SERIES: KM-O(ST) & KM-T(ST) FLANGED BALL VALVE

Transcription

1 FLANGED BALL VALVE as per EC Pressure Equipment Directive 2014/68/EU and as (incomplete machine) as per EC Machinery Directive 2006/42/EC KUGELHAHN-MUELLER.DE YOUR SPECIALIST FOR BALL VALVES

2 CONTENTS DECLARATION OF CONFORMITY AS PER EC DIRECTIVES 1. PRODUCT INFORMATION Bill of Material design Bill of Material O-ring design GENERAL Intended use Pressure + temperature Limits Safety notes on installation, operation and maintenance Ball valve marking Transport and storage INSTALLATION INTO THE PIPE Notes Installation steps Pressure test and commissioning Additional information: Valve disassembly NORMAL OPERATION Maintenance Troubleshooting ASSESSMENT OF BALL VALVE AS PER DIRECTIVE 94/9/EC (ATEX) INFORMATION FROM MANUFACTURER You can download the mentioned (data sheets) and other data and information also in English at kugelhahn-mueller.de or contact us at: KUGELHAHN MÜLLER GMBH Subsidiary of Bray International, Inc. Kölner Straße 686 D Krefeld E: info@kh-m.de T: F: of 17

3 KUGELHAHN MÜLLER GMBH Subsidiary of Bray International, Inc. Kölner Str. 686 D Krefeld T: F: DECLARATION OF CONFORMITY AS PER DIRECTIVE 2014/68/EC AND MANUFACTURER'S DECLARATION AS PER DIRECTIVE 2006/42/EC The manufacturer Kugelhahn Müller GmbH, D Krefeld, Kölner Straße 686, declares that the valves: Flanged ball valves with and O-ring seal at the shaft of Series O and T > with lever or gear with handwheel > with pneumatic, electric or hydraulic actuator > with bare shaft for subsequent actuator assembly comply with the directives mentioned below as follows: Pressure Equipment Directive 2014/68/EC (PED): [only if Art. 3 Clause 1.3 or Art. 3 Clause 3 applies]: The valves are conform with this directive. The conformity assessment procedure applied as per Annex III of the Pressure Equipment Directive 2014/68/EC is for category I to III, module H1. - Category IV does not apply to isolation valves. The valves can be used for various fluids within the permissible pressure and temperature limits, taking the respective influences on the pressure equipment into consideration. Use in fluid group 1 and 2 is permitted. The fluid resistance of the valve incl. the components shall be checked for the operating conditions prior to use. Machinery Directive 2006/42 EC (MD) [applies only if the valve is operated other than by hand]: The vale is an "incomplete machine" within the meaning of Art. 1 and is intended for installation in a pipe system as complete machine. The listing of conformity with the clauses of the Machine Directive as per page 2 and 3 of this declaration and the provided (original installation instructions OM-OST/TST) shall be observed by the planner / user. In relation to the directives above, the following applies: 1. The user shall follow the "intended use" as defined in the above instructions (OM-OST/TST) included with the delivery and observe all safety-relevant notes in these instructions. Disregard of these instructions can release manufacturer from his product liability. 2. The commissioning of the valve (and, where applicable, of the attached actuator) is not permitted until the conformity of the system into which the valve is installed, with all relevant European Directives, is declared by the person responsible and risk of injury is thus ruled out. The manufacturer Kugelhahn Müller GmbH has performed and documented all necessary risk analyses. For the carbon steel used, a corrosion allowance is neither required nor taken into account for the calculation. Standards and rules applied: DIN EN 12516, AD2000 regulations, DIN EN ISO 9001, DIN EN ISO 12100:2009, DIN EN ISO 5211, DIN EN 1983, DIN EN Type description OXST-F1/F27 OX-F1/F27 OAST-F1/F27 OA-F1/F27 Dimension sheets MB OST.00, MB OST.00, MB O.00, MB O.00, TXST-F1/F27 TX-F1/F27 TAST-F1/F27 TA-F1/F27 no special tools required for replacement of wear parts MB TST.00, MB TST.00, MB T.00, MB T.00, Conformity assessment procedures applied: according to Annex III of Pressure Equipment Directive 2014/68/EC; Module H1 Name of notified body: TÜV Rheinland Industrie Service GmbH Am Grauen Stein, Köln Changes to ball valves and/or components that impact the technical data of the ball valve, the (intended use) as per section 1 of these instructions and significantly modify the valve or a provided component make this declaration null and void. ID-number of notified body: 0035 Signature: Name: George Crooks Position: Managing Director Date: 23 March 2018 Management Craig C. Brown George Crooks Register court District court Krefeld HRB 1747 VAT-ID-No.: DE National Bank AG Duisburg SWIFT-BIC: NBAG DE 3 E IBAN: DE

