LEA33 ANSI 125

KEA41 and KEA43 740 psi g @ 100°F

Maximum design pressure

LEA31 and LEA33 200 psi g @ 150°F

Maximum design temperature

LEA31 and LEA33 450°F

Minimum design temperature

LEA31 and LEA33 14°F

Standard packing PTFE chevron 482°F

PTFE soft seat (G) 400°F

Maximum operating

temperature

ANSI 300 1 125 psi g

Maximum cold ANSI 150 425 psi g

hydraulic test

pressure:

ANSI 250 750 psi g

LEA31 and LEA33 ANSI 125 300 psi g

Warning for valves fitted with bellows - Remove bellows before hydraulic testing is done

Maximum differential pressures: See relevant actuator Technical Information sheet

KE A61 and KEA63 ANSI 150 or ANSI 300

KEA71 and KEA73 ANSI 125 or ANSI 250

KEA61 and KEA63 720 psi g @ 100°F

KEA71 and KEA73 450 psi g @ 200°F

KEA41, KEA43, KEA61 and KEA63 800°F

KEA71 and KEA73 450°F

KE A41, KEA43, KEA71 and KEA73 14°F

KEA61 and KEA63 -20°F

KEA41, KEA43, KEA61 and KEA63

KEA71 and KEA73 LEA31 and LEA33

KEA41 and KEA43

KEA61 and KEA63

KEA71 and KEA73

High temperature packing (H) 800°F

High temperature packing (H) 450°F

ANSI 150 450 psi g

ANSI 300 1 100 psi g

ANSI 125 300 psi g

Key to charts on page 11:

The product must not be used in this region.

Graphite stem sealing is required for use in this region. Note: As standard the KEA, KFA, KLA series two-port control valves are supplied with the PTFE stem sealing option.

The product should not be used in this region or beyond its operating range as damage to the internals may occur.

A - B Flanged ANSI 300 and screwed NPT (KEA41 and KEA61). A - D Flanged ANSI 150. A - C Flanged ANSI 250 and screwed NPT (KEA71). A - E Flanged ANSI 125.

IM-S24-15 CH Issue 4

 















































































 







 











KEA41 and KEA43 (cast steel)

KEA61 and KEA63 (stainless steel )

KEA71 and KEA73 (ductile iron)

Steam

Temperature °FTemperature °F

Temperature °F

saturation curve

Steam saturation curve

Pressure psi g

D B

Pressure psi g

LEA31 and LEA33 (ductile iron)

Temperature °F

IM-S24-15 CH Issue 4

Steam saturation curve

Pressure psi g

3. Installation and commissioning

Note: Before actioning any installation, observe the ‘Safety information’ in Section 1.

Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet, check that the product is suitable for the intended installation:

3.1 Check materials, pressure and temperature and their maximum values. Do not exceed

the performance rating of the valve. If the maximum operating limit of the product

is lower than that of the system in which it is being fitted, ensure that a safety device is included in the system to prevent overpressurisation.

3.2 Remove protective covers from all connections.

3.3 Determine the correct installation situation and the direction of fluid flow. The valve

should preferably be installed along a horizontal pipeline with the valve mounted above the pipe. When mounting an actuator to the valve body, the actuator Installation and Maintenance Instructions must be followed.

3.4 Bypass arrangements - It is recommended that isolating valves be fitted upstream

and downstream of the control valve, together with a manual bypass control valve. This enables the process to be controlled manually using the bypass valve while the pneumatic valve is isolated for maintenance.

3.5 Support pipework should be used to prevent stresses being exerted on the valve

body.

3.6 Ensure adequate space is provided for the removal of the actuator from the valve body

for maintenance purposes:

3.7 Isolate connecting pipework. Ensure it is clean from dirt, scale etc. Any debris entering

the valve may damage the PTFE head seal preventing a tight shut-off.

3.8 Open isolation valves slowly, until normal operating conditions are achieved.

3.9 Check for leaks and correct operation.

Fig. 1

Isolating

valve

Bypass

Control

valve

Strainer

(piped horizontally)

* Anti-vacuum valve recommended for steam installations.

