Operating instructions

0570.82/4-10

Shut-off Valves
BOAR-H/HE
NORIR 40
NORIR 160
NORIR 320
NORIR 500
NORIR-A
NORICHEMR
BOACHEMR
Start and Stop Control
Valves
ZJSVA/ZXSVA
Non-return Valves
NORIR 40
NORIR 160
NORIR 320
NORIR-A
RGS
NORICHEMR
Strainers
NORICHEMR

1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Marking of instructions in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Personnel qualification and training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Non-compliance with safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Safety awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.5 Safety instructions for the operator / user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.6 Safety instructions for maintenance, inspection and installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.7 Unauthorized modification and manufacture of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.8 Unauthorized modes of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Description / Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.1 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.2 Drawings / documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3 List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.4 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2 Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.4 Valves with actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.5 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Commissioning / start-up / shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.1 Commissioning / start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 Servicing / maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.3 Valve reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9 Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.2 – Faults > Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

DIN ISO 9001 PED 97/23/EC

1 Declaration of conformity

Hereby we, KSB Armaturen GmbH

Bahnhofplatz 1
91257 Pegnitz
Head Office: Frankenthal (Pfalz)
Germany

declare that the valves listed below comply with the requirements of the
Pressure Equipment Directive 97/23/EC.

Description of the valve types: Shut-off Valves

– BOA-H/HE PN 25/40 DN 10-350
– NORI 40 PN 25/40 DN 10-400
– NORI 160 PN 63-160 DN 10-200
– NORI 320 (ZXLF/ZXSF) PN 250/320 DN 65-200
– NORI 320 (ZXSV) PN 250/320 DN 10-50
– NORI 500 PN 250-500 DN 10-65
– NORI-A PN 250-500 DN 10-50
– NORICHEM PN 10-40 DN 10-200
– BOACHEM PN 10-40 DN 15-100
Start and Stop Control Valves
– ZJSVA/ZXSVA Pmax. = 600 bar DN 65/60-250/125
Non-return Valves
– NORI 40 PN 25/40 DN 10-300
– NORI 160 PN 63-160 DN 10-200
– NORI 320 (RXL/RXS) PN 250-320 DN 65-200
– RGS PN 250-500 DN 10-50
– NORI-A PN 250-500 DN 10-50
– NORICHEM PN 10-40 DN 10-200
Strainers
– NORICHEM PN 10-40 DN 10-200

As per harmonized European standards Currently not applicable for valves

And other standards / directives: TRD 110, TRB 801 No. 45 and AD 2000-directive

Suitable for: Fluid groups 1 and 2

Conformity Assessment Procedure: Module H

Name and address of the notified body TÜV Süddeutschland

responsible for approval and surveillance Bau und Betrieb GmbH
Westendstr. 199
80686 München
Germany

Identification number of notified body: 0036

Certificate number: DGR-0036-QS-110-01

Valves DN ≤ 25 fall under the Pressure Equipment Directive 97/23/EC Art. 3 §3. They must bear neither the
CE-marking nor the identification number of the notified body.

Holger Dach
Quality Management
(This document has been prepared electronically and is valid without signature)

2
2 General instructions For any queries and repeat orders, in particular for purchasing spare
parts, please specify the type series / variant details, the order number,
These operating instructions apply to all KSB shut-off valves,
as well as the year of construction, if possible.
non-return valves, strainers and start and stop control valves as
described in section 5, unless reference is made to other operating The technical data (operating data) of the valves are specified in the
manuals in individual cases. technical literature (type leaflet, valve characteristic, chemical
resistance chart) of the respective valve (cf. section 5).
Only correct installation, maintenance or repair will ensure smooth
operation of the valves.
The manufacturer shall not accept any liability if the instructions set
3 Safety
forth in this manual are not complied with. These operating instructions contain fundamental information which
The design, manufacture and testing of KSB valves are subject to a QM must be complied with during installation, operation and maintenance.
system to DIN EN ISO 9001 as well as the European Pressure Therefore this operating manual must be read and understood both by
Equipment Directive 97/23/EC. Compliance with these requirements, the installing personnel and the responsible trained
however, is based on normal, static loading, e.g. personnel / operators prior to installation and commissioning, and it
– fluids without particularly corrosive, chemical or abrasive effects must always be kept close to the location of operation of the valve for
– flow velocities typical of the fluid handled easy access.
– typical temperature gradients
– without additional influences such as piping forces, vibrations, wind Not only must the general safety instructions laid down in this chapter
load, earthquakes, corrosive environment, fire, traffic load, on ”Safety” be complied with, but also the safety instructions outlined
decomposition pressure of unstable fluids, etc. under specific headings.

