Contents Contents Glossary .............................. 5 General.............................. 6 Principles ................................ 6 Target group.............................. 6 Other applicable documents.......................... 6 Symbols ................................ 6 Safety .............................. 7 Key to safety symbols/markings........................ 7 General................................ 7 Intended use .............................. 8 2.3.1 Prevention of foreseeable misuse....................... 8 Personnel qualification and training....................... 8 Consequences and risks caused by non-compliance with this manual ............ 8 Safety awareness .............................. 9 Safety information for the operator/user ....................... 9 Safety information for maintenance, inspection and installation .............. 9...
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Contents 6.1.2 Valve actuation .......................... 59 6.1.3 Information on the mechanical components................... 60 Shutdown................................ 62 6.2.1 Measures to be taken for shutdown .................... 62 6.2.2 Servicing/Maintenance ........................ 62 Servicing/Maintenance ........................ 64 Safety regulations............................ 64 Trouble-shooting.......................... 65 EU Declaration of Conformity ...................... 66 EU Declaration of Conformity for STAAL 40, STAAL 100, AKG-A/AKGS-A, AKR/AKRS, ZTS, ZRS, VTS .. 66 Index ..............................
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. 5 of 68...
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.
2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER 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...
2 Safety 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.
2 Safety 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 ▪...
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2 Safety 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. 10 of 68...
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 Transport/Temporary Storage/Disposal 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! ▷...
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! ▷...
4 Valve Description 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 ...
4 Valve Description 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 Valve Description 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] Min. permissible temperature [°C] ≥ -10 Max.
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4 Valve Description ▪ 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) ▪...
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4 Valve Description 4.3.3.1.5 Materials PN 10 - 40 PN 40 DN 50 - 200 DN 250 - 600 AKDS AKDS Table 7: Parts list Part No. Description Material Material number Note Body P 250 GH 1.0460 P 265 GH 1.0425 ≥ DN 250 131.1 Connection branch P 235 GH...
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4 Valve Description 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] 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...
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4 Valve Description 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 ▪...
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4 Valve Description 4.3.3.2.5 Materials DN 50/50-250/250 DN 300/300-500/500 AKDS AKDS Table 10: Parts list DN 50/50-250/250 Part No. Description Temperature Material Material number Note [°C] Body ≤ 450 P 250 GH 1.0460 Body die-forged and welded ≤ 530 13 CrMo 4-5 1.7335 Flange ≤...
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4 Valve Description Part No. Description Temperature Material Material number Note [°C] Yoke ≤ 530 13 CrMo 4-5 1.7335 Seat/disc Body ≤ 450 X 20 CrMo 17-1 1.4115 Hard-faced interface Wedge discs ≤ 530 Stellite Stem ≤ 530 X 39 CrMo 17-1 1.4122 Joint ring 1.4541/graphite Serrated gasket Gland follower P 250 GH 1.0460...
4 Valve Description 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] Min. permissible temperature [°C] ≥ -10 Max.
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4 Valve Description 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 ▪...
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4 Valve Description 4.3.4.1.5 Materials AKG-A AKGS-A Table 15: Parts list DN 50/50-250/200 Part No. Description Temperature Material Material number Note [°C] Body ≤ 450 P 250 GH 1.0460 Body die-forged and welded ≤ 550 13 CrMo 4-5 1.7335 Flange ≤ 450 P 250 GH 1.0460 ≤...
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4 Valve Description 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 ▪...
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4 Valve Description 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 ▪...
4 Valve Description Table 19: Parts list Part No. Description Materials for operating temperatures [°C] up to Lower body section P 250 GH 15NiCuMoNb5 16 Mo 3 13 CrMo 4-5 10 CrMo 9-10 X10CrMoVNb 9-1 1.0460 1.6368 1.5415 1.7335 1.7380/ 1.4903 Upper body section 11 CrMo 9-10 X10CrWMoVNb 9-2 Main body 1.7383 1.4901 131.1...
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4 Valve Description 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) ▪...
4 Valve Description 4.4.1.4 Materials UGS: UGSV: UGSVA: without bursting disc, spring-loaded with bursting disc, spring-loaded with bursting disc, without spring loading To be used in combination with lockable globe valve only . Lead-sealed Paint dot Name plate for bursting disc Table 21: Parts list Part No.
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4 Valve Description Part No. Description Material Material number Note Hexagon nut 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.
4 Valve Description 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.
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4 Valve Description Part No. Description Temperature Material Material number Note [°C] Seat/disc Valve disc ≤ 550 °C Stainless steel 1.4370 Hard-faced interface hard-faced Joint ring ≤ 550 °C Pure graphite Segmental ring 13 CrMo 4-5 1.7335 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...
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4 Valve Description 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 42 of 68...
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4 Valve Description 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 Lower body section P 250 GH 15NiCuMoNb5 16 Mo 3 13 CrMo 4-5...
4 Valve Description 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.
5 Installation at Site 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.
5 Installation at Site 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! ▷...
5 Installation at Site 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.
5 Installation at Site 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.
5 Installation at Site 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 For pneumatic or hydraulic actuators, the control pressures specified in the order actuators confirmation must be observed.
Fig. 5: UGS/UGSV body pressure relief valve on gate valve in pressure seal design 200 mm minimum Body pressure relief valve for both ① ② distance flow directions ③ Insulation Body 131.2 Connection branch Pipe, not included in KSB’s scope of supply Pipe union 54 of 68...
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5 Installation at Site 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). 131.2 ⑤ ④ 30° Fig. 6: Closed connection branch for body pressure relief valve ④...
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5 Installation at Site Blocking device Spring-loaded body The body pressure relief valve with bursting disc is supplied fully assembled, i.e. pressure relief valve with equipped with the bursting disc. bursting disc (UGSV) The installation is performed as described above. Non-spring-loaded design Always operate the UGSVA variant in combination with a lockable globe valve.
6 Commissioning/Start-up/Shutdown 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) . ▪...
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6 Commissioning/Start-up/Shutdown 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.
6 Commissioning/Start-up/Shutdown 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.
6 Commissioning/Start-up/Shutdown 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! ▷...
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6 Commissioning/Start-up/Shutdown 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 ▪...
6 Commissioning/Start-up/Shutdown 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.
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6 Commissioning/Start-up/Shutdown 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! ▷...
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.
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...
9 EU Declaration of Conformity 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...
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