KLINGER BALLOSTAR KHI Standard Operation Manual Download Page 1

Page: 1 / 31

wT 2860/02

Page 1

Issued: 08/2017
KLINGER Fluid Control GmbH
Am Kanal 8-10 » 2352 Gumpoldskirchen » Austria
[email protected] » www.klinger.kfc.at » Tel: +43 2252 600-0

Summary of Contents for BALLOSTAR KHI

Page 1: ...wT 2860 02 Page 1 Issued 08 2017 KLINGER Fluid Control GmbH Am Kanal 8 10 2352 Gumpoldskirchen Austria office klinger kfc at www klinger kfc at Tel 43 2252 600 0 ...

Page 2: ...rinciple 13 10 Mode of Operation 14 11 Installation and Putting into Service Regulations 17 11 1 Welding Instructions 17 12 Service and Maintenance 18 12 1 Disassembly 18 12 1 1 Disassembly for Seal Exchange at the Operating Stem 18 12 1 2 Disassembly of Individual Parts for Exchange of Sealing Elements 19 12 1 3 Disassembly of the Sealing Element 21 12 2 Assembly 22 12 2 1 Standard Lubricants 22 ...

Page 3: ...wT 2860 02 Page 3 1 Declaration of Conformity ...

Page 4: ...r 17 O ring 18 O ring 19 O ring spiral wound gasket 20 O ring 21 U sleeve 22 Sealing element 23 Wire ring 24 Back up ring 27 Top flange head screw 29 Circlip 30 O ring DN 700 800 1000 31 1Fillister head screw 31 2Hexagon head screw 32 Hex nut 33 Stud bolt 34 Fillister head screw 35 Trunnion hexagon head screw 36 Fitting key 37 Fitting key 38 Bearing bush 39 Bearing bush 43 Serrated washer DN 125 2...

Page 5: ...nty Please contact the manufacturer under 43 2252 600 0 for further details Subject to technical alterations and misprints 4 Testing of KLINGER Valves KLINGER Valves are pressure tested in accordance with EN 12266 1 The pressure test comprises the tests P10 P11 and P12 Testing the resistance to pressure of the ball P20 is not included in the standard package 5 Labeling of the Valves Each valve is ...

Page 6: ...f the manufacturer As a consequence when utilizing the valve it must be ensured that the valve is only utilized in accordance with its proper use as illustrated under Proper Use the actuator unit which is subsequently mounted on the valve is adjusted to the valve and correctly adjusted in the end position when connecting a valve actuator to the power grid the safety notices of the actuator manufac...

Page 7: ...ance and putting into operation When manipulating lifting appliances the safety regulations for lifting appliances must be complied with Unauthorized and improper handling can result in undesired and spontaneous pressure loss and can result in significant damage With regard to valves featuring a mounting bracket it must be ensured that moving valve parts do not result in a risk of injury Electrica...

Page 8: ...ention must be paid to exiting media when resealing Caution Fire and chemical burn hazard and risk of poisoning caused by valves utilized in dangerous media Attention must be paid to medium residues during maintenance and putting into operation tasks Maintenance and repairs may only be carried out by qualified personnel Placing out of operation hazards When placing out of operation the valves must...

Page 9: ...cid resistant Xc Stainless steel All parts acid resistant The above table may also contain material codes unavailable for this product 7 2 P T Diagrams The applicable maximum limitations of use regarding pressure and temperature are defined by their mutual interdependency A P T diagram is an ideal tool in order to select a suitable valve for pre defined operational characteristics CAUTION The diag...

Page 10: ... 540 1 200 600 M 33 1 400 1 900 700 M 36 1 900 2 400 800 M 39 2 200 2 700 1000 M 39 2 500 Tightening torques of the trunnion hexagon head screw Pos 35 Nominal size Dimension Tightening torques Nm VII VIII X Xc 125 150 M 24 270 270 200 M 30x2 540 540 250 300 M 36x1 5 900 900 350 400 M 48x1 5 2 100 2 100 500 600 M 60x2 5 300 700 800 M 85x2 19 800 1000 M 95x2 21 000 Tightening torques of the top flan...

Page 11: ...connection full bore DN Weight excl gear box Weight incl gear box 150 85 kg 103 kg 200 160 kg 180 kg 250 240 kg 286 kg 300 410 kg 468 kg 350 620 kg 685 kg 400 856 kg 970 kg 500 1 330 kg 1 535 kg 600 1 863 kg 2 068 kg 700 3 350 kg 3 742 kg 800 5 055 kg 5 447 kg 1000 7 480 kg 8 240 kg only available with welding ends ...