4 DECLARATION AS PER EC-DIRECTIVES Requirement as per Annex I MD 2006/42/EC The following applies to ball valves as per list on page 2 if supplied with actuator: g) Intended use See installation and operating instructions c) Foreseeable misuse See installation and operating instructions c) Required protective equipment Same as for pipe section into which the valve is installed e) Accessories No special tools required for replacement of wear parts Wetted parts The materials of the wetted parts are specified in the type data sheet as well as in the order confirmation issued by Kugelhahn Müller. It is assumed that the user carries out a respective risk analysis concerning the resistance to the operating fluid Handling Satisfied by the notes in the installation and operating instructions 1.2 and Control system Is the responsibility of the user in accordance with the documentation of the actuator Preventing breakage For parts under pressure: See Declaration of Conformity to PED 2014/68EC. For functional parts: Ensured when actuator is used as intended Sharp edges or angles Requirements fulfilled /.8 Risks related to moving parts Requirements are fulfilled when used as intended Energy supply Is the responsibility of the user. Also refer to documentation of the actuator Operating temperature Warnings against unauthorized exceedance: see installation and operating instructions, sections (intended use) and (safety notes) Explosion When used in potentially explosive atmosphere: -Protection required for actuator. Must be explicitly agreed on in purchase contract Emission of dangerous substances Not applicable Maintenance See operating instructions. Clarify storage of wear parts with manufacturer Marking Valve: As per section 3 of installation and operating instructions. Actuator: See documentation of actuator manufacturer Operating instructions The installation and operating instructions contains notes on the operation of the valve during regular industrial use as per section 1 of these instructions. Any additions required to the operating instructions of the (complete machine) in case of special application are the responsibility of the planner / user. Annex III Annexes IV, VIII-XI The valve is not a (complete machine): Therefore, there is no CE marking for conformity with the machinery directive. Not applicable. Requirements as per EN Scope Basis for the analysis is the Product Standard EN1983: (Metallic ball valves) with actuator. The basis is also formed by the long-standing experience in the use of the valve types mentioned on page 2. Note: It must be assumed that the user carries out a risk analysis specifically adapted to the operating conditions as per clauses 4 to 6 of EN for the pipe section, including the valves installed therein. Kugelhahn Müller cannot carry out such an analysis for standard valves. 3.20, 6.1 Inherently safe design The valves are designed in accordance with the principle of (inherently safe design). Analysis as per clauses 4, 5 and 6 Experiences with malfunctions and misuse documented at the manufacturer within the scope of claims (documentation as per ISO 9001) served as basis. 5.3 Limits of the machine The limits of the (incomplete machine) were defined as per the (intended use) on both the valve and the actuator. 5.4 Decommissioning, disposal Not the responsibility of the manufacturer Kugelhahn Müller Geometrical factors This section does not apply since valve and actuator are enclosed by the movable functional parts during intended use Technical protective devices If applicable, only required for accessories - see order confirmation Operating instructions Since actuated valves operate "automatically" according to the commands from the control system, the operating instructions describe aspects that are (typical for valves).. 7 Risk analysis The risk analysis has been carried out and documented as per MD Annex VII, B) by manufacturer Kugelhahn Müller. 3 of 17