Other than normal operating conditions must be specified fully and 3.1 Marking of instructions in the manual
clearly in the purchase order, so that the valve manufacturer can The safety instructions contained in this manual whose
prepare and suggest suitable measures. non-observance might cause hazards to persons are specially marked
Such measures may, for example, influence with the general hazard sign, namely
– material selection
– wall thickness
– seal selection
– protection of valve areas prone to wear
– prevention of excessive pressures and temperatures
– special designs for control operation, etc.

Valves exposed to creep-rupture conditions have a limited service life

and have to meet the applicable regulations stipulated in the technical
codes. safety sign in accordance with DIN 4844 – W 9.

CAUTION The valves must not be operated outside the permissi- The electrical danger warning sign is
ble operating range. The limits are indicated on the name plate or cur-
rently applicable type leaflet. The pressure-temperature ratings, in par-
ticular, must not be exceeded. Operation of the valves outside the
above-mentioned conditions may result in overloads which may da-
mage the valves.
The type leaflets can be found at www.ksb.com – product catalogue.

Non-observance of this warning may cause personal injury and safety sign in accordance with DIN 4844 – W 8.
damage to property, for example:

– injuries resulting from fluid leakage (cold/hot, toxic,

under pressure, . . ), The word
– impairment of the valve’s function or its destruction.

The descriptions and instructions set forth in this manual refer to the CAUTION
standard models but are also applicable to variants.

For actuated valves, the operating manual of the actuator must be is used to introduce safety instructions whose non-observance may
adhered to without fail. lead to damage to the valve and its functions.
These operating instructions do not take into account:
Instructions attached directly to the valve (e. g. nominal pressure) must
– any eventualities and events which might occur during installation, always be complied with and be kept in a perfectly legible condition at
operation and maintenance, all times.
– local regulations; the operator must ensure that such regulations are
strictly observed by all, including the personnel called in for 3.2 Personnel qualification and training
installation.
All personnel involved in the operation, maintenance, inspection and
installation of the equipment must be fully qualified to carry out the work
CAUTION The valve must only be operated by skilled, properly involved. Personnel responsibilities, competence and supervision must
trained personnel. be clearly defined by the operator. If the personnel in question is not
Incorrect operation of the valve may have a substantial impact on the already in possession of the requisite know-how, appropriate training
entire system, for example: and instruction must be provided. If required, the operator may
– leakage of the fluid handled, commission the manufacturer / supplier to take care of such training. In
– system / machine brought to a standstill addition, the operator is responsible for ensuring that the contents of the
– impairment / reduction / increase of the system’s / machine’s operating instructions are fully understood by the responsible
function / effect. personnel.
For any queries you may have or in the case of damage, please contact
your nearest KSB sales office.
3
3.3 Non-compliance with safety instructions 4 Transport and storage
Non-compliance with safety instructions can jeopardize the safety of The valves are delivered ready for operation, the obturator is in ’closed’
personnel, the environment and the valve itself. Non-compliance with position and the line connection ports are closed with suitable material
these safety instructions will also lead to forfeiture of any and all rights (caps, plugs, covers).
to claims for damages.
4.1 Transport
In particular, non-compliance can, for example, result in:
Suitable precautions shall be taken to prevent damage during transport.
– failure of important valve / system functions,
– failure of prescribed maintenance and servicing practices, CAUTION The valves must never be suspended by the handwheel
– hazard to persons by electrical, mechanical and chemical effects, or by the actuator, if any.
– hazard to the environment due to leakage of hazardous substances
For transporting large valves, ropes shall be attached to the yoke arms
3.4 Safety awareness or to the cover flange.

It is imperative to comply with the safety instructions contained in this Valves with actuators shall be transported by means of ropes attached
manual, the relevant national health and safety regulations and the to the connection ports and yoke arms, taking into account the centre
operator’s own internal work, operation and safety regulations. of gravity.

Use any lifting lugs provided.

