Glossary Glossary Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 2016 The product regulations Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 2016 lay down rules to be met by equipment and protective systems intended for use in potentially explosive atmospheres in the United Kingdom (except Northern Ireland).
The operating 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.
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1 General Symbol Description 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.
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 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.
2 Safety 2.2.1 Prevention of foreseeable misuse ▪ Never exceed the permissible application and operating limits specified in the data sheet or product literature regarding temperature, etc. ▪ Observe all safety information and instructions in this manual. 2.3 Personnel qualification and training ▪...
2 Safety 2.7 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.
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/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 due to dirt, corrosion, humidity 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! ▷...
4.1.1 Product information as per Regulation No. 1907/2006 (REACH) For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see https:// www.ksb.com/ksb-en/About-KSB/Corporate-responsibility/reach/ 4.1.2 Product information as per Pressure Equipment Directive 2014/68/EU (PED) 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.
4 Valve Description Class PN Fluids in Groups 1 and 2 80 100 125 150 ≥200 ≤25 ≥ ≥ ≥40 Fig. 2: CE marking Class PN ≤25 80 100 125 150 ≥ ≥ ≥40 Fig. 3: UKCA marking Fluid groups In accordance with the current regulations or directives for pressure equipment, Group 1 comprises: all fluids posing physical or health hazards, e.g.
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4 Valve Description 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 ▪...
4 Valve Description 4.3.2 STAAL 100 AKD/AKDS 4.3.2.1 General description ▪ Gate valve with bolted bonnet Valve for preventing backflow in industrial plants, power stations, process engineering and shipbuilding. 4.3.2.2 Design details Design Fig. 5: STAAL 100 AKD/ AKDS ▪ Body of forged or welded steel construction ▪...
4 Valve Description 4.4 Gate valves to DIN/EN in pressure seal design 4.4.1 AKG-A/AKGS-A 4.4.1.1 General description ▪ Gate valve with pressure seal bonnet Valve for preventing backflow in industrial plants, power stations, process engineering and shipbuilding. 4.4.1.2 Design details Design Fig. 6: AKG-A/AKGS-A ▪...
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4 Valve Description For fitting a body pressure relief valve, (ð Section 4.5.1, Page 21) (see type series booklet 7300.1) a connection branch 131.2 with connection dimensions Ø 22 mm / 14.1 mm (or 12.3 mm) is welded to body 100. The connection branch is supplied closed. Body pressure relief valves, if ordered, are supplied unassembled, i.e. attached loosely to the gate valve.
4 Valve Description 4.4.2 ZTS 4.4.2.1 General description ▪ Gate valve with pressure seal bonnet Valve for preventing backflow in industrial plants, power stations, process engineering and shipbuilding. 4.4.2.2 Design details Design Fig. 8: ZTS ▪ Body made of forged steel ▪...
4 Valve Description Wedge/disc holder 367 is screwed onto stem 200. A retainer prevents wedge discs 360 from twisting in wedge/disc holder 367. To prevent twisting of the obturator components, the wedge/disc holder is guided in the body by lateral guide ribs 752. The valve is equipped with a pressure seal bonnet.
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4 Valve Description ▪ The blow-off pressure is set via the threaded insert. ▪ Stellited seat ▪ Lead-sealed screw prevents unauthorised manipulation of set blow-off pressure. Variants ▪ Bursting disc (UGSV and UGSVA) ▪ Blocking device ▪ With lockable shut-off valve 4.5.1.3 Heating up of trapped liquids The problem of trapped liquids heating up primarily concerns gate valves.
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4 Valve Description Spring-loaded body The body pressure relief valve with pre-fitted bursting disc basically consists of two pressure relief valve with assemblies: bursting disc (UGSV) ▪ 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.
4 Valve Description 4.6.2 STAAL 100 AKK/AKKS 4.6.2.1 General description ▪ Swing check valve with bolted cover Valve for preventing backflow in industrial plants, power stations, process engineering and shipbuilding. 4.6.2.2 Design details Design Fig. 12: STAAL 100 AKK/ AKKS ▪ Body of forged or welded steel construction ▪...
