ecoline gt 40 - bluetecglossary ped the 97/23/ec or 2014/68/eu directive, also known as the pressure...

Gate Valve

ECOLINE GT 40

Operating Manual

Legal information/Copyright

Operating Manual ECOLINE GT 40

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited orprocessed for any other purpose, nor otherwise transmitted, published or made available to a third party withoutthe manufacturer's express written consent.

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft, Frankenthal 08.06.2016

Contents

Glossary ......................................................................................................................................... 5

1 General .......................................................................................................................................... 6

1.1 Principles .........................................................................................................................................................6

1.2 Target group ...................................................................................................................................................6

1.3 Other applicable documents ..........................................................................................................................6

1.4 Symbols ...........................................................................................................................................................6

2 Safety ............................................................................................................................................. 7

2.1 Key to safety symbols/markings .....................................................................................................................7

2.2 General ............................................................................................................................................................7

2.3 Intended use ...................................................................................................................................................8

2.4 Personnel qualification and training .............................................................................................................8

2.5 Consequences and risks caused by non-compliance with this manual .......................................................8

2.6 Safety awareness ............................................................................................................................................8

2.7 Safety information for the operator/user .....................................................................................................8

2.8 Safety information for maintenance, inspection and installation ..............................................................9

2.9 Unauthorised modes of operation ................................................................................................................9

3 Transport/Temporary Storage/Disposal ..................................................................................... 10

3.1 Checking the condition upon delivery ........................................................................................................10

3.2 Transport .......................................................................................................................................................10

3.3 Storage/preservation ....................................................................................................................................11

3.4 Return to supplier .........................................................................................................................................12

3.5 Disposal .........................................................................................................................................................12

4 Valve Description ........................................................................................................................ 13

4.1 General description ......................................................................................................................................13

4.2 Marking .........................................................................................................................................................13

4.3 Operating data .............................................................................................................................................13

4.4 Fluids handled ...............................................................................................................................................14

4.5 Design details ................................................................................................................................................14

4.6 Pressure/temperature ratings ......................................................................................................................14

4.7 Materials .......................................................................................................................................................15

4.8 Function ........................................................................................................................................................17

4.9 Scope of supply .............................................................................................................................................17

4.10 Dimensions and weights ..............................................................................................................................17

5 Installation at Site ....................................................................................................................... 18

5.1 General information/Safety regulations .....................................................................................................18

5.2 Installation position and location ................................................................................................................19

5.3 Welding into the pipeline ............................................................................................................................19

5.4 Valves with actuator .....................................................................................................................................20

Contents

ECOLINE GT 40 3 of 30

5.5 Insulation ......................................................................................................................................................21

6 Commissioning/Start-up/Shutdown ........................................................................................... 22

6.1 Commissioning/start-up ...............................................................................................................................22

6.2 Shutdown ......................................................................................................................................................25

7 Servicing/Maintenance ............................................................................................................... 26

7.1 Safety regulations .........................................................................................................................................26

7.2 Maintenance .................................................................................................................................................26

8 EC Declaration of Conformity ECOLINE GT 40 .......................................................................... 28

Index ............................................................................................................................................ 29

Contents

4 of 30 ECOLINE GT 40

Glossary

PED

The 97/23/EC or 2014/68/EU directive, alsoknown as the Pressure Equipment Directive,sets out the requirements to be met by pressureequipment intended to be placed on themarket in the European economic area.

Technical literature

Refer to the product catalogue for thetechnical literature on our products atwww.ksb.com.

Glossary


1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variantsindicated on the front cover. The manual describes the proper and safe use of thisequipment in all phases of operation.

In the event of damage, immediately contact the KSB sales organisation responsiblein order 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 specialisttechnical personnel.

1.3 Other applicable documents

Table 1: Overview of other applicable documents

Document ContentsType series booklet Description of the valveFlow characteristics1) Information on Kv and zeta valuesGeneral assembly drawing2) Sectional drawing of the valveSub-supplier product literature3) Operating manuals and other product literature

for the accessories

Observe the relevant manufacturer's product literature for the accessories.

1.4 Symbols

Table 2: Symbols used in this manual

Symbol Description✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions⊳ Safety instructions⇨ Result of an action⇨ Cross-references1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1) If any2) If inclusion in the scope of supply has been agreed; otherwise refer to the type series booklet.3) If inclusion in the scope of supply has been agreed.