Isolating

valve

AVV*

Bypass valve

IM-S24-15 CH Issue 4

4. Maintenance

The 316 type stainless steel used in the construction of this product particularly for screwed or close ﬁtting par ts, is very susceptible to galling or cold welding. This is an inherent characterisitic of this type of material and great care should therefore be taken when dismantling or reassembling. If the application permits, it is recommended that a lighter smear of a PTFE based grease is applied to any mating parts before reassembly.

4.1 Periodic maintenance

KEA61 and KEA63 Warning

After 24 hours of operation

After 24 hours of operation check the flange bolts for tightness. On valves with graphite stem seal packing compress the gland seal packing by tightening the gland nut by ¼ of a turn. Care should be taken not to overtighten as this may cause the spindle to lock-up.

Every 3 months of operation

Ever y 3 months of normal operation check the stem gland seal for leakage. In the case of leakage proceed as follows:

- For va lves with a PTFE gla nd seal renew the gland se al by following the proced ure in

Section 4.2.

- For valves with a graphite stem seal packing compress the gland seal packing by tightening

the gland nut by ¼ of a turn. If leakage cannot be eliminated, renew the graphite gland seal by following the procedure in Section 4.3.

Annually

Inspect the valve to check for wear or scale deposits. Worn or damaged parts, like the plug or seat may need to be replaced, as well as the gland seal packing. The graphite packing is normally subject to wear. Therefore it is recommended to renew the packing rings annually.

Table 1 Recommended tightening torques N m (lbf ft)

Size Seat (4) Bonnet nuts (15)

(chevron seals ) (9)

DN15 (½") 40 ±5 (30 ±4) 30 ±1.5 (22 ±1) 25 - 30 (19 - 22)

DN20 (¾") 53 ±3 (39 ±2) 30 ±1.5 (22 ±1) 25 - 30 (19 - 22)

DN25 (1") 80 ±5 (59 ±4) 40 ±2 (29 ±1.5) 25 - 30 (19 - 22)

DN32 (1¼") 130 ±5 (96 ±4) 45 ±2 (33 ±1.5) 25 - 30 (19 - 22)

DN40 (1½") 220 ±5 (160 ±4) 45 ±2 (33 ±1.5) 25 - 30 (19 - 22)

DN50 (2") 150 ±5 (110 ±4) 65 ±3 (48 ±2.5) 25 - 30 (19 - 22)

DN65 (2½") 300 ±12 (220 ±9) 65 ±3 (48 ±2.8) 32 - 38 ( 24 - 28)

DN80 (3") 400 ±16 (295 ±12) 60 ±3 (44 ±2) 32 - 38 (24 - 28)

DN100 (4") 600 ±24 (442 ±18) 60 ±3 (44 ±2) 32 - 38 (24 - 28)

DN150 (6") 678 (500) 488 (360) 81 (60)

DN20 0 (8") 678 (500) 488 (360 ) 81 (60)

IM-S24-15 CH Issue 4

Gland nut

4.2 Procedure for renewing PTFE chevron gland seals

- Isolate the valve on both sides.

- Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions

covering Spirax Sarco actuators.

Caution: Care should be taken in removing the bonnet since fluid under pressure may be

trapped between the isolating valves.

- Remove the lock-nut (7).

- Unscrew the bonnet nuts securing the bonnet to the body and remove the bonnet (2)

complete with the plug / stem assembly.

- Unscrew the gland nut (8), withdraw the plug / stem assembly, remove and discard the gland

seal set (10 + 11 + 15) and gland nut gasket (6).

- Examine the parts for signs of damage or deterioration and renew as necessary. Note that

score marks or scaly deposits on the valve stem (5) will lead to early failure of the seals.

- Clean the parts taking care to avoid scratching the stem or bore of the gland nut. Refit the

plug assembly into the valve body.

- Using a new bonnet gasket refit the bonnet ( 2) onto the valve body, leaving the stem

protruding. Replace the bonnet nuts and tighten to the recommended torque (see Table 1, page 13), ensuring that the valve plug is centrally located in the seat whilst tightening.