5 1. PRODUCT INFORMATION 1.1 BILL OF MATERIAL TEFLON DESIGN TYPE TXST-F1/F27 TYPE TAST-F1/F27 STEEL DN 15 DN 200 PN 10/16 PN 40 STAINLESS STEEL Item Qty Designation Materials Item Qty Designation Materials 1 1 Valve body / Counter flange F1/F / Ball / Ball seat PTFE/25% Glass 5 1 Shaft / Spring Guide bushing PTFE-P 8 1 Stuffing box / Package PTFE 12 1 Slide ring PTFE 13 1 Valve body seal PTFE 14 Hexagon screws A Stop pin Hand lever Disk Stainless steel 18 1 Spring washer DIN 127 A Belleville spring Pressure piece / Cylinder screws DIN 912 A of 17

6 PRODUCT INFORMATION 1.2 BILL OF MATERIAL O-RING DESIGN TYP OXST-F1/F27 STAINLESS STEEL TYP OAST-F1/F27 STEEL DN 15 DN 200 PN 10/16 PN 40 Item Qty Designation Materials Item Qty Designation Materials 1 1 Valve body / Counter flange F1/F / Ball / Ball seat PTFE/25% Glass 5 1 Shaft / Spring Hexagon screw A Stop pin Hand lever Disk Stainless steel 15 1 Spring washer DIN 127 A Cylinder screws DIN 912 A Guide bushing PTFE-P 8 1 Slide ring PTFE 9 3 O-ring Viton 10 1 Valve body seal PTFE 5 of 17

7 2. GENERAL These instructions are intended to assist the user during installation, operation and maintenance of ball valves. The instructions also require the observation of all pipe-specific rules that apply to the ball valves. If an actuator is attached, the relevant manufacturer s instructions shall be observed in addition. 2.1 INTENDED USE After installation into a pipe system, these ball valves are exclusively intended to shut off or transport fluids within the approved pressure and temperature limits. During installation, operation and maintenance observe the safety notes contained in section 2. These ball valves are operated either by lever, gear with handwheel or pneumatic / electrical / hydraulic actuator. The table (Pressure and temperature applications for KM flanged ball valves) contains a description of the approved pressure and temperature limits for the ball valves. When using the valve, the information on the valve - see section 3 - shall be observed, particularly in regard to the valve body material. The ball valves can be used as end valve. During normal operation at nominal pressure, especially when using gaseous, hot and/or dangerous fluids, a blind flange should be installed at the open end of the connection piece for safety reasons. Ball valves are only suited for ON or OFF position. Intermediate positions are not allowed. 6 of 17

8 2.2 PRESSURE + TEMPERATURE LIMITS BALL VALVES (F1/F27) MADE OF STEEL (1.0619) 1 BALL SEAT PTFE/25% glass fiber reinforced 2 PTFE/50% stainless steel 3 SIZE RANGE TEMPERATURE OAST O-ring TAST OAST O-ring TAST OAST O-ring TAST OAST O-ring TAST PN 16 PN 40 PN 16 PN C 38 bar 36 bar 50 C 40 bar 40 bar 100 C 37.1 bar 37.1 bar DN C 34 bar 34 bar 150 C 30 bar 30 bar 180 C 22 bar 28 bar 200 C 12 bar 24 bar 220 C 20 bar -10 C 16 bar 38 bar 16 bar 36 bar 50 C 16 bar 40 bar 16 bar 40 bar 100 C 14.8 bar 37.1 bar 14.8 bar 37.1 bar DN C 14.5 bar 34 bar 14.5 bar 34 bar 150 C 14 bar 30 bar 14 bar 30 bar 180 C bar 20 bar bar 25 bar 200 C 10 bar 10 bar 13.3 bar 21 bar 220 C bar 16 bar 1 Min. temp. for : -10 C, according to AD2000, W5 2 Max. temp: Seat material PTFE/25% stainless steel or 3E0 EN Max. temp: Seat material PTFE/50% stainless steel or 3E0 EN 1092 Legend: KM Kugelhahn Müller O O-ring T A Steel (1.0619) ST Standard valve F1/F27 Face-to-Face dimension DT-STAKH R8.EN 7 of 17