1 General


2 SafetyAll the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

! DANGER DANGERThis signal word indicates a high-risk hazard which, if not avoided,will result in death or serious injury.

! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult in damage to the machine and its functions.General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies information aboutprotection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 General

This manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe valve operation and prevent personal injuryand damage to property.

The safety information in all sections of this manual must be complied with.

The operating manual must be read and fully understood by the specialist personnel/operators responsible prior to installation and commissioning.

The contents of this operating manual must be available to the specialist personnelat the site at all times.

Instructions and information attached directly to the valve must always be compliedwith and kept in a perfectly legible condition at all times. This applies to, forexample: flow direction arrow, manufacturer, type designation, nominal pressure,nominal size, year of construction and material.

The operator is responsible for ensuring compliance with all local regulations nottaken into account in this manual.

The design, manufacture and the testing of the valves are subject to a QM system toDIN EN ISO 9001 as well as the European Pressure Equipment Directive 97/23/EC.Compliance with these requirements, however, is based on normal, predominantlystatic loading.

Valves exposed to creep-rupture conditions have a limited service life and have tomeet the applicable regulations stipulated in the technical codes.

In the case of customised special variants, further restrictions may apply with regardto the operating mode and service life. Please refer to the relevant sales literature forthis information.

This operating manual does not take into account:

▪ Any eventualities or incidents which may occur during installation performed bythe customer, operation and maintenance.

▪ Local regulations; the operator must ensure that such regulations are strictlyobserved by all, including the personnel called in for installation.

! DANGER

2 Safety


2.3 Intended use

▪ Only operate valves which are in perfect technical condition.

▪ Do not operate partially assembled valves.

▪ The valve must only handle the fluids specified in the product literature.

▪ Only operate the valve within the permissible operating range specified forpressure and temperature.

▪ Consult the manufacturer about any other modes of operation not described inthe product literature.

Prevention of foreseeable misuse

▪ Never exceed the permissible operating limits specified in the data sheet orproduct literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this operating manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintainand inspect the product this manual refers to and be fully aware of the interactionbetween the valve and the system.

The responsibilities, competence and supervision of all personnel involved intransport, installation, operation, maintenance and inspection must be clearlydefined by the operator.

Deficits in knowledge must be rectified by means of training and instructionprovided by sufficiently trained specialist personnel. If required, the operator cancommission the manufacturer/supplier to train the personnel.

Hands-on training at the valve must always be supervised by specialist technicalpersonnel.

2.5 Consequences and risks caused by non-compliance with this manual

▪ Non-compliance with this operating manual will lead to forfeiture of warrantycover and of any and all rights to claims for damages.

▪ Non-compliance can, for example, have the following consequences:

– Hazards to persons due to electrical, thermal, mechanical and chemicaleffects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

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 and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards, directives and laws

2.7 Safety information for the operator/user

Actuator-operated valves are intended for use in areas which cannot be accessed byunauthorised persons. Operation of these valves in areas which can be accessed byunauthorised persons is only permitted if appropriate protective devices are fitted atthe site. This must be ensured by the operator.

▪ The operator shall fit contact guards for hot, cold and moving parts and checkthat the guards function properly.

2 Safety


▪ Do not remove any contact guards during operation.

▪ Provide the personnel with protective equipment and make sure it is used.

▪ Contain leakages (e.g. at the stem seal) of hazardous fluids (e.g. explosive, toxic,hot) so as to avoid any danger to persons and the environment. Adhere to allrelevant laws.

▪ Eliminate all electrical hazards. (In this respect refer to the applicable nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

2.8 Safety information for maintenance, inspection and installation

▪ Modifications or alterations of the valve require the manufacturer's priorconsent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use ofother parts can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that maintenance, inspection and installation is performedby authorised, qualified specialist personnel who are thoroughly familiar withthe manual.

▪ Carry out work on the valve during standstill only.

▪ The valve body must have cooled down to ambient temperature.

▪ The pressure in the valve body must have been released and the valve must havebeen drained.

▪ When taking the valve out of service always adhere to the procedure describedin the manual.

▪ Decontaminate valves which handle fluids posing a health hazard.

▪ As soon as the work has been completed, re-install and/or re-activate any safety-relevant and protective devices. Before returning the product to service, observeall instructions on commissioning.