- To replace the new gland seal assembly (10, 11, 15), firstly fit the gland spring (11) over

the valve stem (5). New chevron gland seals should be firmly inserted into the gland nut (8 ), as shown in Figure 2. Being careful to avoid damage to the sealing edges, replace the gland nut gasket (6). Refit the gland nut (8) over the valve stem (5), screwing down to ensure the gasket is bedded down onto the bonnet ( 2).

- Ensure that the stem (5 ) moves freely.

- Refit the valve lock-nut (7).

- Refit the actuator, clamping nut (9 ) and connect the actuator to the valve stem.

- Bring the valve back into ser vice.

- Check for any leakage at the gland.

Do not assemble dr y as this will damage the 'O' rings.

'O' ring

Gland nut (8) Gasket (6)

Clamp nut (9)

Spring (11)

Stem (5)

Fig. 2

(7) Lock-nut

Upper

bearing

(10) Chevrons

(15) Lower

bearing

(2) Bonnet

IM-S24-15 CH Issue 4

Seal assembly

4.3 Procedure for renewing graphite gland seals

- Isolate the valve on both sides.

- Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions

covering Spirax Sarco actuators.

Caution: Care should be taken in removing the bonnet since fluid under pressure may be

trapped between the isolating valves.

- Remove the lock-nut (7).

- Unscrew the bonnet nuts securing the bonnet to the body and remove the bonnet (2)

complete with the plug /stem assembly.

- Unscrew the gland nut ( 8). Withdraw the plug / stem assembly, remove and discard the

gland seal set (10 + 15), and gasket from the bonnet.

- Examine the parts for signs of damage or deterioration. Note that score marks or scaly

deposits on the valve stem (5) will lead to early failure of the seals.

- Clean the parts taking care to avoid scratching the stem or bore of the gland nut.

- The replacement graphite gland seal should now be fitted. Note that the gland seal set

contains a top and bottom support ring and a graphite pack. The order of the graphite pack should be maintained as supplied during the fitting procedure. Place the bottom support ring into the bonnet. One by one add the graphite rings and each time use the gland nut (8 ) to drive the ring down into the bonnet. Ensuring the junction of the ring ends are rotated by 90°. Leave the gland nut loosely assembled so that the seals are not compressed.

Ring 1 Ring 2 Ring 3 Ring 4 Ring 5

Fig. 3

IM-S24-15 CH Issue 4

- Refit the valve plug /stem assembly by carefully sliding the valve stem in order to pass

through the seals.

- Using a new bonnet gasket refit the bonnet (2) onto the valve body, ensuring the plug is

on the valve seat, and replace the nuts and tighten to the recommended torque (see Table 1, page 13), ensuring that the valve plug is centrally located in the seat whilst tightening.

- Screw down the gland nut until it just starts to compress the packing. Compress the gland

seal packing by tightening the gland nut (8 ) by 1½ turns. Raise and lower the valve stem after each tightening of the gland nut to encourage the seals to bed down correctly.

- Ensure that the valve spindle is able to travel fully open and fully closed a minimum of

5 times to ensure a smooth operation.

- Tighten the gland nut (8) by ap pr oximately ½ turn to ensure s eats ar e und er load and

re-stroke the valve.

- Commission the actuator according to the appropriate Installation and Maintenance

Instructions.

- Bring the valve back into ser vice.

- Should there be a small amount of seepage from the valve stem, this may be stopped by

carefully tightening the gland nut. Care should be taken not to overtighten as this may cause the spindle to lock-up.

Fig. 4

IM-S24-15 CH Issue 4

4.4 Procedure for renewing the valve plug and seat

- Isolate the valve on both sides.

- Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions

covering Spirax Sarco actuators.

Caution: Care should be taken in removing the bonnet since fluid under pressure may be

trapped between the isolating valves.

- Remove the lock-nut (7).

- Unscrew the four b onn et n uts (13 ) sec uri ng t he bo nnet to the bod y and remove the

bonnet (2) complete with the stem and plug (3 + 5).

- Unscrew the gland nut (8), withdraw the stem and plug (3 + 5) and remove and discard the

gland seal set (10 + 11 + 15) along with the gasket ( 6), taking care not to damage the bore of the gland nut (8). Clean the bonnet and then replace new stem and plug.