4 Valve Description 4.7 Swing check valves with pressure seal cover 4.7.1 AKR/AKRS 4.7.1.1 General description ▪ Swing check valve with pressure seal cover Valve for preventing backflow in industrial plants, power stations, process engineering and shipbuilding. 4.7.1.2 Design details Design Fig. 13: AKR/AKRS ▪...
4 Valve Description Variants ▪ Flanged ends ▪ Minimum flow nozzle ▪ Other butt weld end versions ▪ Inspections to technical codes such as TRD/TRB/AD2000 – German Steam Boiler / Pressure Vessel Regulations – or to customer specification 4.7.2.3 Function Design The swing check valve is equipped with a pressure seal cover.
4 Valve Description 4.8.1.3 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 fully threaded stud 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 are 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 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.
5 Installation at Site 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 Installation at Site CAUTION Change of limit switch points Impairment of the functional reliability! Damage to the actuator! ▷ Never change the pre-set limit switch points. Mounted actuators are factory-set and ready for operation. DANGER Unqualified personnel performing work on valves with actuator Danger of death from electric shock! ▷...
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5 Installation at Site 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. CAUTION Outdoor installation Damage due to corrosion! ▷ Provide weather-proof protection to protect the valve against moisture. For any insulation fitted on the valve observe the following: ▪...
5 Installation at Site 5.6 Body pressure relief valve 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. ▷...
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Pipe, not included in KSB’s scope of supply Pipe union All KSB gate valves with pressure seal bonnet are factory-supplied with a closed connection branch 131.2 with connection dimensions Ø 22 mm / Ø 14.1 mm (or 12.3 mm), suitable for a pipe of Ø 21.3 mm × 3.6 mm (or 4.5 mm).
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5 Installation at Site Fig. 19: Position of connection branch 131.2 ① Type ZTS ② Type AKG-A, AKGS-A On gate valves for PN ≥ 63 with bodies made of P 250 GH (1.0460) the connection branch and pipe union 731 are also made of P 250 GH (1.0460). The gate valve body is also available in the higher quality material 13 CrMo 4-5 (1.7335).
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5 Installation at Site 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.
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5 Installation at Site Part No. Description Material Material number X 39 CrMo 17-1 1.4122 Pipe union P 250 GH 1.0460 13 CrMo 4-5 1.7335 10 CrMo 9-10/ 1.7380 11 CrMo 9-10 1.7383 X 10 CrMoVNb 9-1 1.4903 Screw-type body 9 SMn28 k Bolt Hexagon head bolt Hexagon nut Disc spring Inconel 718 Spring-loaded body The body pressure relief valve with bursting disc is supplied fully assembled, i.e.
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 data and temperature data of the valve are compatible with the operating conditions of the piping. ▪...
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6 Commissioning/Start-up/Shutdown CAUTION Aggressive flushing liquids and pickling agents Damage to the valve! ▷ Ensure that cleaning procedure and duration match the valve body materials and seal materials when performing flushing and pickling. ▷ 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! ▷...
6 Commissioning/Start-up/Shutdown 6.1.3.4 Uncontrolled movements In the following cases, the valve disc'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 6.3 Shutdown 6.3.1 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 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...
NOTE All maintenance work, service work and installation work can be carried out by KSB Service or authorised workshops. For contact details refer to the enclosed "Addresses" booklet or visit "www.ksb.com/contact" on the Internet.
▷ 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 service is required. Table 18: Trouble-shooting Problem Possible cause...
9 Related Documents 9.2 General assembly drawing with list of components for STAAL 100 AKD/ AKDS DN 50/50 - 250/250 DN 300/300 - 600/600 AKDS AKDS Fig. 22: Sectional drawings of STAAL 100 AKD/AKDS Table 21: Parts list DN 50/50 - 250/250 Part No. Description Temperature Material Material number Note...
