KSB BOA-H Manual de usuario

BOA-H/HE, NORI40, NORI160,

NORI320, NORI500,

ZJSVA/ZXSVA, RGS

Operating Manual

Legal information/Copyright

Operating Manual

Original operating manual

edited or processed for any other purpose, nor otherwise transmitted, published or made available to a

third party without the manufacturer's express written consent.

Subject to technical modification without prior notice.

Contents

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Contents

Glossary .................................................................................................................................................. 6

1 General.................................................................................................................................................... 7

1.1 Principles ...........................................................................................................................................................7

1.2 Target group.....................................................................................................................................................7

1.3 Other applicable documents............................................................................................................................7

1.4 Symbols .............................................................................................................................................................7

1.5 Key to safety symbols/markings.......................................................................................................................7

2 Safety...................................................................................................................................................... 9

2.1 General..............................................................................................................................................................9

2.2 Intended use .....................................................................................................................................................9

2.2.1 Prevention of foreseeable misuse.....................................................................................................10

2.3 Personnel qualification and training.............................................................................................................10

2.4 Consequences and risks caused by non-compliance with this manual .......................................................10

2.5 Safety awareness ............................................................................................................................................10

2.6 Safety information for the operator/user.....................................................................................................10

2.7 Safety information for maintenance, inspection and installation ..............................................................11

2.8 Unauthorised modes of operation................................................................................................................11

3 Transport/Storage/Disposal ................................................................................................................ 12

3.1 Checking the condition upon delivery..........................................................................................................12

3.2 Transport.........................................................................................................................................................12

3.3 Storage/preservation......................................................................................................................................13

3.4 Return to supplier...........................................................................................................................................13

3.5 Disposal ...........................................................................................................................................................14

4 Valve Description ................................................................................................................................. 15

4.1 Product information.......................................................................................................................................15

4.1.1 Product information as per Regulation No. 1907/2006(REACH) ....................................................15

4.1.2 Product information as per Pressure Equipment Directive 2014/68/EU(PED)................................15

4.1.3 Product information as per UK Pressure Equipment (Safety) Regulations 2016 ...........................15

4.1.4 Product information as per Directive 2014/34/EU (ATEX) ...............................................................15

4.1.5 Product information as per UK Equipment and Protective Systems Intended for Use in

Potentially Explosive Atmospheres Regulations 2016 .....................................................................15

4.2 Marking...........................................................................................................................................................15

4.3 Globe Valves to DIN/EN with Gland Packing ...............................................................................................16

4.3.1 NORI40 ZXL/ZXS ................................................................................................................................16

4.3.2 NORI 40 ZXLF/ZXSF.............................................................................................................................17

4.3.3 NORI 160 ZXL/ZXS ..............................................................................................................................19

4.3.4 NORI 160 ZXLF/ZXSF...........................................................................................................................20

4.3.5 NORI 320 ZXLF/ZXSF...........................................................................................................................21

4.3.6 NORI 320 ZXSV ...................................................................................................................................22

4.3.7 NORI 500 ZXSV ...................................................................................................................................23

4.3.8 NORI 500 ZXLR/ZXSR..........................................................................................................................24

4.4 Bellows-type Globe Valves to DIN/EN............................................................................................................25

4.4.1 BOA-H/HE/HV/HEV .............................................................................................................................25

4.4.2 NORI40 ZXLBV/ZXSBV .......................................................................................................................26

4.4.3 NORI40 ZXLB/ZXSB............................................................................................................................27

4.4.4 NORI40 ZYLB/ZYSB............................................................................................................................28

4.5 Start and Stop Control Valves to DIN/EN ......................................................................................................29

4.5.1 ZJSVA/ZXSVA......................................................................................................................................29

4.6 Lift Check Valves to DIN/EN ...........................................................................................................................31

4.6.1 NORI 40 RXL/RXS................................................................................................................................31

4.6.2 NORI 160 RXL/RXS..............................................................................................................................32

4.6.3 NORI 320 RXL/RXS..............................................................................................................................32

4.6.4 NORI 500 RXLR/RXSR..........................................................................................................................33

4.6.5 RGS......................................................................................................................................................34

Contents

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4.7 Strainers to DIN/EN.........................................................................................................................................35

4.7.1 NORI 40 FSL/FSS..................................................................................................................................35

4.8 Scope of supply...............................................................................................................................................35

4.9 Dimensions and weights ................................................................................................................................35

5 Installation at Site................................................................................................................................ 36

5.1 General information/Safety regulations .......................................................................................................36

5.2 Installation position........................................................................................................................................36

5.2.1 Installation position of globe valves with gland packing ...............................................................36

5.2.2 Installation position of bellows-type globe valves ..........................................................................37

5.2.3 Installation position of start and stop control valves ......................................................................38

5.2.4 Installation position of lift check valves ...........................................................................................38

5.2.5 Installation position of strainer.........................................................................................................38

5.3 Preparing the valve ........................................................................................................................................39

5.4 Piping ..............................................................................................................................................................39

5.4.1 Flange connections ............................................................................................................................39

5.4.2 Welding into the pipeline .................................................................................................................39

5.5 Valves with actuator.......................................................................................................................................40

5.6 Insulation ........................................................................................................................................................41

6 Commissioning/Start-up/Shutdown................................................................................................... 43