2.9 Unauthorised modes of operation

Never operate the valve outside the limits stated in the data sheet and in thisoperating manual.

The warranty relating to the operating reliability and safety of the valve supplied isonly valid if the valve is used in accordance with its intended use. (⇨ Section 2.3 Page8)

Shut-off valves are not suitable for regulating volume flow.

Gate valves are used in such a way that they are either fully open or fully closed. Anintermediate position (throttling function) is not permitted.

2 Safety


3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

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 andnotify KSB or the supplying dealer (as applicable) and the insurer about thedamage in writing immediately.

3.2 Transport

Always close the valve manually before transporting it. The valve is delivered readyfor operation and its line connection ports may still be closed with caps, if applicable.Original spare parts are only ready for operation following assembly/installation andsubsequent shell and leak testing of the valve.

DANGER

The valve could slip out of the suspension arrangementDanger to life from falling parts!

▷ Only transport the valve in the specified position.

▷ Never suspend the valve from its handwheel.

▷ Pay attention to the weight data and the centre of gravity.

▷ Observe the applicable local accident prevention regulations.

▷ Use suitable, permitted lifting accessories.

▷ Transport devices (if any) on the actuator may not be suitable for beingattached to a suspension arrangement in order to transport the valve/actuatorassembly. Refer to the actuator operating manual for the permissible loads.

To transport the valve, suspend it from the lifting tackle as illustrated.



Fig. 1: Transporting the valve

3.3 Storage/preservation

A single coat of alkyd/acrylic enamel, blue RAL 5002, is applied at the factory toprotect the external surfaces. The flange faces have been coated with an anti-corrosive which can easily be removed.

The inner surfaces are protected with a fully synthetic silicone-free anti-corrosive(water hazard class 1) for long-term preservation.

If properly stored indoors, the equipment is protected for a maximum of 12 months.

If commissioning is to take place some time after delivery, we recommend that thefollowing measures be taken for storing the valve:

CAUTIONIncorrect storageDamage to the valve due to dirt, corrosion, moisture and/or frost!

▷ Store the valve in a dust- and vibration-free, frost-proof room where theatmospheric humidity is as constant as possible (use suitable caps or film forprotection).

▷ Close the valve using little force and store in the closed position.

▷ Protect the valve from contact with solvents, lubricants, fuels or otherchemicals.



NOTEFor actuated valves, also observe the actuator's operating manual.

3.4 Return to supplier

1. Drain the valve as described in the manual.

2. Always flush and clean the valve, particularly if it has been used for handlingnoxious, explosive, hot or other hazardous fluids.

3. If the fluids handled by the system leave residues which might lead to corrosiondamage when coming into contact with atmospheric humidity, or which mightignite when coming into contact with oxygen, the valve must also beneutralised and blown through with anhydrous inert gas for drying purposes.

4. When returning valves used for handling Fluids in Group 1 always complete andenclose a certificate of decontamination.Always indicate any safety and decontamination measures taken.

NOTEIf required, a blank certificate of decontamination can be downloaded from theKSB web site at: www.ksb.com/certificate_of_decontamination

3.5 Disposal

WARNINGFluids, consumables and supplies which are hot and/or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the valve.Collect greases and other lubricants during dismantling.

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 current regulations or in anothercontrolled manner.



http://www.ksb.com/GRAS-Cert

4 Valve Description

4.1 General description

The sectional drawings below provide examples of the general design/configurationof the valve. For additional and more detailed information, refer to the respectivetype series booklet.

4.2 Marking

Table 4: General marking

Nominal size DN ...Nominal pressure class or max. permissible pressure/temperature PN ... / ... bar / ...

°CManufacturer KSBType series/model or order number ECOLINE...Year of construction 20..Material .......Traceability of the material .......CE marking PED

Identification number of the notified body 0036Customer's marking e.g. plant/

system No., etc.

The CE marking on the valve indicates that it is in conformity with the EuropeanPressure Equipment Directive 97/23/EC.

Class PN DN≤25 32 40 50 65 80 100 125 150 ≥200

1016

≥25

≥≥40

150

300

Group 1 comprises fluids defined as

▪ Explosive

▪ Extremely flammable

▪ Highly flammable

▪ Flammable: The maximum allowable temperature is above flashpoint

▪ Very toxic

▪ Toxic

▪ Oxidising

Group 2 comprises all other fluids not referred to in Group 1.