Page 12: ...at protective sheeting or shrinking foils are used it must be ensured through adequate measures that the atmosphere within the covers remain free of condensation Corresponding protective measures are recommended for storage in dusty rooms In order to avoid mix ups all stored parts should be labeled in accordance with the shipping notes and stored in the correct place The temperature in the storage...

Page 13: ...f the differential pressure created in the valve Fig 1 The forces generated at the ball comprising the shut off section multiplied by the prevailing differential pressure are not transmitted to the sealing rings but instead onto the trunnions for the ball installed for this purpose As a consequence in terms of construction the trunnion mounting and sealing function are decoupled from each other Th...

Page 14: ... points are continuously maintained in the bore The differential areas at the sealing element cause the pressure of the medium on the upstream side of the ball valve to press the sealing ring onto the surface of the ball If pressurization exceeding the nominal pressure originates from the cavity between the sealing rings then the sealing element on the non pressurized side or the downstream side i...

Page 15: ...all valves belonging to the pressurized pipe without hazard The medium cannot enter the repair section An operating stem is utilized to operate the ball The connection stem hub is achieved via fitting keys The tightness to atmosphere is ensured by means of consecutively arranged O rings In order to simplify their replacement they are located in the bush inserts The occurring bearing forces are abs...

Page 16: ... between the body and the end piece is sealed by means of a static O ring Fig 6a A spiral wound gasket Fig 6b is utilized for the high temperature design The parts are held together by a bolted connection i e the flanges are pressed against each other across their entire surface This serves to absorb the occurring tensile and bending forces All seals and bearings are MAINTENANCE FREE Cushion joint...

Page 17: ...ies which are not part of the medium have been removed from the pipeline system and or from the facility A pressure and a function test must be carried out prior to putting into operation Prior to putting into service of valves in steam pipes proper condensate draining must be ensured in order to avoid steam hammer hazards In extreme cases a steam hammer may lead to breaking of the valve Rapid inc...

Page 18: ...intenance work it must be ensured that the pipeline system is depressurized and that no medium residues are contained within In the event of tightness to atmosphere not being achieved at certain positions the tightening torques at the corresponding positions should be checked for their conformity with the tightening torque table When removing an actuator it is necessary to protect it against rotat...

Page 19: ...ndividual Parts for Exchange of Sealing Elements Bring valve into the OPEN position Depressurize the pipe system Remove valve from the pipe system For improved handling during disassembly of the individual parts place body on connection flange Place on an appropriate material that does not lead to damaging of the contact surface Mark the removal positions of the parts with regard to each other Fig...

Page 20: ...nto the bore of the ball careful application of force remove flat gasket Pos 13 CAUTION A washer must be used in the same amount and strength for installation Remove consoles etc Withdraw head screws Pos 31 and pull out flange Pos 7 over end of operating stem Remove washer Pos 16 5 29 13 14 12 35 Bearing Bush Pos 39 in the event of undamaged bearing surface remains in the ball hub Fig 9 Fig 10 15 ...

Page 21: ...Insert two larger screwdrivers on opposing sides into the gap between the sealing element and the body end piece push the sealing element Pos 22 and the back up ring Pos 24 out of the groove by applying leverage Remove the remaining seals Pos 18 21 from the interior CAUTION All individual parts especially seals and sealing surfaces must be diligently checked prior to installation and must be repla...

Page 22: ...e periphery of the sealing element and press down place U sleeve Pos 21 on top with closed side facing upwards lightly squeeze open side and press into the nut Insert back up ring Pos 24 and lock with wire ring open end of the wire ring in the vicinity of the trunnion It must snap on into the ring nut spread the open end in order to ensure firm seating Should bringing the wire ring into position p...

Page 23: ... body Push down with an aid device in order to align with receiving bores Bolt hexagon head screw Pos 35 with degreased soft nickel gasket Pos 14 and tighten with pre defined tensioning torque Tab 2 if necessary apply counter pressure with two pin wrench on interior side Place washer Pos 12 in the same amount and at the same height as during disassembly on the trunnion and lock with circlip Pos 29...

Page 24: ...means of a measurement device from the bore of the ball to the sealing element a Discs Pos 12 on the trunnion The space between the trunnion and the lower edge of the circlip determines the number and height of the discs Insert discs Insert circlip Pos 29 Push the ball as far as possible in the direction of the trunnion b Cushion joints Pos 16 on the top flange Comparison of measurements Projectio...

