KSB MIL 41000 Installation & Operating Manual
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KSB MIL 41000 Installation & Operating Manual

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Control Valve
MIL 41000
Installation/Operating Manual

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Summary of Contents for KSB MIL 41000

  • Page 1 Control Valve MIL 41000 Installation/Operating Manual...
  • Page 2 All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without the manufacturer's express written consent. Subject to technical modification without prior notice. © KSB SE & Co. KGaA, Frankenthal 2023-08-25...

  • Page 3: Table Of Contents

    General information/Safety regulations ....................... 18 Installation position............................ 18 Preparing the valve ............................ 19 Piping ................................ 19 Valves with actuator............................ 21 Insulation ................................ 22 Commissioning/Start-up/Shutdown.................... 23 Commissioning/Start-up .......................... 23 Operating Limits ............................. 23 Shutdown................................ 24 Returning to service ............................ 24 Servicing/Maintenance ........................ 25 Safety regulations............................ 25 Servicing/inspection............................ 26 Tightening torques............................ 40 MIL 41000 3 of 52...
  • Page 4 Contents Trouble-shooting.......................... 43 Related Documents .......................... 45 General assembly drawing with list of components .................. 45 EU Declaration of Conformity for MIL 41000.................. 47 Certificate of Decontamination...................... 48 Index .............................. 49 MIL 41000 4 of 52...

  • Page 5: Glossary

    Pressure Equipment Directive 2014/68/EU (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. MIL 41000 5 of 52...

  • Page 6: General

    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.
  • Page 7 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. MIL 41000 7 of 52...

  • Page 8: Safety

    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. MIL 41000 8 of 52...

  • Page 9: Personnel Qualification And Training

    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.) MIL 41000 9 of 52...

  • Page 10: Safety Information For Maintenance, Inspection And Installation

    (ð Section 6.1, Page 23) 2.8 Unauthorised modes of operation ▪ The valve is operated outside the limits stated in the operating manual. ▪ The valve is not operated in accordance with the intended use. (ð Section 2.2, Page 8) MIL 41000 10 of 52...

  • Page 11: Transport/Storage/Disposal

    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.
  • Page 12 1. Upon receipt, unpack the valve and check it for in-transit damage. 2. Report any in-transit damage to the manufacturer immediately. 3. Dispose of packaging material in accordance with local regulations. MIL 41000 12 of 52...

  • Page 13: Storage/Preservation

    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. MIL 41000 13 of 52...

  • Page 14: Description Of The Valve

    With pressure-energised polymer seal ring (static) With pressure-energised polymer seal ring (dynamic) With pilot plug With metal seal ring With polymer seal ring High flow, unbalanced With pilot plug, soft-seated With graphite seal ring Trim characteristic Undefined Linear Equal-percentage MIL 41000 14 of 52...

  • Page 15: Marking

    Group 1 comprises all fluids posing physical or health hazards, e.g. fluids defined as ▪ Explosive ▪ Extremely flammable ▪ Highly flammable ▪ Very toxic ▪ Toxic ▪ Oxidising Fluid group 2 comprises all other fluids not referred to in Group 1. MIL 41000 15 of 52...

  • Page 16: Name Plate

    ▪ Rangeability 50:1 for version with anti-cavitation / low-noise trim ▪ Extended bonnet: temperature range -100 °C to -30 °C ▪ Cryogenic bonnet: temperature range -196 °C to -100 °C ▪ Flanged body with raised-face flanges (RF) ▪ Flanged body with ring joint flanges (RTJ) MIL 41000 16 of 52...

  • Page 17: Function

    80 dB in acc. with IEC 60534-8-4. Unfavourable piping layouts or off- design operating conditions may give rise to physical phenomena like cavitation, resulting in significantly higher sound pressure levels. MIL 41000 17 of 52...

  • Page 18: Installation At Site

    (position 5a). Avoid any installation positions with the actuator hanging downward (positions 3 and 4, risk of malfunction). Fig. 4: Installation positions The valve bodies are marked with an arrow indicating the flow direction. MIL 41000 18 of 52...

  • Page 19: Preparing The Valve

    ▷ Protect printed name plates prior to applying paint. 5.4.1 Flange connection Fasteners Only use fasteners and sealing elements of approved materials. Always use all flange bolt holes provided when connecting the valve to the pipe. MIL 41000 19 of 52...
  • Page 20 ▷ 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)! ▷ Never earth the electric welding equipment on the valve’s functional parts. MIL 41000 20 of 52...

  • Page 21: Valves With Actuator

    Changing the stroke The stroke can be changed on site. ▪ Shortening stroke: Extend the stem by the respective difference. ▪ Extending stroke: Shorten the stem by the respective difference. For a new stem, contact the manufacturer. MIL 41000 21 of 52...

  • Page 22: Insulation

    ▷ Insulate the valve. ▷ Fit warning signs. For any insulation fitted on the valve observe the following: ▪ The valve's function must not be impaired. ▪ The bonnet must remain freely accessible and visible. MIL 41000 22 of 52...

  • Page 23: Commissioning/Start-Up/Shutdown

    17,7 1500 258,6 258,6 257,6 250,8 243,2 231,8 214,4 206,6 200,1 189,2 173,6 143,8 115,0 85,4 57,9 29,5 2500 430,9 430,9 429,4 418,1 405,4 386,2 357,1 344,3 333,5 315,3 289,3 239,7 191,7 142,4 96,5 49,2 MIL 41000 23 of 52...

  • Page 24: Shutdown

    6.4 Returning to service For returning the equipment to service, observe the sections on commissioning/start- up (ð Section 6.1, Page 23) and the operating limits (ð Section 6.2, Page 23) . In addition, carry out all servicing/maintenance operations before returning the valve to service. (ð Section 7, Page 25) MIL 41000 24 of 52...

  • Page 25: Servicing/Maintenance

    Before removing the valve from the piping, ensure that the pipe has been taken out of service and released for repair/maintenance work. NOTE All maintenance work, service work and installation work can be carried out by KSB Service or authorised workshops. Find your contact in the attached Addresses booklet or visit https://www.ksb.com/en-global/contact.

  • Page 26: Servicing/Inspection

    ▷ Always have lapping performed by trained personnel. ▷ Use a suitable paste for lapping. ▷ Ensure that line contact is maintained. Maintain the different seating surface angles of pilot plug, valve disc and seat ring. MIL 41000 26 of 52...
  • Page 27 57° 30' Fig. 8: Seating surface angles ① Valve disc ② Pilot plug Seat ring ③ Table 11: Seating surface angles Version Angle A Angle B [°] [°] MIL 41100 MIL 41200 MIL 41300 MIL 41400 MIL 41500 MIL 41000 27 of 52...
  • Page 28 As an alternative: Drill a hole through a flat steel plate and fasten the plate to the stem using two locknuts. 5. Apply slight pressure and rotate the stem (1) in short back and forth turns (approx. 8 to 10 times). MIL 41000 28 of 52...
  • Page 29 15. Carefully pull out the stem/valve disc assembly (1/14). 16. Thoroughly clean the seating surfaces of the seat ring (16) and valve disc (14). 17. Remove the cage (15), the seat ring (16) and the spiral wound gasket (11) from the body (18). MIL 41000 29 of 52...
  • Page 30 ▷ Always have repair work and maintenance work performed by specially trained, qualified personnel. Always observe the safety instructions and information. (ð Section 7, Page 25) In the event of damage you can always contact KSB Service. 7.2.4.2 Preparing the valve 1. Interrupt the power supply and make sure it cannot be switched on again unintentionally.
  • Page 31 1. Pull the stem/valve disc assembly (1/14) upwards and out of the body (18). ð This removes the valve disc (14) and cage (15) from the body (18). 2. Lift the cage (15) off the stem (1). MIL 41000 31 of 52...
  • Page 32 Valve sizes 3 in. or 4 in. (80 mm or 100 mm) 1. Apply pressure on the pilot plug (20). 2. Remove the circlip (21). 3. Pull the pilot plug (20) and spring (22) off the valve disc (14). MIL 41000 32 of 52...
  • Page 33 7.2.5.2 Fitting the gland packing NOTE Always replace the complete gland packing. In an emergency, string packing may be used as a temporary repair measure only. A new gland packing as specified must be installed as soon as possible. MIL 41000 33 of 52...
  • Page 34 Drilled hole in valve disc guiding sec- Pin diameter tion Valve disc shank Drilled hole position Spanner size Shouldered stem: correct pin position F Pin length Standard stem: correct pin position Distance of reference marking MIL 41000 34 of 52...
  • Page 35 ð The reference mark should be flush with the end of the valve disc guiding section. 5. Shouldered stem: Screw the stem (1) tightly into the valve disc (14), observing the specified tightening torque. MIL 41000 35 of 52...
  • Page 36 ð The reference mark should be flush with the end of the valve disc guiding section. 5. Shouldered stem: Screw the stem (1) tightly into the valve disc (14), observing the specified tightening torque. MIL 41000 36 of 52...
  • Page 37 MIL 41300 MIL 41200 MIL 41500 MIL 41600 MIL 41900 Fig. 13: Detailed views of sealing elements Cage Valve disc Clamping cage Backing ring Seal ring Tec Seal ring Static pressure-energised seal ring (PTFE + Ekonol) MIL 41000 37 of 52...
  • Page 38 2. The joints of the seal rings are arranged offset from each other by 180 °. 3. Insert the cage (15) into the body (8) and onto the seat ring (16). 4. Insert the valve disc (14) into the cage (15). MIL 41000 38 of 52...
  • Page 39 7.2.5.6 Installing the bonnet ü The required spare parts are available. ü All dismantled parts have been cleaned and checked for wear. ü Any damaged or worn parts have been replaced by original spare parts. MIL 41000 39 of 52...

  • Page 40: Tightening Torques

    - 10 UNC - 2 A 2500 - 8 UN - 2 A 2500 - 8 UN - 2 A 1480 900 - 1500 - 11 UNC - 2 A 2500 - 11 UNC - 2 A MIL 41000 40 of 52...
  • Page 41 /2 - 8 UN - 2 A 2990 - 8 UN - 2 A 1470 3000 M 56 x 4,5 4300 ≤ 300 - 8 UN - 2 A ≤ 300 M 36 x 4 M 42 x 4,5 1680 MIL 41000 41 of 52...
  • Page 42 - 8 UN - 2 A 5750 12 x 8 2500 - 8 UN - 2 A 4790 14 x 10 2500 - 8 UN - 2 A 4090 M 48 x 5 1800 M 56 x 4,5 1900 MIL 41000 42 of 52...

  • Page 43: Trouble-Shooting

    ▷ 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 19: Trouble-shooting Fault Possible cause...
  • Page 44 Tighten the gland packing to the spe- cified tightening torque . The valve does not respond Problem with the interaction of actu- Check actuator and accessories. properly to the control com- ator and fitted accessories mand. MIL 41000 44 of 52...

  • Page 45: Related Documents

    ≤ 180 °C Graphite > 180 °C Spacer ring / lantern ring 304 SST Bonnet ASTM A216 Gr. WCC ASTM A217 Gr. WC6 ASTM A217 Gr. WC9 ASTM A217 Gr. C5 / C12 / C12A Recommended spare parts MIL 41000 45 of 52...
  • Page 46 CA6NM + Stellite No. 6, chrome- ≤ 343 °C plated CA6NM + Stellite No. 6, nitrided > 343 °C Circlip Spring steel ≤ 343 °C Inconel X 750 > 343 °C Spring Spring steel ≤ 343 °C Inconel X 750 > 343 °C Guide bush MIL 41000 46 of 52...

  • Page 47: Eu Declaration Of Conformity For Mil 41000

    10 EU Declaration of Conformity for MIL 41000 10 EU Declaration of Conformity for MIL 41000 Hereby we, KSB MIL Controls Limited Meladoor, Annamanada -680741 Thrissur District, Kerala India declare that the product: Control valve MIL 41000 Class 150 - 3000 NPS ½...

  • Page 48: Certificate Of Decontamination

    We confirm that the above data and information are correct and complete and that shipping is effected in accordance with the relevant legal provisions....................................Place, date and signature Address Company stamp Required fields MIL 41000 48 of 52...

  • Page 49: Index

    Fluids in Group 1 15 Fluids in Group 2 15 Insulation 22 Intended use 8 Key to safety symbols/markings 6 Maintenance 25 Marking 15 Materials 45 Name plate 16 Noise characteristic 17 Operating limits 8, 24 Other applicable documents 6 Piping 19 Reassembly 33 Return to supplier 13 Returning to service 24 MIL 41000 49 of 52...
  • Page 52 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com KSB MIL Controls Limited Meladoor, Annamanada, Pin 680 741 Thrissur Dist., Kerala (India) Tel : +91 (480) 2695700 Fax : + 91 (480) 2890952 E-Mail: sales.mil@ksb.com...

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