- Unscrew and remove the valve seat (4). Remove the seat gasket (16) and replace with a

new seat gasket.

- Lightly smear the threads of the new seat (4) with silicon grease and screw it into the body.

Tighten to the recommended torque (see Table 1, page 13) ensuring the valve plug is on its seat.

- Using a new bonnet gasket (12) refit the bonnet (2) onto the valve body. Replace the four

bonnet nuts (13) and tighten to the recommended torque (see Table 1, page 13).

- Fit new gland seal and gasket as described in Section 4.2. If graphite seals are used refer

to Section 4.3. Ensure the valve stem (5 ) moves freely af ter assembly.

- Bring the valve back into ser vice.

- Check for any leakage at the gland.

2 5

Fig. 5 LE33 DN15 to DN65 shown

IM-S24-15 CH Issue 4

7 8

15 13

4.5 Replacing a PTFE soft seal (DN150 and DN200 valves)

When replacing a soft seal plug / assembly, proceed as follows:

- Taking care not to damage the stem, post or head remove the 6 bolts which attach the

retaining cover (A) to the valve head (B ) and remove the old PTFE seal.

- Clean all mating surfaces and fit the new PTFE seal (C). Refit the retaining cover (A), by

assembling the 6 bolts (D) and tightening to a torque of 40 N m (30 lbf ft). The threaded holes in the valve head have locking wire thread inserts which provide a locking function for the bolts.

- Reassemble the plug / stem assembly, then reassemble the valve using a new bonnet

gasket.

- Bring the valve back into ser vice.

- Check for any leakage at the gland.

Fig. 5

IM-S24-15 CH Issue 4

4.6 Procedure for renewing stem seals on bellows sealed valves

Note: These valves are fitted with a bellows stem seal as the primary seal together with a

supplementary graphite stem seal. Any leakage from the stem will indicate a failure of the bellows seal. In normal ser vice the supplementary graphite seal should be left finger tight and only tightened to provide a temporary stem seal if the bellows stem seal is leaking.

- Isolate the valve on both sides.

- Remove the actuator from the valve. Note : take care not to rotate the valve stem when

removing the actuator from the valve, since this will destroy the bellows. Refer to the Installation and Maintenance Instructions covering Spirax Sarco actuators.

Caution: Care should be taken in removing the stem seal if the bellows has failed, since

fluid under pressure may be trapped between the isolating valves.

- Remove the lock-nut (7).

- Unscrew the gland nut (8 ), remove the gland nut gasket ( 6), remove and discard the stem

seal set (10 + 15).

- Examine the par ts for signs of damage or deterioration and renew as necessary. Note the

stem seal set on this valve is intended for emergency use in the event of bellows failure. Score marks of scaly deposits on the valve stem ( 5) will impair sealing efficiency.

- Clean the parts taking care to avoid scratching the stem or bore of the bellows assembly

top end.

- New graphite stem seal set (10 + 15), should be fitted into the bellows assembly top end,

care being taken to avoid damage (see Section 4.3).

- Refit the gland nut gasket (6) and finger tighten the gland nut ( 8) over the valve stem.

- Ensure the valve stem (5 ) moves freely.

- Refit the lock-nut (7).

Fig. 6

IM-S24-15 CH Issue 4

10 and 15

4.7 Procedure for renewing the valve plug, seat and bellows assembly (Figure 7)

Note: Due to the delicate nature of the bellows assembly, it is highly recommended that for

renewal of the stem / bellows assembly, valve plug and /or seats, the complete valve is returned to Spirax Sarco service department.

- Isolate and remove the valve from the pipeline.

Caution: Care should be taken in removing the valve since fluid under pressure may be

trapped between the isolating valves.

- Remove the actuator from the valve.

Note: take care not to rotate the valve stem when removing the actuator from the valve,

since this will destroy the bellows. Refer to the Installation and Maintenance Instructions covering Spirax Sarco actuators.

- Remove the lock-nut (7).

- Unscrew the nuts (13) securing the bonnet.

- Withdraw the bonnet (2) together with the plug stem / bellows assembly (5). Remove the

gland nut (8), gland nut gasket (6) and the stem seal set (10 + 15) see Figure 7. Unscrew the plug / stem / bellows assembly lock-nut ( 25 ) and anti-rotation screw (22) withdraw the assembly from the bonnet.