4.3 Operating data

Table 5: Operating properties

Characteristic ValueNominal pressure PN 10-40Nominal size DN 50 - 600Max. permissible pressure 40 barMin. permissible temperature -10 °CMax. permissible temperature +400 °C

Selection as per pressure/temperature ratings (⇨ Section 4.6 Page 14)

Fluids in Groups 1 and 2

Fluid groups

4 Valve Description


4.4 Fluids handled

▪ Water

▪ Steam

▪ Other non-aggressive fluids such as gas or oil on request.

4.5 Design detailsDesign

Valves to type series booklet 7367.1

▪ Bolted bonnet

▪ Non-rotating stem with external screw

▪ Back seat

▪ Flexible wedge

▪ Yoke head suitable for mounting electric and pneumatic actuators (DIN ISO 5210)

▪ The valves satisfy the safety requirements of Annex I of the European PressureEquipment Directive 97/23/EC (PED) for fluids in Groups 1 and 2.

▪ The valves do not have a potential internal source of ignition and can be used inpotentially explosive atmospheres, Group II, category 2 (zones 1+21) andcategory 3 (zones 2+22) to ATEX 2014/34/EU.

Variants

▪ Stem protecting tube

▪ Stem protecting tube with position indicator

▪ Stem protecting tube with position switch

▪ Bypass

▪ Installation kit for electric actuators to EN ISO 5210 Type A

▪ Spur gear

▪ Bevel gear

▪ Electric actuators

▪ Seat/disc interface made of wear-resistant and corrosion-proof Stellite

▪ TA-Luft-compliant model for applications to VDI 2440 up to 400 °C (max.)

▪ Other flange designs

▪ Other butt weld end versions

4.6 Pressure/temperature ratings

Table 6: Permissible operating pressures in bar at temperatures in °C (to EN 1092-1)4)

Nominalpressure

Material RT5) 100 150 200 250 300 350 400

10 GP 240 GH 10,0 9,2 8,8 8,3 7,6 6,9 6,4 5,916 16,0 14,8 14,0 13,3 12,1 11,0 10,2 9,525 25,0 23,2 22,0 20,8 19,0 17,2 16,0 14,840 40,0 37,1 35,2 33,3 30,4 27,6 25,7 23,8

4) Operating pressures to DIN 2401 are also permissible5) RT: room temperature (-10 ℃ to +50 ℃)

4 Valve Description


Table 7: Test pressures

Nominal pressure Shell and leak test (body) Leak test (back seat) Leak test (seat)

With water With air

P 10, P 116) API 598 P 127)

PN [bar] [bar] [bar]10 15 11 616 24 17,6 625 38 27,5 640 60 44 6

4.7 MaterialsModel with flanged ends

PN 10-25DN 50-300

PN 40DN 50-300

515

904

961

921

514

544

166

920.2

456

452

900

461.1

563

940

500

450

411

920.1

160

200

361

902.1

100

636

902.2

920.3

461.2

515

904

514

636

544

166

920.2

456

452

900

461.1

563

940

500

450

411

920.1

160

200

361

902.1

100

961

921

902.2

920.3

461.2

PN 10-25DN 350-600

PN 40DN 350-400

6) DIN EN 12266-1 (P 10, P 11)7) DIN EN 12266-1 (P 12, leakage rate A)

4 Valve Description


Model with butt weld ends

PN 10-25DN 50-300

PN 40DN 50-300

PN 10-25DN 350-600

PN 40DN 350-400

Table 8: Parts list

Part No. Description Material Material number Note100 Body GP 240 GH 1.0619 131 Connection branch P 265 GH 1.0425 160 Bonnet GP 240 GH 1.0619 166 Yoke A 216 WCB Equivalent DIN material:

GP 240 GH200 Stem A 182 F6A Equivalent DIN material:

X 10 Cr 13361 Flexible wedge A 216 WCB Equivalent DIN material:

GP 240 GHSeat/discinterface

Body Stellite 6 Wedge discs 13 % Cr

411 Joint ring SS316-Graphit 450 Back seat A 276 410 Equivalent DIN material:

X 12 Cr 13452 Gland follower A 216 WCB Equivalent DIN material:

GP 240 GH456 Gland bush A 276 410 Equivalent DIN material:

X 12 Cr 13

4 Valve Description


Part No. Description Material Material number Note461.1 Packing ring Graphite 461.2 Graphite Packing end rings500 Neck ring A 276 410 ≥ DN 400514 Yoke bush A 29 M 1035 Equivalent DIN material:

C 35515 Seat ring A 105 P 250 GH544 Threaded bush A 439 D-2 Free from non-ferrous

metals563 Grooved pin A 29 M 1035 Equivalent DIN material:

C 35636 Lubricating nipple SS304 900 Eyebolt A 307-B Equivalent DIN material:

St 50.11902.1/.2 Stud A 193 B7 Equivalent DIN material:

24 CrMo 5904 Grub screw 920.1/.2/.3 Hexagon nut A 194 2H Equivalent DIN material:

C 35921 Slotted round nut A 29 M 1035 Equivalent DIN material:

C 35940 Key A 29 M 1035 Equivalent DIN material:

C 35961 Handwheel QT400-18 ≤ DN 350, nodular cast iron

A 29 M 1020 > DN 350Equivalent DIN material:C 22

4.8 Function

The valves consist of the pressure-retaining parts, i.e. body (100) and yoke (166), andthe functional unit.

The body (100) and yoke (166) are connected by studs (902.1) and hexagon nuts(920.1), and the joint is sealed off by the joint ring (411).

The functional unit mainly consists of a flexible wedge (361), the stem (200) and theactuating element, i.e. the handwheel (961) or actuator.

The seating faces of the body (100) and of the flexible wedge (361) are hard-faced.The gland packing (461), which seals off the stem (200), is tightened via the glandfollower (452) by means of the eyebolts (900) and the hexagon nuts (920.2).

4.9 Scope of supply

▪ Valve

▪ Operating manual for each packaging unit

4.10 Dimensions and weights

For dimensions and weights please refer to the type series booklet.

4 Valve Description


5 Installation at Site

5.1 General information/Safety regulations

The operator ensures that maintenance, inspection and installation is performed byauthorised, qualified specialist personnel who are thoroughly familiar with themanual.

Responsibility for positioning and installing the valve lies with the consultant,construction company or operator/user. Planning and installation errors may impairthe reliable function of the valve and pose a substantial safety hazard.

DANGER

Dead-end valveHigh-pressure hazard!Risk of burns!

▷ Protect the valve against unauthorised or unintentional opening.

WARNINGCold/hot piping and/or valveRisk of thermal injury!

▷ Insulate the valve.

▷ Attach warning signs.

WARNINGExposed rotating partsRisk of injury!

▷ Do not touch rotating parts.

▷ When the equipment is in operation, perform any work with utmost caution.

▷ Take suitable precautions, e.g. provide safety covers.

WARNINGImpermissible loads resulting from operating conditions and/or valve-mountedcomponents, e.g. actuatorsLeakage from or rupture of the valve body!

▷ Provide adequate support.

▷ Additional loads, e.g. traffic, wind or earthquakes are not taken into accountfor standard variants; these require a separate design.

CAUTIONCondensation water forming in air-conditioning, cooling and refrigerating systemsIce forming!Actuating element blockage!Damage due to corrosion!

▷ Insulate the valve to prevent diffusion.

CAUTIONImproper installationDamage to the valve!

▷ Remove the caps prior to installation.

▷ Clean the mating flange faces.

▷ Protect the body and bonnet/cover from any impacts.



CAUTIONOutdoor installationDamage due to corrosion!

▷ Protect the valve appropriately against moisture.

CAUTIONPainting of pipesImpairment of the valve's function and loss of information!

▷ Protect stem and plastic components prior to applying paint.

▷ Protect printed name plates prior to applying paint.

CAUTIONImpermissible loadDamage to the actuating element!

▷ Do not use the valve as a foothold.

NOTEOnly 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 boltholes provided when connecting the valve to the piping. Refer to the type seriesbooklet for details on flange connections.

NOTEFor the valves to reach the documented Kv values, the flow direction mustcorrespond to the flow direction arrow.

NOTEThe mating flange faces must be clean and undamaged and the gaskets on themating flanges must be properly centred.

NOTEUse an appropriate tool to evenly tighten the bolts crosswise, applying thepermissible torques.