9 PRESSURE + TEMPERATURE LIMITS BALL VALVES (F1/F27) MADE OF STAINLESS STEEL (1.4408) BALL SEAT PTFE/25% glass fiber reinforced 1 PTFE/50% stainless steel 2 SIZE RANGE TEMPERATURE OXST O-ring TXST OXST O-ring TXST OXST O-ring TXST OXST O-ring TXST PN 16 PN 40 PN 16 PN C 40 bar 40 bar 40 bar 40 bar -25 C 40 bar 40 bar 50 C 40 bar 40 bar 100 C 40 bar 40 bar DN C bar bar 150 C 30 bar 30 bar 180 C 22 bar 28 bar 200 C 12 bar 24 bar 220 C 20 bar -60 C 16 bar 40 bar 16 bar 40 bar -25 C 16 bar 40 bar 16 bar 40 bar 50 C 16 bar 40 bar 16 bar 40 bar 100 C 16 bar 40 bar 16 bar 40 bar DN C bar bar bar bar 150 C 14.5 bar 30 bar 14.5 bar 30 bar 180 C bar 20 bar bar 25 bar 200 C 10 bar 10 bar 13.4 bar 20.5 bar 220 C bar 16 bar Note: 1 Restriction of temperature data (min/max) due to seat material used, PTFE/25% glass or EN E0 2 Restriction of temperature data (min/max) due to seat material used, PTFE/50% glass or EN E0 FDA DESIGN SEAT: PURE PTFE SIZE RANGE TEMPERATURE TXST TXST PN 16** PN 40* *DN C 16 bar 40 bar 125 C bar bar **DN C 8 bar 10 bar Note: Temperature data (min/max) due to seat material used, pure PTFE or EN E0 Legend: KM Kugelhahn Müller O O-ring T X Stainless steel (1.4408) ST Standard valve F1/F27 Face-To-Face dimension DT-STXKH R8.EN 8 of 17

10 2.3 SAFETY NOTES ON INSTALLATION, OPERATION AND MAINTENANCE DANGER Failure to observe the following cautions and warnings may result in danger, invalidating manufacturer's warranty. In case of any questions please contact the manufacturer. See back for addresses. Ball valves are subject to the same safety regulations as the pipe system into which they are installed and the control system to which the actuator is connected. Additional safety notes may also be included in the instructions of the actuator assembly. The manufacturer is not responsible and therefore, before using the ball valve, it must be ensured that > after installation into a pipe system, these ball valves are exclusively used to shut off or transport fluids within the approved pressure and temperature limits. DANGER TO LIFE It is not allowed to install a valve whose approved pressure/temperature range (= "rating") is not sufficient for the operating condition. The approved range is described in the planning document > Pressure and temperature applications. See last page for reference address Failure to observe this regulation may present a danger. > the valve is only installed by personnel qualified to perform work on pipes under pressure. (Qualified personnel within the meaning of these instructions are persons who are able to properly assess and perform any task associated with the valve and anticipate or recognize any possible dangers and eliminate them as quickly as possible) DANGER Protection against incorrect use of ball valve: In particular, it must be ensured that the selected materials of the wetted ball valve parts are suitable for the fluids in the pipe section. Failure to observe these precautions may present a danger to the user and cause damage to the pipe system. > the ball valve is installed and operated in such a way as supplied by the manufacturer Kugelhahn Müller. Any changes performed without the approval of the manufacturer (except the retrofitting of an actuator) are not allowed and relieve manufacturer of his product liability. > an actuator unit subsequently attached to a ball valve is adapted to the ball valve and correctly adjusted in its end positions, particularly in open position, > the pipe system and control system for the actuator (if any) have been properly installed and are subject to regular checks. The design of the wall thickness of the ball valve body takes the usual additional pipe load Fz into account for such a properly laid pipe system (Fz = π/4*dn²*ps). (PS = maximum permissible design pressure see type plate in section 3). > the usual flow rates in this pipe system are not exceeded during continuous operation and abnormal operating conditions such as vibrations, water hammers, cavitation, decomposition of unstable fluids, earthquake and increased content of solids in the fluid, particularly abrasive solids, have been clarified with the manufacturer Kugelhahn Müller. > the valve is correctly connected to this system, > the pipe system has the required free space for operation and for disassembly/assembly for the purpose of inspection or maintenance. 9 of 17