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9 Related Documents Part No. Description Temperature Material Material number Note [°C] Joint ring ≤ 530 1.4541/graphite Serrated gasket Gland follower P 250 GH 1.0460 Neck ring G-X70 CrMo 292 1.4136 461.1/.2 Gland packing Graphite Compression-moulded rings (with packing end rings) Threaded bush Cu Zn 35 Ni 2 2.0540 On axial needle bearing 902.1...
9 Related Documents 9.3 General assembly drawing with list of components for AKG-A/AKGS-A AKG-A AKGS-A Fig. 23: Sectional drawings of AKG-A/AKGS-A Table 23: Parts list DN 65/80 - 300/250 Part No. Description Temperature Material Material number Note [°C] Body ≤ 450 P 250 GH 1.0460 Body die-forged and welded ≤...
9 Related Documents 9.4 General assembly drawing with list of components for ZTS DN 50/50 - 200/175 DN 50/50 - 200/175 461.2 461.1 461.2 461.2 461.1 461.1 131.2 131.2 131.1 Fig. 24: Sectional drawings; ZTS 1) With connection branch extensions 2) Without connection branch extensions Table 24: Parts list Part...
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9 Related Documents Part Description Materials for operating temperatures [°C] up to Threaded bush Copper base alloys Handwheel Steel 59 of 72...
9 Related Documents 9.5 General assembly drawing with list of components for UGS 32-2 32-2 550.1 550. 550.2 550.2 UGS: without bursting disc, spring- UGSVA: with bursting disc, not UGSV: with bursting disc, spring- loaded spring-loaded, to be used in loaded combination with lockable globe valve only...
9 Related Documents 9.6 General assembly drawing with list of components for STAAL 40 AKK/ AKKS AKKS Fig. 26: Sectional drawings of STAAL 40 AKK/AKKS Table 26: Parts list Part No. Description Material Material number Note Body P 235 GH 1.0345 P 265 GH 1.0425 131.1 Connection branch P 235 GH 1.0305 Body cover...
9 Related Documents 9.7 General assembly drawing with list of components for STAAL 100 AKK/ AKKS DN 80/80 - 250/250 DN 300/300 - 400/400 AKKS Fig. 27: Sectional drawings of STAAL 100 AKK/AKKS Table 27: Parts list DN 80/80-250/250 Part No. Description Temperatur Material Material number Note e [°C]...
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9 Related Documents Table 28: Parts list DN 300/300 - 400/400 Part No. Description Temperatur Material Material number Note e [°C] 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 Flange ≤ 450 P 250 GH/ 1.0460/1.0425 P 265 GH...
9 Related Documents 9.8 General assembly drawing with list of components for AKR/AKRS AKRS Fig. 28: Sectional drawings of AKR/AKRS Table 29: Parts list Part No. Description Temperatur Material Material number Note e [°C] Body ≤ 450 °C P 250 GH 1.0460 Body die-forged and welded ≤...
9 Related Documents 9.9 General assembly drawing with list of components for ZRS DN 50/50 - 200/175 DN 200/200 - 500/450 Fig. 29: Sectional drawings of ZRS Table 30: Parts list Part No. Description Materials for operating temperatures [°C] up to Lower body section P 250 GH 15NiCuMoNb5 16 Mo 3...
9 Related Documents 9.10 General assembly drawing with list of components for VTS Fig. 30: VTS Table 31: Parts list Part No. Description Materials for operating temperatures [°C] up to Body P 250 GH 15NiCuMoNb5 16 Mo 3 13 CrMo 4-5 10 CrMo 9-10 X10CrMoVNb 9-1 Hard-faced with 1.0460 1.6368 1.5415 1.7335 1.7380/...
10 EU Declaration of Conformity 10 EU Declaration of Conformity 10.1 EU Declaration of Conformity for STAAL 40, STAAL 100, AKG-A/AKGS- A, AKR/AKRS, ZTS, ZRS, VTS, UGS Herewith we, KSB SE & Co. KGaA Bahnhofplatz 1 91257 Pegnitz Registered office: Frankenthal (Pfalz) Germany...
11 UK Declaration of Conformity 11 UK Declaration of Conformity 11.1 UK 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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