3.5 Safety instructions for the operator / user
Any hot or cold valve components (e. g. body components or For the valve weights refer to the relevant manufacturer documentation
handwheel) that could pose a hazard must be equipped with a guard (type leaflet ––> section 5.2; order confirmation).
by the operator. After delivery and prior to installation, check the valve for potential
Guards which are fitted to prevent accidental contact with moving parts damage acquired in transit.
(e.g. coupling) must not be removed whilst the unit is operating.
Leakages (e.g. at the stem seal) of hazardous media handled (e.g.
4.2 Storage
explosive, toxic, hot) must be contained so as to avoid any danger to Storage / interim storage of the valves must ensure that even after a
persons and the environment. All relevant laws must be heeded. prolonged period of storage the valves’ function is not impaired. The
following requirements must be met:
Electrical hazards must be eliminated. (For details please refer to VDE
regulations and the safety regulations laid down by the local energy
– Storage is performed with the valve in the closed position (to protect
supply companies, for instance).
the seat / disc contact faces against damage),
– Measures are taken to protect the valves against dirt, humidity, frost
3.6 Safety instructions for maintenance, and corrosion (e.g. by using foils or caps; indoor storage).
inspection and installation work
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by authorized, qualified 5 Description / Related documents
specialist personnel who are thoroughly familiar with the manual.
5.1 Marking
As a rule, work on the valve must only be carried out after the valve has The valves are marked in accordance with the Pressure Equipment
cooled down and valve pressure has been released. The fluid Directive 97/23/EC and the pertinent standards on valve types/design,
temperature must be below the vaporization temperature limit in all
as well as TRD 110 (German Steam Boiler Regulations) and TRB 801
areas in contact with the fluid.

Work on (actuated) valves must be carried out only during standstill. No. 45 (German Pressure Vessel Regulations).
The shutdown procedure described in the manual for taking the valve
out of service must be adhered to without fail. Marking includes as a minimum:
– manufacturer
Valves handling fluids injurious to health must be decontaminated. – year of construction
– type or order no.
Immediately following completion of the work, all safety-relevant and – DN
protective devices must be re-installed and / or re-activated. – PN or max. permissible pressure/temperature
– material
Please observe all instructions set out in section 7
Commissioning / start-up before returning the valve to service.
The CE marking on the valve means it is in conformity with the
European Pressure Equipment Directive 97/23/EC.
3.7 Unauthorized modification and manufacture
of spare parts Class PN DN
Modifications or alterations of the valve supplied are only permitted ≤25 32 40 50 65 80 100 125 150 ≥200
after consultation with the manufacturer. Original spare parts and 10
accessories authorized by the manufacturer ensure safety. The use of 150
other parts can invalidate any liability of the manufacturer for 16
consequential damage. 25
≥300
≥40
3.8 Unauthorized modes of operation
The warranty relating to the operating reliability and safety of the valve
supplied is only valid if the equipment is used in accordance with its
designated use as described in section 2 General of this manual. The
limits stated in the technical literature must not be exceeded under any
circumstances.

4
5.2 Drawings / documentation
The sectional drawings below provide examples of the general design / configuration of the valves. For illustrations relating to specific valve series
and further information please refer to the respective type leaflets.

5.2.1 Shut-off valves with gland packing

Type DN PN Material Type leaflet No.
NORIR 40 ZXL/ZXS 10-400 7621.1
25/40 C 22.8
22 8 / GP 240 GH+N
NORIR 40 ZXLF/ZXSF 10-200 7622.1
NORIR 160 ZXL/ZXS 10-200 63-160 7631.1
C 22.8
22 8 / 13 CrMo 44 / GP 240 GH+N / GS
GS-17
17 CrMo 55
NORIR 160 ZXLF/ZXSF 10-200 63-160 7633.1
NORIR 320 ZXLF/ZXSF 65-200 250/320 GP 240 GH+N / GS-17 CrMo 55 7653.1
NORIR 320 ZXSV 10-50 250/320 15 Mo 3 / 13 CrMo 44 / 10 CrMo 9 10/ 7640.1
15 Mo 3 / 13 CrMo 44/ 10 CrMo 9 10 /
NORIR 500 ZXSV 10-65 250-500 15 NiCuMoNb 5 / X 10 CrMoVNb 9-1 / 7641.1
X 11 CrMoWVNb 9-1-1
NORIR-A ZXLR/ZXSR 10-50 250-500 15 Mo 3 / 13 CrMo 44 / 10 CrMo 9 10 7655.1
NORICHEMR ZYA/ZXA 10-200 10-40 1.4408 8111.1

Sectional drawings (shut-off valves with gland packing)

NORICHEMR ZYA

NORIR 40 ZXL NORIR 40 ZXLF NORIR 160 ZXS NORIR 160 ZXSF

NORIR 320 ZXSV NORIR 500 ZXSV NORIR-A ZXSR NORIR 320 ZXLF
5
5.2.2 Shut-off valves with bellows

Type DN PN Material Type leaflet No.

BOAR-H/HE 10-350 7161.1

NORIR 40 ZXLBV/ZXSBV 10-200 25/40 C 22.8 / GP 240 GH+N 7168.1

NORIR 40 ZXLB/ZXSB 10-200 7165.1

BOACHEMR 10-100 7621.1

10-40
10 40 1.4408
1 4408
NORICHEMR ZYAB/ZXAB 10-200 8111.1

Sectional drawings (shut-off valves with bellows)

BOAR-H/HE NORIR 40 ZXLBV/ZXSBV NORIR 40 ZXLB/ZXSB

BOACHEMR NORICHEMR ZYAB/ZXAB

5.2.3 Start and stop control valves

Type DN PN Material Type leaflet No.

C 22.8 / 15 NiCuMoNb 5 / 15 Mo 3 /
65/60- Pmax. =
ZXSVA/ZJSVA 13 CrMo 44 / 10 CrMo 9 10 / X 20 CrMo V 12 1 / 7253.1
250/125 600 bar
X 10 CrMoVNb 9-1 / X 11 CrMoWVNb 9-1-1

Sectional drawing (start and stop control valves)

ZJSVA/ZXSVA

6
5.2.4 Non-return valves

Type DN PN Material Type leaflet No.

NORIR 40 RXL/RXS 10-300 25/40 C 22.8 / GP 240 GH+N 7673.1

NORIR 160 RXL/RXS 10-200 63-160 C 22.8 / 13 CrMo 44 / GP 240 GH+N / GS-17 CrMo 55 7681.1

NORIR 320 RXL/RXS 65-200 250/320 GP 240 GH+N / GS-17 CrMo 55 7657.1

RGS 10-50 250-500 C 22.8 / 13 CrMo 44 / 10 CrMo 9 10 7692.1

15 Mo 3 / 13 CrMo 44 /
NORIR-A RXLR/RXSR 10-50 250-500 7693.1
10 CrMo 9 10

NORICHEMR RYA/RXA 10-200 10-40 1.4408 8112.1

Sectional drawings (non-return valves)

NORIR 40 RXL NORIR 160 RXS NORIR 320 RXS RGS

NORIR-A RXSR NORICHEMR RYA

5.2.5 Strainers

Type DN PN Material Type leaflet No.

NORICHEMR FSA 10-200 10-40 1.4408 8113.1

Sectional drawing (strainer)

NORICHEMR FSA

7
5.3 List of components 5.4.2 Shut-off valves without separate bonnet
Part No. Description NORI 320 and NORI 500 shut-off valves without separate bonnet
consist of a die-forged body (100) and a forged yoke (166) which holds
100 Body the disc stem (203) or throttling disc stem (204) and the actuating
139 Bonnet element. The bayonet-type connection between body (100) and yoke
160 Cover (166) is secured against turning by a hex. head bolt (901.1) and hex. nut
166 Yoke (920.1) with spring washer (930.1).
172 Bonnet In the body (100), fluid flow is shut off by the disc stem (203) or throttling
200 Stem disc stem (204).
203 Valve disc stem
The valve seat/disc interface is made of wear-resistant material
204 Throttling disc stem
(stellite). The gland packing (461), which seals off the body (100) and
206 Upper stem the disc stem (203 or 204), is tightened at the gland cover (452) by
207 Lower stem means of two studs (902) with two hex. nuts (920.2) pressing the gland
323 Cylindrical roller bearing packing against the gland ring (457).
350 Valve disc
The throttling disc stem (204) is secured against turning by the stud
351 Check valve disc (562) on NORI 320 valves, or by a stop (579) pinned to the stem on
352 Throttling valve disc NORI 500 valves. At the same time, the pin or stop also serve to indicate
411.1 Joint ring the position of the disc inside the body.
414 Thrust plate The threaded bush (544) runs in bearings in the yoke head and is
442 Bellows supported by the bolted connection (514). The handwheel is connected
452 Gland cover to the threaded bush (544) by a key (940) and secured with a circlip.
457 Gland ring
5.4.3 Start and stop control valves
461 Gland packing
The main components of start and stop control valves are the
501 Segmental ring
block-forged body (100), the bonnet (139) with gland packing (461), the
540 Yoke bush throttling valve disc (352) rigidly connected to the stem, and the yoke
544 Threaded bush (166) with the actuating element.
562 Parallel pin
The valve features a pressure seal bonnet. The pressure inside the
579 Stop
body (100) presses the bonnet (139) against the joint ring (411.1). The
729 Intermediate flange contact faces in the body and on the throttling valve disc (352) are
758 Strainer insert stellited.
900.1 T-head bolt
The gland packing (461), which seals off the stem (200), is tightened by
901.1 Hex. head bolt means of the studs (902.3) and nuts (920.1) at the gland cover (452).
902.1 Stud
914.1 Socket head cap screws The stem (200) is moved in axial direction by a rotating threaded bush
(544) which is fitted with cylindrical roller bearings (323). It lifts off the
920.1/920.2 Hex. nut
throttling valve disc (352) or presses it against its seat in the valve body.
925 Stem nut
930.1 Spring washer The threaded bush (544) is positioned in the yoke head by an
940 Key intermediate flange (729) and socket head cap screws (914.1). The
handwheel (961) is located on the threaded bush (544) and connected
950 Spring
by a key (940). It is secured by a circlip.
961 Handwheel
5.4.4 Non-return valves
5.4 Function Non-return valves are check valves which close automatically if fluid
5.4.1 Shut-off valves with bolted bonnet flow is reversed. Non-return valves with separate cover consist of the
pressure-retaining components of body (100) and cover (160), as well
The valves consist of the pressure-retaining parts, i.e. body (100) and
as the functional unit.
yoke (166) or bonnet (172), and the functional unit.
The body (100) and cover (160) are connected by studs (902) and nuts
The body (100) and yoke (166) or bonnet (172) are connected by studs
(920.1), and the joint is sealed off by the joint ring (411).
(902) and nuts (920.1), and the joint is sealed off by the joint ring (411).
The high-pressure non-return valve RGS is in pressure seal design. It
On shut-off valves with gland packing, the trim mainly consists of the
is sealed by the bonnet (139), joint ring (411) and segmental ring (501).
valve disc (350/352), stem (200) or throttling disc stem (204); the
The joint ring is pre-loaded via the nuts (920).
actuating element is a handwheel (961) or actuator.
The check valve disc (351) is guided in the cover (160) or bonnet (139).
The stem (200) passage in the yoke (166) is sealed by the gland
The position of the check valve disc (351) is determined both by the flow
packing (461), which is tightened by means of two nuts (920.2) at the
conditions and by the spring (950), if any.
gland cover (452).
The contact faces of body (100) and/or valve disc (350) are made of 5.4.5 Strainers
rust-proof materials. Strainers feature the same pressure-retaining components and sealing
On shut-off valves with bellows and back-up gland, the trim mainly design as non-return valves with separate cover (5.4.4)
consists of the valve disc (350/352), stem (200), and bellows (442); the The strainer insert (758) is clamped between the body seat and the
actuating element is a handwheel (961) or actuator. cover, where it removes particles from the flow, depending on the mesh
The passage of the stem (200) [or lower stem (207)] in the yoke (166) size selected.
or bonnet (172) is sealed off by the bellows (442) in accordance with the
German clean air regulations. The back-up gland packing (461) is
tightened by means of two nuts (920.2) at the gland cover (452) [or
threaded bush (544) BOA-H]. The bellows-type stem seal is
maintenance-free.
The contact faces of body (100) and/or valve disc (350) are made of
rust-proof materials.

8
6 Installation 6.2.4 Strainers
6.1 General Strainers shall always be installed in such a way that the fluid flows
through the strainer insert from the inside towards the outside (cage
As a rule, the engineering contractor, construction company or effect of the strainer insert).
operator / user are responsible for the positioning and installation of the
valves. We recommend to fit shut-off valves in the pipeline on both sides of the
strainer, so that the strainer can be replaced or cleaned without having
Planning and installation errors may impair the reliable function of the to drain the entire system. Strainers shall be installed with sufficient
valves and pose a substantial safety hazard. Compliance with the clearance for removing the strainer insert. In both horizontal and vertical
following requirements is of particular importance: pipes, we recommend to install the strainer with the strainer insert
hanging downwards to facilitate cleaning. Compliance with the
CAUTION The piping must be laid such that detrimental thrust and
directional arrow is essential.
torsional forces are kept away from the valve body (100) during
installation and operation to avoid both leakage and damage to the 6.2.5 Special designs
body. Valves with separate throttling valve disc shall always be installed in
such a way that the pressure to be sealed off lies beneath the disc, to
CAUTION The caps on the connection ports shall be removed ensure a reliable throttling effect.
immediately prior to installation. For higher differential pressures integral throttling valve disc-stem
connections are required (e.g. NORI 320, NORI 500 valves). In such
cases we recommend to install the valves so that the pressure lies
When painting the pipelines and valves, do not apply paint to the above the disc.
bolts, stems and plastic components (valve function will be impaired). If you have questions concerning optimum valve selection or
If construction work is still in progress, the valves must be protected permissible differential pressures for valves with throttling discs, please
against dust, sand and building material (cover with suitable material). contact the valve manufacturer.
Do not use valve handwheels as footholds. Drainage, vent or manual start-up pipes are normally fitted with valve
combinations consisting of a shut-off valve (pressure beneath the disc)
and a throttling valve (integral throttling disc–stem connection,
For safety reasons, valves and piping systems operated at high pressure above the disc).
(> 50 °C) or low (< 0 °C) temperatures must be insulated, or a warning Valves with pilot plug are always installed so that the pressure to be
sign must point out the risk of personal injury involved when touching sealed off lies above the plug.
the hot or cold components.
If the valves are to be used as dead-end valves, double shut-off should
Valves with external moving elements must be fitted with protective be ensured for safety reasons.
covers, or other suitable measures must be taken to prevent accidents.
6.3 Installation instructions
6.3.1 Flanged valves
Valves used as dead-end valves in a pipeline should be
protected against unauthorized or unintentional opening, to prevent The mating flange faces must be clean and undamaged.
damage to property and/or personal injury.
6.2 Installation position
Align the flanges carefully before tightening the bolts. The
The valve bodies are marked with an arrow indicating flow direction, if gaskets on the mating flanges must be properly centered. Only
necessary. The valves must be installed such that the flow direction of fasteners and sealing elements made of approved materials shall be
the fluid corresponds to the direction shown by the arrow cast on the used. For the flange connection between valve and pipe use all flange
valve body. If no directional arrow is cast on the valve body, the valve bolt holes provided.
can be installed in any position.
Use suitable tools to tighten the bolts evenly and crosswise at the
6.2.1 Shut-off valves permissible torques.
Shut-off valves can be installed in any position. However, the best
installation position is with the stem pointing vertically upwards. Valves 6.3.2 Welding instructions
with bellows should not be installed with the stem pointing downwards, Responsibility for welding the valves into the piping and for any heat
if possible, to prevent dirt deposits between the folds of the bellows. treatment required lies with the pipeline contractor.
Shut-off valves must be installed in the line so as to ensure that the fluid
CAUTION When welding valves with butt or socket weld ends into
enters the valve beneath the disc and flows out above the disc.
However, they can also be installed in lines with alternating flow. If the the piping or when performing welding jobs on a pipeline after the valves
valves are to be used for throttling applications, a throttling valve disc have been installed (pipeline installation) make sure that no
must be used. For flow incidence on throttling valve discs please refer contamination enters the valve body and stays there, to prevent
to the respective type leaflets. If in doubt, please contact the KSB damage to the seat/disc interface or stem guiding elements.
factory.
CAUTION When welding the valve into the pipeline, take special
6.2.2 Start and stop control valves
precautions e.g. welding in several steps, so that the temperature rise
Start and stop control valves must be installed so that the fluid enters in the middle of the valve body does not exceed the max. permissible
the valve above the throttling valve disc (352) and flows out beneath the operating temperature. The valve must be in ’open’ position during
disc. This avoids erosion due to the more favourable downward flow welding.
and achieves better tightness in the seat.
6.2.3 Non-return valves CAUTION The welding cable (opposite pole) must not be attached
to functional valve elements, to prevent scorching.
To ensure proper operation, non-return valves must always be installed
in such a way that the fluid enters the valve beneath the check valve disc On valves with socket weld ends, the insertion depth given in the
(351). When equipped with a spring (950), they can be used in both applicable technical code must be complied with. A gap between the
pipes with upward flow and pipes with downward flow. pipe end and the socket base will prevent impermissible stresses in the
Non-return valves without closing spring (950) shall only be installed in weld.
horizontal position with the cover pointing upwards in horizontal pipes.
6.4 Valves with actuator
Valves with transmission gear and/or actuators must be installed with
the stem in vertical position, if possible. If this requirement cannot be
met, adequately support the actuator on site or consult the
manufacturer.

9
 The bonnet/cover bolting 902.1/920.1 with the joint ring (411.1) shall be
gradually tightened crosswise, evenly and in clockwise direction after
Electrical connection shall be effected by suitably trained the first loading or heating up of the valves and in the event of leakage
personnel only. at the joint ring (411.1). For tightening torques please contact the
manufacturer, if necessary.
VDE 0100 and VDE 0165 (explosion protection) regulations must be
adhered to! CAUTION Open the valve by two full handwheel turns before
All electrical equipment such as actuator, control panel, solenoid valve, re-tightening nuts 920.1, to prevent jamming of the seat.
limit switch, etc. must be installed in dry flood-proof rooms.
Re-tightening the nuts (920.1) of the bonnet/cover bolting is particularly
Voltage and frequency must correspond to the data on the name plate. important for valves installed in heat transfer systems to DIN 4754.

6.5 Insulation 7.1.4 Valves with actuator

If the valve is to be insulated, make sure that the insulation does not On valves with electric / pneumatic /hydraulic actuators, the
impair the function of the valve. In particular, make sure that the sealing strokes / actuating forces must be limited.
areas at the cover joints and at the stem passage (gland packing) are
Electrical actuators are factory-set ready for operation. They shall be
easily accessible and visible.
wired as follows:
Globe valve ”CLOSE” torque-dependent
7 Commissioning / start-up / shutdown Globe valve ”OPEN” travel-dependent
(Please also refer to section 6 Installation)
The wiring diagrams are given in the terminal boxes.
7.1 Commissioning / start-up
For pneumatic/hydraulic actuators, the control pressures specified in
7.1.1 General the order shall be complied with. Non-observance may damage the
Prior to commissioning / start-up compare the material, pressure and actuator.
temperature data on the valves with the operating conditions of the
Closing and opening torques or actuating forces shall be enquired from
piping to check the material’s chemical resistance and stability under
the manufacturer, if necessary.
load.
7.2 Shutdown
In the event of prolonged shutdowns, fluids which change their physical
Surge pressure (water hammer), which might occur, must not
condition due to changes in concentration, polymerization,
exceed the max. permissible pressure. Safety measures are required
crystallization, solidification, etc. must be drained from the piping. If
to be taken.
required, flush the piping with the valves fully opened.
In new systems and particularly after repair, the complete piping system
must be thoroughly flushed with the valves fully opened so that particles 8 Servicing / maintenance
and / or welding beads that might damage the seat/disc interface are
removed. 8.1 Safety instructions
If the piping system is cleaned by means of a pickling procedure, Repair and maintenance work must only be performed by skilled,
responsibility for the compatibility of the pickling media used and the properly trained personnel taking into account the relevant health and
pickling procedure itself lies with the pickling company. safety regulations.
Venting the valve by undoing the bonnet/cover bolting or removing the It is imperative that the below safety instructions and the general
gland packing is dangerous and therefore not permitted. information on safety as per section 2, Safety, be observed for all
To prevent damage to the valve material or joint seals, the usual start-up servicing and maintenance work to be performed.
and shutdown velocities must be adhered to.
CAUTION Always use suitable spare parts and tools, even in
7.1.2 Valve actuation emergencies, to ensure proper functioning of the valves.
The valves are closed by turning the handwheel in clockwise direction
and opened by turning it in counter-clockwise direction (top view). 8.1.1 Valve dismantling
Direction symbols are found on the top of the handwheel.
Before removing the complete valve from the pipeline or before repair
CAUTION Valves with handwheels may only be actuated by hand. or maintenance work to the valve itself, i.e.
As the valve can be damaged by applying excessive forces, it is not – prior to undoing the flange bolting between valve and pipe
allowed to use additional levers to move the handwheel. – prior to undoing the cover/yoke or pressure seal bonnet/cover from
the body
Shut-off valves are normally used in such a way that they are either fully – prior to removing any drain or vent plugs
open or fully closed. – prior to undoing the gland cover to replace packing rings
For control functions in continuous operation, throttling discs should be – prior to removing an actuator bolted directly to the yoke head
fitted. – prior to opening the yoke head for maintenance work to the bearing
and threaded bush
CAUTION Performing throttling operations without a throttling disc
may result in an excessive noise level, excessive wear or even
destruction of the valve by cavitation. valve pressure must be released and the valve must be
allowed to cool down such that the temperature is below the fluid’s
7.1.3 Functional test vaporization temperature in all areas in contact with the fluid in order to
The following functions must be checked: effectively prevent any risk of scalding.

Check the shut-off function of the installed valves prior to

commissioning / start-up by opening and closing them several times.
The gland packing (461) shall be checked for leakage when it is
subjected to full operating pressure and temperature for the first time.
Re-tighten the nuts (920.1) at the gland cover (452) evenly, if
necessary.
On valves in pressure seal design, the hex. head bolts (901.1)
pre-loading the bonnet (139) and the joint ring (411.1) must always be
tightened under operating conditions such that leakage at the
bonnet/cover, which might be caused by the bonnet (139) sinking as a
result of low pressure inside the body (100), is avoided.