- Unscrew and remove the valve seat (4).

Note : To remove and re place seat (4 ) a special tool is required which can be obtained

from Spirax Sarco by quoting the valve size and type.

- Replace seat gasket (16) and insert the new seat (4 ) into the body. Tighten to the

recommended torque (see Table 2, below).

- Insert the new stem / bellows assembly into the bore of the new plug and secure with the

cross pin (24). The pin should be centralised within the plug and should be retained by deforming the metal around the pin hole by peening. Care should be taken to ensure that no metal is raised on the sur face of the plug diameter - any raised metal should be removed.

- Inser t the replacement plug / stem / bellows assembly ( 5 ) with new bellows ﬂange

gasket (21) and bonnet gasket (12) into the bonnet (2) taking care not to damage the bellows. Replace the bellows assembly anti-rotation washer (20) and lock-nut (25) and tighten to the recommended torque (see Table 2, below).

Table 2 Recommended tightening torques N m ( lbf ft)

Valve size

KE LE

DN15 ½" 205 (150) 40 (55) 16 (25) 25 (35)

DN20 ¾" 205 (150) 53 (72) 20 (30) 25 (35)

DN25 1" 180 (245) 90 (122) 25 (35) 25 (35)

DN32 1¼" 180 (245) 130 (176) 40 (55) 25 (35)

DN40 1½" 180 ( 245) 220 (300) 40 (55) 25 (35)

DN50 2" 180 (245) 180 (244) 60 (80) 25 (35)

DN65 2½" 220 (300) 300 (405) 47 (65) 40 (55)

DN80 3" 220 (300) 400 (545) 55 (75) 40 (55)

DN100 4" 220 (300) 600 (815) 45 (60) 40 (55)

DN150 6" 500 (678) - - -

DN200 8" 500 (678) - - -

Seat (4) Bellows housing Bellows lock-nut

nuts (13 ) (8 )

IM-S24-15 CH Issue 4

- Using a new gasket (12) reﬁt the bonnet and stem / bellows assembly onto the valve body.

While pushing the stem so that the valve plug is on the seat, tighten the bonnet nuts (13) to the recommended torque (see Table 2).

- Fit the new stem seal set (10 + 15) see Section 4.3, Figure 3 as described in Section 3.1,

ensuring that the valve stem ( 5) moves freely after assembly.

- Reﬁt the actuator and connect the actuator to the valve stem.

Note : take care not to rotate the valve stem when ﬁtting the actuator to the valve since

this will destroy the bellows. Refer to the Insta llation and Maintenance Instructions covering Spira x Sarco actuator s.

- Bring the valve back into ser vice.

- Check for leakage around all gasket joints.

6 10 and 15



Fig. 7

IM-S24-15 CH Issue 4

5. Spare parts

Spare parts - KE43, KE61, KE63, KE71 and KE73 - DN15 to DN100

All s pare parts avai lable are shown in sol id o utline. Pa rts shown in b roken li ne a re not supplied as spares.

Note: When placing an order for spares please indicate clearly the date code (found on the label of the valve body e.g. C04), this will ensure that the correct spare parts are supplied.

Available spares

Actuator clamping nut A

PTFE gland seal kit for DN15 to DN50 (gasket, chevrons, spring, upper and lower bearings, B 'O' ring and gland nut)

PTFE gland seal kit for DN65 to DN100 Gland seal kits (gasket, chevrons, guide bush and spring)

Graphite gland seal kit (H - high temperature seal) (graphite stem seals, stufﬁng box gasket) Note: The graphite gland seal kit is suitable for stufﬁng box and bonnet designs.

Plug and stem Standard plug and stem assembly with bonnet gasket D, E

Soft seated plug and stem assembly with bonnet gasket D1, E Note: Please state equal percentage, linea r o r fast opening pl ug when pl acing a n o rd er

Bonnet gasket (set of 3) E

Seat, seat gasket and bonnet gasket F, G, E

How to order spares

Always order spares by using the description given in the column headed 'Available spares' and state the size and type of valve including the date code.