5.2 Installation position and location

Any installation position can be chosen for gate valves. For gate valves installed inhorizontal pipes a vertical stem position is recommended (handwheel or actuator ontop). Installation with the stem in a horizontal or inclined position (e.g. in a verticalpipe) is permitted; in this case, however, the actuator must be adequately supported.

Make sure that the non-rising handwheel can be operated and that there is sufficientclearance available for the rising stem.

The position and flow direction must be in accordance with the manufacturer’s data.

The valve must not be fitted downstream of tees and level or three-dimensionaldouble bends.

5.3 Welding into the pipeline

Responsibility for welding the valve into the piping and for any heat treatmentrequired lies with the commissioned construction company or the plant operator.



CAUTIONWeld beads, scale and other impuritiesDamage to the valve!

▷ Take suitable measures to protect the valve against impurities.

▷ Remove any impurities from the piping.

▷ If necessary, install a strainer.

CAUTIONIncorrect earthing during welding work on the pipingDamage to the valve (scorching)!

▷ Open the valve during welding.

▷ Never earth the electric welding equipment on the valve's functional parts.

CAUTIONNon-compliance with the max. permissible application temperatureDamage to the valve!

▷ Complete the weld seam in several steps to ensure that the temperature in themiddle of the body does not exceed the max. permissible applicationtemperature.

NOTEFor valves with socket weld ends, comply with the insertion depth given in theapplicable technical code. A gap between the pipe end and the base of the weldsocket prevents impermissible stress on the weld.

5.4 Valves with actuator

Install valves with transmission gear and/or actuators with the stem in the verticalposition. If this requirement cannot be met, adequately support the actuator on siteor consult KSB.

Mounted actuators are factory-set and ready for operation. Changes to thesesettings, e.g. changes to the set switching points of the limit positions, may impairthe valve's function and result in damage to the actuator, valve or the system.

DANGER

Unqualified personnel performing work on valves with actuatorDanger of death from electric shock!

▷ Ensure that the connection to the power supply and the process control systemis performed by a trained electrician.

▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

DANGER

Work on valves with energy storage, e.g. spring mechanisms or compressed airstorageDanger to life resulting from incorrect assembly

▷ Ensure that work on the actuator is performed by qualified specialist personnel.

▷ Mount/remove the actuator in accordance with the operating manual.

NOTEIf the valves are fitted with actuators, ensure that the actuator's operating manualis also observed.



On valves with electric, pneumatic or hydraulic actuators, the actuator strokes/forcesmust be limited.

Electric actuators are 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 orderconfirmation must be observed. Non-observance may damage the actuator.

If required, consult the manufacturer for closing and opening torques or actuatingforces.

5.5 Insulation

NOTEAny insulation fitted on the valve must not impair the valve's function. The sealingareas at the cover/bonnet joint and at the stem passage (gland packing) must bedirectly accessible and visible.

Electric actuators

Pneumatic/hydraulicactuators



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 requirementsare met:

▪ The material, pressure and temperature data on the valve complies with theoperating conditions of the piping. (⇨ Section 4 Page 13) .

▪ The material's chemical resistance and stability under load have been checked.

The nominal pressure classes only apply at room temperature. For values for highertemperatures, refer to the pressure/temperature ratings tables. (⇨ Section 4 Page13) . Using the valve in conditions deviating from those specified will lead tooverload which the valves cannot withstand.

CAUTIONWelding beads, scale and other impurities in the pipingDamage to the valve!

▷ Remove any impurities from the piping.

▷ If necessary, install a strainer.

1. Thoroughly clean, flush and blow through all vessels, pipelines and connections(especially of new installations).

2. Remove the valve's flange covers before installing it in the piping.

3. Check that the inside of the valve is free from any foreign objects. Remove anyforeign objects.

4. If required, install a strainer in the piping.

DANGER

Surge pressure/water hammer potentially occurring at high temperaturesDanger to life caused by burns and scalds!

▷ The max. permissible valve pressure must not be exceeded (⇨ Section 4 Page13) .

▷ Use valves made of nodular cast iron or steel.

▷ Operator shall provide general safety measures for the system.

CAUTIONAggressive flushing and pickling agentsDamage to the valve!

▷ Match the cleaning operation mode and duration of flushing and pickling tothe body and seal materials used.

▷ Responsibility for the compatibility of the pickling media used and the picklingprocedure itself lies with the pickling company.