Page 25: ...sulting from improper actuator installation In case of doubt it is recommended to discuss every actuator installation with the manufacturer of the actuator and the valve Installation work may only be carried out by qualified personnel Bring ball valve into the OPEN position Mount the coupling element Attach the console to the ball valve DN 150 DN 200 or mount the actuator flange on the gear box ac...

Page 26: ...ng spiral wound gasket 202 8x3 53 222 5x206x4 5 20 2 O Ring 46 99x5 33 21 2 U Sleeve KFC 25 125 KLN 2416 22 2 Sealing element VIII KFC X KFC 125 KLN 2414 2 38 2 Bearing bush St Bz Flon AISI 316 L PTFE 90 45 50x20 39 1 Bearing bush St Bz Flon AISI 316 L PTFE 90 50 55x30 Pos Pcs Individuals Parts Designation Material Dimension VII VIII X Xc 13 1 Gasket Soft nickel 35 43x1 14 1 Gasket Soft nickel 26 ...

Page 27: ... wound gasket 304 39x3 53 344 5x328x4 5 20 2 O Ring 62 87x5 33 21 2 U Sleeve KFC 25 200 KLN 2416 22 2 Sealing element VIII KFC X KFC 200 KLN 2414 2 38 2 Bearing bush St Bz Flon AISI 316 L PTFE 90 60 65x28 39 1 Bearing bush St Bz Flon AISI 316 L PTFE 90 60 65x44 Pos Pcs Individuals Parts Designation Material Dimension VII VIII X Xc 13 1 Gasket Soft nickel 50 65x1 14 1 Gasket Soft nickel 36 55x1 15 ...

Page 28: ... wound gasket 456 06x3 53 486 5x470x4 5 20 2 O Ring 72 39x5 33 21 2 U Sleeve KFC 25 300 KLN 2416 22 2 Sealing element VIII KFC X KFC 300 KLN 2414 2 38 2 Bearing bush St Bz Flon AISI 316 L PTFE 90 70 75x40 39 1 Bearing bush St Bz Flon AISI 316 L PTFE 90 70 75x50 Pos Pcs Individuals Parts Designation Material Dimension VII VIII X Xc 13 1 Gasket Soft nickel 61 85x1 14 1 Gasket Soft nickel 50 75x1 15 ...

Page 29: ...l wound gasket 582 68x5 33 634x604x7 2 20 2 O Ring 97 79x5 33 21 2 U Sleeve KFC 25 400 KLN 2416 22 2 Sealing element VIII KFC X KFC 400 KLN 2414 2 38 2 Bearing bush St Bz Flon AISI 316 L PTFE 90 90 95x48 39 1 Bearing bush St Bz Flon AISI 316 L PTFE 90 95 100x73 Pos Pcs Individuals Parts Designation Material Dimension VII VIII X Xc 13 1 Gasket Soft nickel 75 100x1 14 1 Gasket Soft nickel 61 85x1 15...

Page 30: ...3 19 1 O Ring Spiral wound gasket 890x5 33 929x894x7 2 20 2 O Ring 126 37x6 99 21 2 U Sleeve KFC 25 600 KLN 2416 22 2 Sealing element VIII KFC X KFC 600 KLN 2414 2 38 1 Bearing bush St Bz Flon AISI 316 L PTFE 90 120 125x60 39 2 Bearing bush St Bz Flon AISI 316 L PTFE 90 120 125x100 Pos Pcs Individuals Parts Designation Material Dimension VII VIII X Xc 13 1 Gasket Soft nickel 90 130x1 14 1 Gasket 1...

Page 31: ...x1 14 1 Gasket 1 4401 90 120x1 15 1 Cushion Joint KFC 25 150 180x2 16 3 Cushion Joint K Sil 151 190x0 3 0 5 17 2 O Ring 151 77x6 99 18 2 O Ring 920x7 19 1 O Ring Spiral wound gasket 1220x5 33 1259x1225x7 2 20 2 O Ring 177 17x6 99 21 2 U Sleeve KFC 25 800 KLN 2416 22 2 Sealing element VIII KFC X KFC 800 KLN 2414 2 30 1 O Ring 120 02x5 33 38 2 Bearing bush St Bz Flon AISI 316 L PTFE 90 150 155x80 39...

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