Exampl e: 1 - P TFE gland seal kit for a Sp irax Sarco DN25 KE73 two- port contro l valve.

Date coded C04.

How to ﬁt spares

Full ﬁtting instructions are given in the Installation and Maintenance Instructions supplied with the spare.

IM-S24-15 CH Issue 4

DN15 - DN50

C B B1

DN40 - 100

DN65 - DN100

Valve sizes

DN15 - 50

(soft seal)

DN65 - 100

(soft seal)

Valve size

DN15 - 32

(KE71, 73, 43)

Fig. 8 KE43, KE61, KE63, KE71 and KE73 - DN15 to DN100

IM-S24-15 CH Issue 4

including

DN15 - 32

KE61, 63

Date code location

Spare parts - KEA series 6" and 8" (DN150 and DN200)

The spa re par ts available are sh own in solid outline. Parts dr awn i n broken line are not supplied as spares.

Note: When placing an order for spares please indicate clearly the date code (found on t he label of the val ve body e.g. C04) this will ensure that the correct spare part s ar e supplied.

Available spares

Actuator clamping nut A

PTFE gland seal kit for DN15 to DN50 (gasket, chevrons, guide bush and spring) Gland seal kits

(H - high temperature seal option) C (top support ring, graphite stem seal, bottom support ring)

Plug and stem Soft seated plug and stem assembly with bonnet gasket D, E

Not e: Please st ate equal percentag e, linear or fast opening plug when placing an or de r

Bonnet gasket (set of 3) E

Seat, seat gasket and bonnet gasket F, G, E

Soft seat seal kit (PTFE) sof t seal and bonnet gasket H, E

How to order spares

Always order spares by using the description given in the column headed 'Available spares' and state the size and type of valve including the date code.

Example: 1 - Seat, seat gasket and bonnet gasket for a Spirax Sarco 6" KEA73 two-port control valve Cv 280 having flanged ANSI 250 connections. Date coded C04.

How to fit spares

Full fitting instructions are given in the Installation and Maintenance Instructions supplied with the spare.

Graphite gland seal kit

Standard plug and stem assembly with bonnet gasket D, E

IM-S24-15 CH Issue 4

6" and 8"

standard plug

6" and 8" soft seal plug (2" travel only)

Fig. 9 KE A series 6" and 8" (DN150 and DN200 )

IM-S24-15 CH Issue 4

Date code location

Spare parts - LE31, LE33, LEA31 and LEA33 - DN15 to DN100

All spar e pa r ts availab le a re s hown i n so li d ou tline. Parts shown in bro ke n li ne a re n ot supplied as spares.

Note: When placing an order for spares please indicate clearly the date code (found on the label of the valve body e.g. C04) this will ensure that the correc t spare pa rts are supplied.

Available spares

Actuator clamping nut A

PTFE gland seal kit for DN15 to DN50 (gasket, chevrons, spring, upper and lower bearings, B 'O' ring and gland nut)

PTFE gland seal kit for DN65 to DN100 Gland seal kits (gasket, chevrons, guide bush and spring)

Graphite gland seal kit (H - high temperature seal) (graphite stem seals, stufﬁng box gasket) Note: The graphite gland seal kit is suitable for stufﬁng box and bonnet designs.

Plug and stem Soft seated plug and stem assembly with bonnet gasket D1, E

Not e: Please state e qual pe rc entage, linear or fast opening plug whe n pla cing an or de r

Bonnet gasket (set of 3) E

Seat, seat gasket and bonnet gasket F, G, E

Valve plug and stem kit DN15 and DN100 H, D

Valve seat only DN15 and DN100 F

How to order spares

Always order spares by using the description given in the column headed 'Available spares' and state the size and type of valve including the date code.

Standard plug and stem assembly with bonnet gasket D, E

Ex amp le: 1 - P TFE gl and seal ki t for a Spir ax Sa rco 1" LE A33 two -po rt co ntrol va lve.

Date coded C04.

How to ﬁt spares

Full ﬁtting instructions are given in the Installation and Maintenance Instructions supplied with the spare.