1. Check the shut-off function of the installed valve prior to commissioning/start-up by opening and closing it several times.

2. Check the gland packing (461) for leakage when it is subjected to full operatingpressure and operating temperature for the first time.

3. If the gland follower (452) is loose, evenly re-tighten the nuts (920.2).

4. Check the bonnet/cover bolting (902.1/920.1) and the joint ring (411) fortightness after the valve has been subjected to load conditions or heated up forthe first time.

5. To avoid stress or distortion, open the valve by approx. two full counter-clockwise handwheel turns.

Functional check



6. If the bonnet/cover bolting (902.1/920.1) has loosened, evenly re-tighten itcrosswise.

NOTERe-tightening the bonnet/cover bolting is particularly important for valves operatedat temperatures exceeding 200 °C.

On valves with electric, pneumatic or hydraulic actuators, the actuator strokes/forcesmust be limited.

DANGER

Unqualified personnel performing work on valves with actuatorDanger of death from electric shock!

▷ Ensure that the connection to the power supply and the process control systemis performed by a trained electrician.

▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

WARNINGIncorrect connection to the mainsDamage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.


1. Check the available mains voltage against the data on the name plate of theactuator.

2. Select an appropriate start-up method.

Electric actuators are 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 orderconfirmation must be observed. Non-observance may damage the actuator.

If required, consult the manufacturer for closing and opening torques or actuatingforces.

Shut-off valves are not suitable for regulating volume flow. Gate valves are used insuch a way that they are either fully open or fully closed. An intermediate position(throttling function) is not permitted.

6.1.2 Valve actuation

NOTEViewed from above, the valve is closed by turning the handwheel in clockwisedirection, and opened by turning the handwheel in counter-clockwise direction.Direction symbols are found on the top of the handwheel.

CAUTIONExcessively long idle periodsDamage to the valve!

▷ Check the function by opening and closing the valve at least once or twice ayear.

Actuated valves



CAUTIONUse of leversDamage to the valve as a result of excessive forces!

▷ Only actuate handwheel-operated valves by hand.

▷ Levers may only be used in exceptional cases and in compliance with thefollowing tables.

▷ Do not use levers in the area of the position indicator.

6.1.3 Information on the mechanical components

6.1.3.1 Moving parts

The valve/actuator combination comprises moving parts which are not fully enclosed.Depending on the type and design, these include the following:

▪ Stem

▪ Stop

▪ Position switches

▪ Coupling

▪ Other force-transmitting equipment

Depending on the actuator type and design, further moving parts may be present,e.g. emergency handwheels turning along with the actuator.

Valve commissioning/start-up is not permitted until both valve ends have beenconnected to the pipeline and any risk of injuries can be ruled out.

6.1.3.2 Electric actuator overtravel

Depending on the mass to be accelerated, electric actuators may be subject to acorresponding overtravel effect. Take into account this overtravel effect when settingthe actuator.


6.1.3.3 Self-locking function

As standard, the trapezoidal stem thread is self-locking. For special designs, e.g.multiple threads, the self-locking function is taken over by the actuator assembly.The self-locking effect may be reduced over time due to wear.

6.1.3.4 Uncontrolled movements

In the following cases, the valve's position may change in an uncontrolled mannerdue to the system's pressure with resultant effects on the plant:

▪ Control failure

▪ Signal error

▪ Power supply failure during operation

▪ Incorrect actuator setting

▪ De-activation of the position switches in the actuator



6.2 Shutdown

6.2.1 Measures to be taken for shutdown

During prolonged shutdown periods, ensure that the following conditions are met:

1. Drain fluids which change their physical condition due to changes inconcentration, polymerisation, crystallisation, solidification, etc. from thepiping.

2. If required, flush the piping with the valves fully opened.



7 Servicing/Maintenance

7.1 Safety regulations

The operator ensures that maintenance, inspection and installation is performed byauthorised, qualified specialist personnel who are thoroughly familiar with themanual.

DANGER

Valve under pressureHigh-pressure hazard!Leakage of hot and/or toxic fluids!Risk of burns!

▷ The valve and its surrounding system must be depressurised prior to anymaintenance and installation work.

▷ If the bellows are defective or fluid escapes, ensure the valve is depressurised.

▷ Ensure the valve is depressurised before removing any drain, opening or ventplugs.