11 > the use of a ball valve actuator in an ambient atmosphere that is other than normal - particularly in potentially explosive environment - has been clarified with the manufacturer Kugelhahn Müller, > ball valves installed in pipe systems with operating temperatures > +50 C or < 20 C are protected against contact, together with the pipe section. Such thermal insulation is not the responsibility of Kugelhahn Müller GmbH. > Make sure that the pressure of the ball valve corresponds to the operating conditions of the pipe. Size and pressure range are indicated in more detail on our ball valves. Before installation, open and close valve while simultaneously checking whether any problems occur during opening/closing and whether the ball is in the correct position. DANGER TO LIFE PARTICULAR DANGERS Before disassembly of the ball valve from the pipe, the pipe must be completely decompressed to prevent leakage of the fluid to outside. DANGER The bolting on the connection of the valve body parts shall be loosened only after disassembly of the valve. A detailed description of reassembly is contained in the Kugelhahn-Müller assembly instructions. Ball valves used as end valve: During normal operation, especially when using gaseous, hot and/or dangerous fluids, install a blind flange at the open end of the valve or securely and permanently lock the ball valve in "CLOSED" position. When disassembling a valve from the pipe, fluid may leak from the pipe or the ball valve. When using harmful or dangerous fluids, the pipe must be completely drained before disassembling the ball valve. Use caution with residues that still flow out of the pipe or have remained in the dead spots of the ball valve. If a ball valve that is used as end valve in a pipe section under pressure must be opened, use greatest care and do it in such a way that any fluid splashing out does not cause damage. Risk of crushing hand or fingers: Do not operate an actuated valve as long as the valve is not yet installed. Do not operate a valve installed at the open end of a pipe section. 10 of 17

12 2.4 BALL VALVE MARKING for Marking Note Manufacturer KM KM = Kugelhahn Müller, see back for address Valve type e.g.: OXST, TXST OXST = Type OXST-F1 see Kugelhahn Müller catalogue. The 2nd letter indicates the valve body material: X = / A = Valve body material e.g.: Material number (valve body marking) Size DN (and number) Number in mm, e.g. DN100 (valve body marking) Design pressure PN (and number) PN = Standard for flange connection Number = maximum permissible pressure [bar] at 120 C Year of manufacture e.g.: 11/1234 1st + 2nd number = year of manufacture, e.g. 11 = 2011 / 1234 = consecutive serial number Heat No. e.g.: 022E Batch no./melt no. of primary material Conformity CE ID number 0035 The conformity is certified separately by manufacturer "Notified body" as per EC Directive = TÜV Rheinland customer-specific e.g.: 02ZS1637 Special marking as requested by customer Markings shall not be damaged to ensure identifiability of valve. 2.5 TRANSPORT AND STORAGE Ball valves shall be handled, transported and stored with care: > The valve shall be stored in its protective packaging and/or with the protective caps at the connection ends. Ball valves that are heavier than approx. 10 kg should be stored and transported on a pallet (or similar support) (up to the place of installation). > During storage prior to installation, protect valve and actuator from harmful influences such as dirt or humidity, usually in an enclosed space. > Ensure that particularly an actuated ball valve and the ball valve flanges for connection to the pipe are not subject to damage by mechanical or other influences. > To protect the internal parts, the ball valves are usually supplied in fully open position. The ball valve shall be transported/stored in the same position as delivered. 11 of 17

13 3. INSTALLATION INTO THE PIPE Accurate piping is of utmost importance. Stresses and displacements in the pipe system can result in an increased torque and leakage between valve body and connection ends. The distance between the pipe ends should correspond precisely to the dimensions of the ball valve. 3.1 NOTES The installation of ball valves into a pipe is subject to the same instructions as the flange connection of pipes and similar pipe elements. In addition, the following instructions apply to ball valves. For transport to place of installation, section 2.5 shall also be observed. WARNINGS AND NOTES For actuators, observe the following: Do not use valve (and actuator) as "ladder" - Do not apply external loads to valve (and actuator); this may damage or destroy the ball valve. Actuators whose weight exceeds the weight of the ball valve: They shall be supported if the weight and/or actuator position result in a permanent deformation of the valve body. Risk of crushing hand or fingers: Do not operate an actuated valve as long as the valve is not yet installed. Do not operate a valve installed at the open end of a pipe section. WARNINGS AND NOTES If retrofitting an actuator unit on site, ensure that the torque, direction of rotation, angle of activation and the setting of the end stops "OPEN" and CLOSED" are adapted to the ball valve. It is of particular importance that retrofitted connection parts (bracket and adapter) are precisely aligned with the ball valve shaft, thus ensuring a plane-parallel mounting of the actuator to the ball valve. Failure to observe this precaution may present a danger to the user and cause damage to the pipe system or ball valve. An actuator supplied together with the ball valve is adjusted to the operating data indicated in the order. The setting of the end stops "OPEN" and "CLOSED" shall not be changed without the permission of the manufacturer. Applies only to ball valves with electric actuator: Make sure that actuator in end positions is switched off by thesignal of the limit switch. If switch-off takes place via the signal of the torque switch, then this signal shall also be used as failure signal. The fault must be eliminated as quickly as possible, see section 4.2 (Troubleshooting) For additional notes see instructions for the electric actuator Closing/opening times for pneumatic piston actuators: Adapt compressed air supply/decompression to the valve in such a way that - unless otherwise specified - the closing time of a ball valve equals the guide value: t [sec] = DN [mm] / 25. FOR ACTUATORS, OBSERVE THE FOLLOWING: 12 of 17

14 3.2 INSTALLATION STEPS > Transport the ball valve in its protective packaging to the place of installation; to protect valve against contamination, do not unpack until it is ready to be inserted into the pipe. Remove protective caps at the connection ends of the valve immediately prior to the installation. > Check valve (and actuator) for transport damage. Do not install damaged ball valves or actuators. > Ensure that only ball vales are installed whose pressure class, materials of wetted parts, connection type and flange dimensions are in compliance with the operating conditions. See relevant ball valve markings. > The connection data for the actuator unit shall correspond to the data of the control system. See type plate on actuator unit. The pipe flanges shall be aligned with the ball valve flanges and have plane-parallel ends. > Even if the ball valves were transported in a clean environment, make sure to check the ball valve and connecting pipe for contamination or foreign matter prior to installation. In case of a negative result, thoroughly clean the valve and, most importantly, remove any hard foreign matter. INFO As a rule, flange seals and flange screws are not included: The torque of the flange screws shall be specified by the supplier of the flange seal. > To connect an actuator unit to the control unit, the relevant instructions apply. >After installation is finished, perform a functional test: A ball valve with lever or gear/handwheel shall be easy to OPEN and CLOSE. > The following applies to an actuated ball valve: The valve must properly close and open according to the control commands. Any obvious malfunctions must be eliminated prior to commissioning. See also section 4.2 (Troubleshooting). > Use water or compressed air to clean the valves. Place opening of valve perpendicular to the floor and clean it. Ensure that the dust is completely removed from the opening. Next, check and clean the pipe opening and the connection place. There shall be no joints, rust spots and foreign matter in order to prevent blocking and leakiness. > The valve can be installed in any position. An actuator, however, should not be located directly below the ball valve: A leakage at the shaft may damage the actuator. When installing a valve with horizontal actuator shaft and the actuator dimension exceeds the valve dimension, the plant supervisor shall decide whether the actuator requires a support on site. Incorrectly executed control commands could cause a danger to life and damage to the pipe system. > When sliding the ball valve (and the necessary seals) into an already existing pipe, ensure that the space between the pipe flanges is sufficient to prevent damage to the flange connection surfaces and the seals. However, in order to prevent any additional stresses in the pipe, this space should not be larger than required. 13 of 17

15 3.3 PRESSURE TEST AND COMMISSIONING 3.4 ADDITIONAL INFORMATION: VALVE DISASSEMBLY INFO Prior to commissioning, flush the system to remove dirt. Observe the same safety rules as for the pipe system and the (electrical/pneumatic) supply system/control system. > (if applicable) Securely interrupt the energy supply > Open valve and drain pipe section. Ensure that ball valve is open during the entire flushing process; do not operate ball valve until cleaning is finished. The manufacturer Kugelhahn Müller has already performed the required tests on every finished valve as per the European Standard EN The following restrictions and notes apply if a pressure test of the pipe section is required together with the installed ball valve: > To remove all foreign matter, carefully flush newly installed pipe systems before closing them for the first time. > When valve is in open position, the test pressures shall not exceed the value 1.5 x design pressure (PN or PS) as per valve marking. >When ball valve is in closed position, the maximum test pressure to be applied = 1.1 x (PN or PS). If the valve is marked with "Class" only, limit the test pressure [bar] to x Class. (PS = maximum permissible operating pressure) >If a leakage occurs in a valve, observe the notes in section 4.2 (Troubleshooting). WARNING In completely open/closed position, fluid remains in the ball valve: To drain the valve body completely, place ball in intermediate position directly prior to removal. > Loosen valve/pipe section connection and disassemble valve. Make sure that ball surface is bare and free from damage. >To store valve, observe section 2.5 (Transport and storage). DANGER Ball valves have a cavity between ball and valve body in which small amounts of water collect from the pressure test: To remove this water, e.g. by drying the pipe section, the ball valve must remain in an intermediate position (z.b. half-open) while the pipe section dries. 14 of 17

16 4. NORMAL OPERATION Normal manual force is sufficient to operate ball valves designed for manual operation. The use of lever extensions to increase the actuating torque is not permitted. Note: In EN 12570: Manual forces, standard values are defined according to lever length or handwheel-ø. Operate actuated ball valves via the control system signals. Ball valves supplied with actuator by manufacturer Kugelhahn Müller are precisely adjusted and shall not be changed as long as the valve functions correctly. Ball valves do not require regular maintenance. However, when checking the pipe section at suitable intervals make sure that there is no leakage at the flange and screw connections of the valve body and at the shaft seal. Concerning leakage and repairs, see section 4.2 (Troubleshooting). It is recommended to operate ball valves that permanently remain in the same position once or twice per year. 4.1 MAINTENANCE Subject to regular visual inspection of the pipe section, the valve does not require special maintenance. If an actuator is available, observe the respective manufacturer's instructions. If valve is used in corrosive/abrasive fluids and/or at the threshold of the pressure/temperature limits and/or subject to (very) frequent operation, the ball valve should be inspected at suitable intervals, but at least once or twice per year. In case of faults, see section 4.2 (Troubleshooting). 15 of 17

17 4.2 TROUBLESHOOTING When troubleshooting as per the following table, observe section (Safety notes on installation, operation and maintenance). Note 1: Install only original Kugelhahn-Müller parts. Note 2: If, after disassembly, it is determined that the valve body and/or internal parts are not sufficiently resistant to the fluid, a more suitable material should be selected in consultation with Kugelhahn Müller. Note 3: It is essential to correctly reassemble a ball valve after disassembly for reasons of maintenance/repair and to perform a subsequent pressure test with water as per section 3.3. The instructions provided by Kugelhahn-Müller include detailed information for reassembly. Send request to: info@kh-m.de Leakage at flange connection to pipe When a leakage occurs in this area, first retighten flange connection. If this does not eliminate the leakage, disassemble the valve. Observe warnings under (Particular dangers) and replace flange seal. Leakage at the connection of the valve body parts Use a torque wrench to retighten screws as indicated in the Kugelhahn-Müller assembly instructions. If this does not eliminate the leakage, disassemble the valve. Observe warnings under (Particular dangers) and replace flange seal. Observe section 3.4 (Valve disassembly) and replace valve body seal. Request spare parts and respective instructions from manufacturer. Assembly as per Kugelhahn-Müller assembly instructions Leakage at shaft seal (applies only to type T) The ball valve type T has an adjustable stuffing box with Belleville spring preload: If leakage occurs at the shaft seal, use the following steps to retighten the Belleville spring. Observe warnings under (Particular dangers): 1. Unscrew lever or actuator unit from connection flange to valve body. 2. Retighten stuffing box (=item 8 in sectional drawing). Observe the following tightening torques: DN15 32 = 40 Nm, DN40 65 = 70 Nm, DN = 100 Nm, DN150 = 140 Nm 3. Rotate shaft several times to check proper operation. 4. Check tightness of stuffing box with operating pressure in the valve: Observe warnings under (Particular dangers)! Then reattach lever or actuator unit. Leakage at shaft seal (applies only to type O) or excessive leakage in CLOSED position Repair is required. Request spare parts and respective assembly instructions from manufacturer Kugelhahn Müller. Disassembly as per section 3.4, assembly as per Kugelhahn-Müller assembly instructions. Observe notes under (Particular dangers). Malfunction Check actuator unit and control commands. If actuator and control are OK, disassemble valve. Observe notes under(particular dangers) and check valve. Repair is required if ball valve is damaged - see above. Request spare parts and respective instructions from manufacturer. For malfunctions concerning the actuator unit, see actuator instructions. 16 of 17

18 5. ASSESSMENT OF BALL VALVE AS PER DIRECTIVE 94/9/EC (ATEX) An Ignition Hazard Assessment as per DIN EN Part 1 has been performed for ball valves type O and T. However, in case of an actuator/valve combination, this only applies to the ball valve itself. No potential ignition source was found. Thus, the ball valves fall outside the scope of Directive 94/9/EC and therefore shall not be marked according to this Directive. DANGER A valve/actuator combination has the same ignition hazard as identified by the actuator manufacturer in the Ignition Hazard Assessment. The operator shall observe the respective operating instructions. Thus, the use of actuated ball valves in areas with potentially explosive atmosphere is permitted within the scope of intended use. It is however necessary to ensure on site that > ball valves used in such a way have been included in the potential equalization measures of the system section, > der Verwender einer Kombination Antrieb/Armatur eine Zündgefahrenbewertung des Systemabschnitts durchführt. 17 of 17

19 YOUR SPECIALIST FOR BALL VALVES KUGELHAHN MÜLLER GMBH Subsidiary of Bray International, Inc. Kölner Str. 686 D Krefeld T. +49 (0) F. +49 (0) All statements, technical information and recommendations related to this brochure are only intended for general use. If you have specific requirements and questions concerning material selection for your desired application, please contact us. We reserve the right to change or modify the design or the product without prior notification. Patented worldwide and patents applied worldwide. Kugelhahn Müller GmbH is a subsidiary of Bray International, Inc. Bray is a registered trademark of Bray International, Inc Bray International, Inc. All rights reserved. OM_KM_OST-TST_EU-EN_ KUGELHAHN-MUELLER.DE