IM-S24-15 CH Issue 4

DN15 to DN40 and ½" to 1½"

screwed

DN15 to DN65

(½" to 2½")

screwed

and ﬂanged

(DN15 to DN50)

Valve sizes

DN15 to DN32

(DN65 to DN100)

DN40 to DN100

Valve sizes

DN65 to DN100

and 1½" screwed

DN80 to DN100

(3" to 4") screwed

and ﬂanged

Fig. 10 LE, LE33, LEA31 and LEA33 - DN15 to DN100

IM-S24-15 CH Issue 4

Date code location

Bellows sealed valve

Spares parts - KE series - DN15 to DN15 (½" to 8")

All ava ilable spare p arts are ide ntifi ed below an d cl ear ly s hown in Fi gure 11, page 29.

Note: when placing an order for spares please indicate clearly the date code (found on the label of the valve body e.g. C04) this will ensure that the correct spare parts are supplied.

Available spares

PTFE gland seal kit for DN15 to DN50 (gasket, chevrons, spring, upper and lower bearings, B 'O' ring and gland nut)

PTFE gland seal kit for DN65 to DN100 Gland seal kits (gasket, chevrons, guide bush and spring) B1

Graphite gland seal kit (B1 only) (graphite stem seals, stufﬁng box gasket) Note: The graphite gland seal is suitable for stufﬁng box and bonnet designs.

Plug and pin Soft seated plug J1, K

Note: Please state equal percentage, linear or fast opening plug when placing an order

Seat and seat gasket F, G

Bonnet gasket (pack of 3) E

Bellows gasket (pack of 6) M

B1 Spindle/bellows assembly and plug pin K, L, M

B4 Spindle/bellows assembly and plug pin K, L

Standard plug J, K

How to order spares

Always order spares by using the description given in the column headed 'Available spares' and state the size and type of valve including the date code.

Examp le: 1 - Se at and seat gasket kit fo r a S pirax S arco D N25 KE73B1 bellow se aled two-port control valve. Date coded C04.

How to fit spares

Full fitting instructions are given in the Installation and Maintenance Instructions supplied with the spare.

IM-S24-15 CH Issue 4

DN15 to DN32 and

½" to 1¼" screwed

DN40 to DN100 and

1½" to 2" screwed

DN15 t o DN3 2

(Shown in detail above)

B, B1 and C

DN40 to DN100

Fig. 11 Bellows sealed KE series - DN15 to DN200 (½" to 8")

IM-S24-15 CH Issue 4

J F

Bellows sealed valve

Spare parts - LE31B1 and LE33B1 - DN15 to DN100

All ava ilable spare p arts are ide ntifi ed below an d cl ear ly s hown in Fi gure 12, pa ge 31.

Note: When placing an order for spares please indicate clearly the date code (found on the label of the valve body e.g. C04) this will ensure that the correct spare parts are supplied.

Available spares

(graphite stem seals, stufﬁng box gasket) Gland seal kits

Note: The graphite gland seal is suitable for stufﬁng box and bonnet designs.

Plug and pin Soft seated plug D1, J

Not e: Please state e qual pe rc entage, linear or fast opening plug whe n pla cing an or de r

Seat and seat gasket F, G

Bonnet gasket (pack of 3) E

Bellows gasket (pack of 6) M

B1 Spindle/bellows assembly and plug pin H, J, M

B4 Spindle/bellows assembly and plug pin H, L

How to order spares

Always order spares by using the description given in the column headed 'Available spares' and state the size and type of valve including the date code.

Example: 1 - Seat, seat gasket and bonnet gasket for a Spirax Sarco DN25 LE33B1 Kvs 10 flanged to PN16. Date coded C04.

Graphite gland seal kit ( B1 only)

Standard plug D, J

How to fit spares

Full fitting instructions are given in the Installation and Maintenance Instructions supplied with the spare.

IM-S24-15 CH Issue 4

DN15 to DN40 and

½" to 1½" screwed

DN65 to DN100 and

1½" screwed

DN15 to DN32

(Shown in detail above)

DN40 to DN100

Fig. 12 LE31B1 and LE33B1 - DN15 to DN100

IM-S24-15 CH Issue 4

Spirax Sarco KE71, KE71B1, KE73, KE71B4, KE73B4 Installation And Maintenance Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual