KSB BOA-Compact EKB Operating Manual
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KSB BOA-Compact EKB Operating Manual

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BOA-SuperCompact, BOA-Compact,
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  • Page 1 BOA-SuperCompact, BOA-Compact, BOA-Compact EKB, BOA-W, BOA-H, BOA-R, BOA-RVK, BOA-S 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 01/02/2018...

  • Page 3: Table Of Contents

    Commissioning/Start-up .......................... 41 Shutdown................................ 43 Servicing/Maintenance ........................ 44 Safety regulations............................ 44 Maintenance .............................. 44 Trouble-shooting.......................... 49 EU Declaration of Conformity ...................... 50 10.1 EU Declaration of Conformity for BOA-H, BOA-R .................. 50 10.2 EU Declaration of Conformity for BOA-SuperCompact, BOA-Compact, BOA-Compact EKB, BOA-W .. 51 3 of 60...
  • Page 4 Contents 10.3 EU Declaration of Conformity for BOA-RVK.................... 52 10.4 EU Declaration of Conformity for BOA-S EN-GJL-250 .................. 53 10.5 EU Declaration of Conformity for BOA-S EN-GJS-400-18-LT................ 54 Certificate of Decontamination...................... 55 Index .............................. 56 4 of 60...

  • Page 5: Glossary

    EPDM Ethylene-propylene-diene rubber Technical literature Refer to the product catalogue for the technical literature on our products at www.ksb.com. 5 of 60...

  • Page 6: General

    The manual describes the proper and safe use of this equipment in all phases of operation. In the event of damage, immediately contact the KSB sales organisation responsible in order to maintain the right to claim under warranty.

  • Page 7: Safety

    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...

  • Page 8: Intended Use

    2 Safety In the case of customised special variants, further restrictions may apply with regard to the operating mode and service life. Please refer to the relevant sales literature for this information. This operating manual does not take into account: ▪...

  • Page 9: Safety Awareness

    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 ▪...

  • Page 10: General Safety Regulations

    3 General Safety Regulations 3 General Safety Regulations DANGER Handling actuated valves Danger to life! ▷ If the valves are fitted with actuators, ensure that the actuator's operating manual is also observed. DANGER Surge pressure/water hammer potentially occurring at high temperatures Danger to life caused by burns or scalds! ▷...
  • Page 11 3 General Safety Regulations CAUTION Condensation water forming in air-conditioning, cooling and refrigerating systems Ice forming! Blockage of actuating element! Damage due to corrosion! ▷ Insulate the valve to prevent diffusion. CAUTION Improper installation Damage to the valve! ▷ Remove the caps prior to installation. ▷...

  • Page 12: Transport/Temporary 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 13: Storage/Preservation

    4. When returning valves used for handling Fluids in Group 1 (ð Section 5.2, Page 15) always complete and enclose a certificate of decontamination. Always indicate any safety and decontamination measures taken. (ð Section 11, Page 55) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination 13 of 60...

  • Page 14: Disposal

    4 Transport/Temporary Storage/Disposal 4.5 Disposal WARNING Fluids handled, consumables and supplies which are hot and/or pose a health hazard Hazard to persons and the environment! ▷ Collect and properly dispose of flushing fluid and any fluid residues. ▷ Wear safety clothing and a protective mask if required. ▷...

  • Page 15: Valve Description

    Fluids in Group 2 ≤32 ≥200 ≥40 Fig. 3: BOA-SuperCompact, BOA-Compact, BOA-Compact EKB, BOA-W und BOA-RVK Fluid groups In accordance with Article 13 Para. 1 of the current Pressure Equipment Directive, Group 1 comprises all fluids posing physical or health hazards, e.g. fluids defined as ▪ Explosive ▪...

  • Page 16: Soft-Seated Globe Valves To Din/En

    5 Valve Description Group 2 comprises all other fluids not referred to in Group 1. 5.3 Soft-seated Globe Valves to DIN/EN 5.3.1 BOA-SuperCompact 5.3.1.1 Operating data Table 5: Operating properties Characteristic Value PN 6/10/16 Nominal pressure DN 20 - 200 Nominal size Max.
  • Page 17 5 Valve Description ▪ Exterior coating: blue, RAL 5002 ▪ The valves satisfy the safety requirements of Annex I of the European Pressure Equipment Directive 2014/68/EU (PED) for fluids in Group 2. ▪ Type-tested to the specifications of Germanischer Lloyd and Bureau Veritas. Variants ▪ Lead-sealable cap (prevents unauthorised actuation) as assembly set ▪...
  • Page 18 5 Valve Description Part No. Description Material Note Retaining ring Galvanised steel DN 200 Bearing bush Stainless steel/PTFE Stop Galvanised steel DN 200 Plastic, glass-fibre reinforced, impact-resistant Insulation cap Plastic Travel stop Galvanised steel Locking device Galvanised steel Plug Plastic Travel stop Galvanised steel Stem nut...
  • Page 19 5 Valve Description 5.3.2.3 Design details Design Valves to type series booklet 7112.1 ▪ Straight-way globe valve with slanted seat ▪ Slanted seat design ▪ Short face-to-face length to DIN EN 558/14 ▪ Single-piece pressure-retaining body ▪ Non-rising handwheel ▪ Flanges to DIN EN 1092-2 Type 21 ▪...
  • Page 20 5 Valve Description 5.3.2.5 Materials DN 15-150 DN 200 shown offset by 90° Table 10: Parts list Part No. Description Material Note Body EN-GJL-250 (5.1301) Stem Stainless steel, min. 13 % chrome (Cr) Valve disc Grey cast iron/EPDM Profile seal Elastomer EPDM Retaining ring Plastic DN 20-150...
  • Page 21 5 Valve Description 5.3.3 BOA-Compact EKB 5.3.3.1 Operating data Table 11: Operating properties Characteristic Value PN 10/16 Nominal pressure DN 15 - 200 Nominal size Max. permissible pressure [bar] Min. permissible temperature [°C] Max. permissible temperature [°C] 5.3.3.2 Fluids handled ▪ Drinking water ▪...
  • Page 22 5 Valve Description 5.3.3.4 Pressure/temperature ratings Table 12: Test pressure and operating pressure Shell test Leak test (seat) Permissible operating pressure With water Tests P10 and P11 to Test P12, leakage rate A -10 to +80 °C DIN EN 12266-1 to DIN EN 12266-1 [bar] [bar] [bar] 15-200...
  • Page 23 5 Valve Description Part No. Description Material Note Travel stop Galvanised steel Locking device Galvanised steel Plug Plastic Travel stop Galvanised steel Stem nut Galvanised steel Handwheel Plastic, glass-fibre reinforced, impact-resistant DN 20-50 Aluminium, die-cast DN 65-150 Grey cast iron (5.1300) DN 200 5.3.3.6 Function The valve consists of a single-piece, pressure-retaining body 100 without a separate...
  • Page 24 5 Valve Description ▪ Flanges to DIN EN 1092-2 Type 21 ▪ Position indicator outside the insulating material ▪ Locking device, travel stop, position indicator, throttling plug and insulating cap with anti-condensation feature as standard ▪ Suitable for full insulation in acc. with German energy-saving regulations ▪...

  • Page 25: Bellows-Type Globe Valves To Din/En

    5 Valve Description Part No. Description Material Note 506.1 Retaining ring, long Plastic Galvanised steel DN 200 506.2 Retaining ring, short Plastic Galvanised steel DN 200 580.1 Plastic, glass-fibre reinforced, impact- resistant 580.2 Protective cap Plastic Insulation cap Plastic Travel stop Galvanised steel 904.1 Locking device...
  • Page 26 5 Valve Description Characteristic Value EN-GJL-250 EN-GJS-400-18-LT Max. permissible pressure [bar] ≥ -10 ≥ -10 Min. permissible temperature [°C] ≤ +300 ≤ +350 Max. permissible temperature [°C] Selection as per pressure/temperature ratings (ð Section 5.4.1.4, Page 27) 5.4.1.2 Fluids handled ▪ High-temperature hot water ▪ Saturated steam ▪ Thermal oil ▪...
  • Page 27 5 Valve Description ▪ Certification to customer specification ▪ Globe valve with gland packing and electric actuator ▪ Globe valve with gland packing and pneumatic actuator 5.4.1.4 Pressure/temperature ratings Table 18: Test pressure and operating pressure Material Shell test Leak test (seat) Permissible operating pressure [bar] 14)15) With water...

  • Page 28: Lift Check Valves To Din/En

    5 Valve Description Part No. Description Material Material number Spacer bush 15-65 Plastic, glass-fibre reinforced Collar bush Stainless steel Disc Steel 15-150 Plastic, glass-fibre reinforced, impact- resistant 200-350 Steel Hexagon head bolt 8.8 on EN-GJL-250 variant Stud C 35 E on EN-GJS-400-18-LT variant Grub screw Steel Plug...
  • Page 29 5 Valve Description Characteristic Value EN-GJL-250 EN-GJS-400-18-LT Min. permissible temperature [°C] +300 +350 Max. permissible temperature [°C] Selection as per pressure/temperature ratings (ð Section 5.5.1.4, Page 30) 5.5.1.2 Fluids handled ▪ High-temperature hot water ▪ Saturated steam ▪ Thermal oil ▪ Liquids and gases not chemically or mechanically aggressive to the valve materials.
  • Page 30 5 Valve Description 5.5.1.4 Pressure/temperature ratings Table 21: Test pressure and operating pressure Material Shell test Leak test (seat) Permissible operating pressure [bar] 17)18) With water to DIN EN 12266-1 Tests P10 and P11 to Test P12, [°C] DIN EN 12266-1 leakage rate A DIN EN 12266-1 [bar] [bar] -10 to +120...
  • Page 31 5 Valve Description 5.5.2 BOA-RVK 5.5.2.1 Operating data Table 23: Operating properties Characteristic Value PN 6 PN 6/10/16 PN 6 Nominal pressure PN 6/10/16 DN 15 - 200 DN 15 - 200 Nominal size Max. permissible pressure [bar] Min. permissible temperature [°C] +100 +250 Max.

  • Page 32: Strainers To Din/En

    5 Valve Description 5.5.2.4 Pressure/temperature ratings Table 24: Test pressure and operating pressure Shell test Leak test (seat) Permissible operating pressure [bar] 23)24) With water Tests P10 and P11 to Test P12, leakage rate [°C] DIN EN 12266-1 B to DIN EN 12266-1 [bar] [bar] 15-100 125-200 6/10/16...
  • Page 33 5 Valve Description 5.6.1.1 Operating data Table 26: Operating properties Characteristic Value EN-GJL-250 EN-GJS-400-18-LT PN 6/16 PN 16/25 Nominal pressure DN 15 - 400 DN 15 - 300 Nominal size Max. permissible pressure [bar] Min. permissible temperature [°C] +300 +350 Max. permissible temperature [°C] Selection as per pressure/temperature ratings (ð Section 5.6.1.4, Page 34) 5.6.1.2 Fluids handled ▪...
  • Page 34 5 Valve Description 5.6.1.4 Pressure/temperature ratings Table 27: Test pressure and operating pressure Material Shell and leak test Permissible operating pressure [bar] 26)27) With water Tests P10 and P11 to [°C] DIN EN 12266-1 [bar] -10 to +120 EN-GJL-250 14,4 13,4 12,8 11,8 11,2 EN-GJS-400-18-LT 15,5...

  • Page 35: Scope Of Supply

    5 Valve Description 5.6.1.6 Function The valve consists of the pressure-retaining parts, i.e. body 100, body cover 160 and screen 758. Actuating elements are not required and therefore not supplied. Body 100 and body cover 160 are joined by studs 902 and nuts 920, and the joint is sealed to atmosphere by joint ring 411.

  • Page 36: Installation At Site

    6 Installation at Site 6 Installation at Site 6.1 General information/Safety regulations The consultant, construction company or operator are responsible for positioning and installing the valves. Planning errors and installation errors may impair the reliable function of the valves and pose a substantial safety hazard. 6.2 Installation CAUTION Welding in close proximity to soft-seated valves...

  • Page 37: Soft-Seated Globe Valves To Din/En

    6 Installation at Site CAUTION Condensation water forming in air-conditioning, cooling and refrigerating systems Ice forming! Blockage of actuating element! Damage due to corrosion! ▷ Insulate the valve to prevent diffusion. ① ② ③ ④ Fig. 7: Proper diffusion-tight insulation (schematic) ①...

  • Page 38: Bellows-Type Globe Valves To Din/En

    6 Installation at Site 6.5 Bellows-type Globe Valves to DIN/EN 6.5.1 BOA-H CAUTION Installation of the valve with the stem pointing downwards Dirt collecting between the folds of the bellows! Damage to the bellows! Valve blockage! ▷ Install the valve with the stem pointing upwards or to the side. WARNING Installation of the valve with the stem pointing downwards in steam applications Damage to the valve through steam hammer!
  • Page 39 6 Installation at Site A minimum pressure is required for opening. If this minimum pressure is not reached, the spring can be dismantled. Table 32: Opening pressures (p ) as a function of flow direction in mbar ↑ Without spring ↔ ↓...

  • Page 40: Strainers To Din/En

    6 Installation at Site Provide the following straight minimum upstream stabilisation distances free from any source of potential interference, irrespective of the installation position: ▪ At least 5x DN between BOA-RVK and single sources of interference such as 90° bends, branches or open shut-off valves. ▪...

  • Page 41: Commissioning/Start-Up/Shutdown

    Direction symbols are found on the top of the handwheel. Globe valves are normally used in either "fully open" or "fully closed" position. For control duties, valves should be fitted with throttling plugs, unless throttling plugs are installed as standard. BOA-SuperCompact, BOA-Compact, BOA-Compact EKB, BOA-H DN 15-100 41 of 60...
  • Page 42 ▷ Do not use levers in the area of the position indicator. Permissible torque limits for levers The valves mentioned below can be used with suitable levers up to the following torque limits: Table 33: Permissible torque limits for BOA-SuperCompact, BOA-Compact, BOA- Compact EKB, BOA-W [Nm] Width across flats Table 34: Permissible torque limits, BOA-H...

  • Page 43: Shutdown

    7 Commissioning/Start-up/Shutdown Table 35: Widths across flats of travel stop Type series Nominal size 200 - 350 BOA-Compact BOA-SuperCompact BOA-W BOA-Control BOA-Control IMS BOA-H 5.1301 Slotted BOA-H 5.3103 Slotted 7.2 Shutdown 7.2.1 Measures to be taken for shutdown During prolonged shutdown periods, ensure that the following conditions are met: 1.

  • Page 44: Servicing/Maintenance

    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.
  • Page 45 8 Servicing/Maintenance WARNING Failure to test overhauled valves Hazard to persons and the environment! ▷ After reassembly and prior to commissioning/start-up, the valves must be subjected to shell testing and leak testing to DIN EN 12266-1. NOTE Do not apply additional sealing agents to asbestos-free gaskets. In the case of valves with anti-adhesive coatings, only use agents explicitly recommended by the sealing element manufacturer.
  • Page 46 8.2.5 Bolt lengths for flange connections Connecting elements are needed to install a valve in a pipeline. These are bolts and nuts. For BOA-SuperCompact fully threaded studs with nuts can also be used (see type series booklet 7113.1). The bolts and nuts must be selected in accordance with DIN EN 1515-4 "Flanges and their joints, Part 4, Selection of bolting".
  • Page 47 8 Servicing/Maintenance BOA-SuperCompact BOA-Compact BOA-W BOA-H BOA-R BOA-S BOA-RVK 5.1301 5.1301 5.1301 5.1301 5.1301 5.1301 4x M16 x 150 4x M16 x 55 4x M16 x 55 4x M16 x 60 4x M16 x 50 4x M16 x 100 4x M16 x 180 4x M16 x 55 4x M16 x 55 4x M16 x 60 4x M16 x 50 4x M16 x 110 8x M16 x 200 8x M16 x 60...
  • Page 48 8 Servicing/Maintenance BOA-SuperCompact BOA-Compact BOA-W BOA-H BOA-R BOA-S BOA-RVK 5.1301 5.1301 5.1301 5.3103 5.3103 8x M20 x 75 8x M20 x 75 8x M24 x 80 8x M24 x 80 8x M24 x 85 8x M24 x 85 12x M24 x 90 48 of 60...