10
 9.2 – Faults > Remedy
Danger of death when opening a valve under pressure! – Leakage at the seat
If toxic or easily inflammable fluids were handled, or fluids whose Possible causes:
residues may cause corrosion in conjunction with air humidity, drain the
– contaminations/solids in the fluid
valve and flush or vent it.
– erosion, corrosion, abrasion
– excessive loads from pipeline forces or thermal stresses
If required, wear safety clothing and a protective mask!
> Rework the seat / disc contact faces at the valve disc and body using
Depending on the installation position, fluid residues may be left in the a suitable reseating tool after the valve has been dismantled. The
valve; these must be collected and properly disposed of. re-seating process of the seat / disc contact faces shall be continued
until the contact faces exhibit a uniform bright surface.
Prior to any transport, flush and drain the valve thoroughly.

If you have any questions please contact the manufacturer. – Leakage at the cover gasket
Possible causes:
8.1.2 Removing actuators
– gasket has settled as a result of high temperature fluctuations
– impermissible pressure loads
– poor maintenance
If actuators powered by an external source of energy (electric, – poor gasket resistance to temperature and fluid handled
pneumatic, hydraulic) need to be removed from the valves or
dismantled, the energy supply must be shut down prior to starting any
D Bolted bonnet/cover
work and the instruction in sections 3, 8.1.1 and the operating manual
> Re-tighten the bonnet/cover bolting (902/920.1 or 902.1)
of the actuator must be observed.
> Replace the gasket (411)
after having removed the bonnet/cover bolting (902.1/920.1).
Clean the sealing surfaces carefully before inserting a new gasket.
Actuators with integrated spring mechanism contain
pre-loaded springs. They shall only be dismantled with extreme care, D Pressure seal bonnet/cover
using the requisite locking devices.
> Re-tighten the hex. head bolts (901.1) or the nuts as described in
If you have any questions please contact the manufacturer. section 7.1.3
> Replace the gasket (411.1)
8.2 Maintenance after removing the pressure seal bonnet/cover.
Clean the sealing surfaces carefully before inserting a new gasket.
All valve components have been designed to be largely
maintenance-free. The materials of the moving parts have been – Leakage at the gland packing
selected for minimum wear. To ensure reliable operation and to reduce Possible causes:
repair costs, however, all valves should be checked regularly,
particularly those rarely used or difficult to access. – worn packing material
– poor maintenance
The operator/user is responsible for fixing appropriate inspection and – poor packing resistance to temperature and fluid handled
servicing intervals as required by the service conditions of the valves.
> Re-tighten the gland packing at the nuts (920/920.2) of the gland
The service life of valves can be prolonged by:
cover (452). Make sure that the friction forces at the stem do not
– actuating the valve (open-close) at least once or twice a year increase too much.
– lubricating the movable parts such as stem (200) and gland bolts (not
for oxygen valves) with standardized lubricants to DIN 51825, > Replace the packing rings of the gland packing (461): Undo the nuts
– adding or changing packing rings in the gland packing (461) in time, (920.2) and lift off the gland cover (452).
– re-tightening or replacing the cover gasket (411.1) in time. Clean the gland packing chamber carefully before inserting new
packing rings. Split packing rings shall be inserted in such a way that
The safety instructions in sections 3 , 9.3. and the instructions in the cut edges are offset by 120°–180°.
sections 9 must be complied with.
CAUTION Do not use additional sealing agents for non-asbestos
8.3 Valve reassembly
gaskets and packing rings. With anti-adhesive coatings, only use
Valve reassembly shall be effected in reverse order to dismantling. agents explicitly recommended by the seal element manufacturer.
To maintain functional reliability, new gaskets and gland packings shall
be used whenever the valve is reassembled. If you have any questions please contact the manufacturer.

After reassembly and prior to commissioning / start-up, the valves shall

be subjected to a leak test in accordance with DIN 3230, Part 3.

9 Trouble-shooting
9.1 General
KSB valves are robust in design. Nevertheless, malfunctions e.g.
caused by maloperation, lack of maintenance or improper use cannot
be ruled out completely.

All repair and maintenance work shall be performed by skilled, properly

trained personnel using suitable tools and original spare parts.
We recommend to have this work performed by our service personnel.
The safety instructions in sections 3 and 8must be complied with.

11
 Subject to technical modification without prior notice
01.02.2003
0570.82/4-10

KSB Aktiengesellschaft
Bahnhofplatz 1 • 91257 Pegnitz (Germany)
Tel.: +49 (92 41) 71 0 • fax: +49 (92 41) 71 17 95 • e-mail: [email protected] • www.ksb.com