▷ Allow the valve to cool down so that the temperature is below the fluid'svaporisation temperature in all areas in contact with the fluid in order toeffectively prevent any risk of scalding.

▷ Never vent the valve by removing the bonnet/cover bolting or gland packing.

▷ Use appropriate spare parts and tools, even in emergencies.

WARNINGFluids, consumables and supplies which are hot and/or pose a health hazardRisk of injury!

▷ Observe all relevant laws.

▷ When draining the fluid take appropriate measures to protect persons and theenvironment.

▷ Decontaminate valves used for handling fluids posing a health hazard.

NOTEBefore removing the valve from the piping, ensure that the pipe has been takenout of service and released for repair/maintenance work.

A regular maintenance schedule will help avoid expensive repairs and contribute totrouble-free, reliable operation of the valve with a minimum of maintenanceexpenditure and work.

NOTEAll maintenance, service and installation work can be carried out by KSB Service orauthorised workshops. For contact details please refer to the enclosed "Addresses"booklet or visit "www.ksb.com/contact" on the Internet.

Never use force when dismantling and reassembling the valve.

7.2 Maintenance

This valve has been designed to be largely maintenance-free. The materials of thesliding parts have been selected for minimum wear.

NOTEThe user is responsible for defining appropriate intervals for checks andmaintenance, depending on the application of the valve.



NOTEIf several valves are serviced at the same time, take appropriate measures toprevent the dismantled parts from getting mixed up.

The service life can be extended by taking the following measures:

▪ Checking the function by opening and closing the valve at least once or twice ayear

▪ Lubricating the moving parts such as stem (200) and gland bolts usingappropriate lubricants (e.g. lubricants suitable for high temperatures)

▪ Adding or replacing packing rings in the gland packing (461) in time

▪ Re-tightening or replacing the bonnet/cover gasket (411) in time

After reassembly and prior to commissioning/start-up, the valves must be subjectedto shell and leak testing to DIN EN 12266-1.

Testing overhauled valves



8 EC Declaration of Conformity ECOLINE GT 40Herewith we, KSB Valves (Changzhou) Co., Ltd.

No. 68 Huanbao Four Road, Environment Protection IndustrialPark,

Xinbei District,Changzhou CityJiangsu Province

P. R. China

declare that the product:

Gate valve ECOLINE GT 40 PN 10-40 DN 50 - 600

satisfies the safety requirements laid down in the Pressure Equipment Directive 97/23/EC (until 18 July 2016) and2014/68/EU (from 19 July 2016).

Codes applied:AD 2000-Merkblatt HP 0 / A 4 and EN ISO 3834-2

Suitable for:Fluids in Groups 1 and 2

Conformity assessment procedure:Module H

Name and address of the notified body responsible for approval and surveillance:TÜV SÜD Industrie Service GmbHWestendstraße 19980686 München (Germany)

Identification number of the notified body:0036

This Declaration of Conformity also confirms the conformity of the casting suppliers for ECOLINE GT 40 with therequirements of Pressure Equipment Directive 97/23/EC (until 18 July 2016) and 2014/68/EU (from 19 July 2016) and"AD 2000-Merkblatt HP 0" regarding the materials used for the pressure-retaining parts.

Jason Ji Head of Quality Management This document has been prepared electronically and is valid without a signature.

8 EC Declaration of Conformity ECOLINE GT 40


Index

AApplications 8

CCE marking 13Commissioning/start-up 22

DDisposal 12

FFluids in Group 1 13Fluids in Group 2 13Function 17

IIntended use 8

MMaintenance 26Marking 13Materials 16Misuse 8

OOperating data 13Other applicable documents 6

PPressure Equipment Directive 97/23/EC 13Pressure/temperature ratings 14

RReturn to supplier 12

SSafety 7Safety awareness 8Scope of supply 17Shutdown 25Storage 11

TTransport 10

WWelding into the pipeline 19

Index


7367

.8/0

3-EN

KSB AktiengesellschaftJohann-Klein-Straße 9 • 67227 Frankenthal (Germany)Tel. +49 6233 86-0 • Fax +49 6233 86-3476E-Mail: [email protected] • www.ksb.com

ecoline gt 40 - bluetecglossary ped the 97/23/ec or 2014/68/eu directive, also known as the pressure...

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