  • Page 49: Trouble-Shooting

    If problems occur that are not described in the following table, consultation with the KSB customer service is required. Table 45: Trouble-shooting Problem Possible cause...

  • Page 50: Eu Declaration Of Conformity

    10 EU Declaration of Conformity 10 EU Declaration of Conformity 10.1 EU Declaration of Conformity for BOA-H, BOA-R KSB SE & Co. KGaA Herewith we, Johann-Klein-Straße 9 67227 Frankenthal (Germany) declare that the product: BOA-H EN-GJL-250 PN 16 DN 15-300...

  • Page 51: Eu Declaration Of Conformity For Boa-Supercompact, Boa-Compact, Boa-Compact Ekb, Boa-W

    10 EU Declaration of Conformity 10.2 EU Declaration of Conformity for BOA-SuperCompact, BOA-Compact, BOA-Compact EKB, BOA-W KSB SE & Co. KGaA Herewith we, Johann-Klein-Straße 9 67227 Frankenthal (Germany) declare that the product: BOA-SuperCompact PN 6/10/16 DN 20-200 BOA-Compact PN 6, 16 DN 15-200 BOA-Compact EKB...

  • Page 52: Eu Declaration Of Conformity For Boa-Rvk

    10 EU Declaration of Conformity 10.3 EU Declaration of Conformity for BOA-RVK KSB SE & Co. KGaA Herewith we, Johann-Klein-Straße 9 67227 Frankenthal (Germany) declare that the product: BOA-RVK PN 6/10/16 DN 15-200 satisfies the safety requirements laid down in the Pressure Equipment Directive 2014/68/EU.

  • Page 53: Eu Declaration Of Conformity For Boa-S En-Gjl-250

    10 EU Declaration of Conformity 10.4 EU Declaration of Conformity for BOA-S EN-GJL-250 KSB SE & Co. KGaA Herewith we, Johann-Klein-Straße 9 67227 Frankenthal (Germany) declare that the product: BOA-S EN-GJL-250 PN 6 DN 15-200 BOA-S EN-GJL-250 PN 16 DN 15-400 satisfies the safety requirements laid down in the Pressure Equipment Directive 2014/68/EU.

  • Page 54: Eu Declaration Of Conformity For Boa-S En-Gjs-400-18-Lt

    10 EU Declaration of Conformity 10.5 EU Declaration of Conformity for BOA-S EN-GJS-400-18-LT KSB SE & Co. KGaA Herewith we, Johann-Klein-Straße 9 67227 Frankenthal (Germany) declare that the product: BOA-S EN-GJS-400-18-LT PN 16 DN 15-300 BOA-S EN-GJS-400-18-LT PN 25 DN 15-200 satisfies the safety requirements laid down in the Pressure Equipment Directive 2014/68/EU.

  • Page 55: Certificate Of Decontamination

    11 Certificate of Decontamination 11 Certificate of Decontamination Type: ..........................Order number/ Order item number ..........................Delivery date: ..........................Field of application: ..........................Fluid handled ..........................Please tick where applicable ⃞ ⃞ ⃞ ⃞ Radioactive Explosive Corrosive Toxic ⃞ ⃞ ⃞...

  • Page 56: Index

    Index Operating data CE marking 15 BOA-Compact 18 Certificate of decontamination 55 BOA-Compact EKB 21 Commissioning/start-up 41 BOA-H 25 BOA-R 28 BOA-RVK 31 BOA-S 33 Design 16, 19, 21, 23, 26, 29, 33 BOA-SuperCompact 16 Design details BOA-W 23 BOA-Compact 19 Operating ranges 8 BOA-Compact EKB 21 BOA-R 29 Other applicable documents 6 BOA-RVK 31 BOA-S 33 BOA-SuperCompact 16 Pressure/temperature ratings BOA-W 23 BOA-Compact 19...
  • Page 60 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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