6.1 Commissioning/Start-up.................................................................................................................................43

6.1.1 Prerequisites for commissioning/start-up .........................................................................................43

6.1.2 Valve actuation ..................................................................................................................................45

6.1.3 Information on the mechanical components...................................................................................45

6.2 Operating limits..............................................................................................................................................46

6.2.1 Pressure/temperature ratings for NORI 40 ZXL/ZXS.........................................................................46

6.2.2 Pressure/temperature ratings for NORI 40 ZXLF/ZXSF .....................................................................46

6.2.3 Pressure/temperature ratings for NORI 160 ZXL/ZXS.......................................................................47

6.2.4 Pressure/temperature ratings for NORI 160 ZXLF/ZXSF ...................................................................47

6.2.5 Pressure/temperature ratings for NORI 320 ZXLF/ZXSF ...................................................................47

6.2.6 Pressure/temperature ratings, NORI 320 ZXSV.................................................................................48

6.2.7 Pressure/temperature ratings for NORI 500 ZXSV............................................................................48

6.2.8 Pressure/temperature ratings, NORI 500 ZXLR/ZXSR .......................................................................49

6.2.9 Pressure/temperature ratings for BOA-H/HE/HV/HEV......................................................................50

6.2.10 Pressure/temperature ratings for NORI40 ZXLBV/ZXSBV................................................................50

6.2.11 Pressure/temperature ratings for NORI40 ZXLB/ZXSB ....................................................................50

6.2.12 Pressure/temperature ratings for NORI40 ZYLB/ZYSB ....................................................................51

6.2.13 Pressure/temperature ratings for ZJSVA/ZXSVA ..............................................................................51

6.2.14 Pressure/temperature ratings for NORI 40 RXL/RXS ........................................................................51

6.2.15 Pressure/temperature ratings for NORI 160 RXL/RXS ......................................................................52

6.2.16 Pressure/temperature ratings for NORI 320 RXL/RXS ......................................................................52

6.2.17 Pressure/temperature ratings for NORI 500 RXLR/RXSR ..................................................................52

6.2.18 Pressure/temperature ratings for RGS ..............................................................................................53

6.2.19 Pressure/temperature ratings for NORI 40 FSL/FSS ..........................................................................53

6.3 Shutdown........................................................................................................................................................54

6.3.1 Measures to be taken for shutdown ................................................................................................54

6.4 Returning to service .......................................................................................................................................54

7 Servicing/Maintenance........................................................................................................................ 55

7.1 Safety regulations...........................................................................................................................................55

7.2 Maintenance...................................................................................................................................................55

7.2.1 Valves with actuator..........................................................................................................................56

7.2.2 Valve reassembly................................................................................................................................56

8 Trouble-shooting.................................................................................................................................. 57

9 Related Documents.............................................................................................................................. 58

9.1 General assembly drawing with list of components for NORI40ZXL/ZXS .................................................58

9.2 General assembly drawing with list of components for NORI 40 ZXLF/ZXSF..............................................60

9.3 General assembly drawing with list of components for NORI 160 ZXL/ZXS ...............................................62

Contents

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9.4 General assembly drawing with list of components for NORI 160 ZXLF/ZXSF............................................64

9.5 General assembly drawing with list of components for NORI 320 ZXLF/ZXSF............................................66

9.6 General assembly drawing with list of components for NORI 320 ZXSV....................................................67

9.7 General assembly drawing with list of components for NORI 500 ZXSV....................................................68

9.8 General assembly drawing with list of components for NORI 500 ZXLR/ZXSR...........................................70

9.9 General assembly drawing with list of components for BOA-H/HE/HV/HEV ..............................................71

9.10 General assembly drawing with list of components for NORI40 ZXLBV/ZXSBV........................................73

9.11 General assembly drawing with list of components for NORI40 ZXLB/ZXSB.............................................75

9.12 General assembly drawing with list of components for NORI40 ZYLB/ZYSB.............................................77

9.13 General assembly drawing with list of components for ZJSVA/ZXSVA.......................................................78

9.14 General assembly drawing with list of components for NORI 40 RXL/RXS.................................................79

9.15 General assembly drawing with list of components for NORI 160 RXL/RXS...............................................80

9.16 General assembly drawing with list of components for NORI 320 RXL/RXS...............................................81

9.17 General assembly drawing with list of components for NORI 500 RXLR/RXSR ..........................................82

9.18 General assembly drawing with list of components for RGS.......................................................................83

9.19 General assembly drawing with list of components for NORI 40 FSL/FSS...................................................84

10 EU Declaration of Conformity............................................................................................................. 85

10.1 EU Declaration of Conformity for BOA-H/HE, NORI40, NORI160, NORI320, NORI500, ZJSVA/ZXSVA,

RGS ..................................................................................................................................................................85

10.2 EU Declaration of Conformity for NORI40ZYLB/ZYSB, FSL/FSS ..................................................................87

11 UK Declaration of Conformity............................................................................................................. 88

11.1 UK Declaration of Conformity for BOA-H/HE, NORI40, NORI160, NORI320, NORI500, ZJSVA/ZXSVA,

RGS ..................................................................................................................................................................88

11.2 UK Declaration of Conformity for NORI40ZYLB/ZYSB, FSL/FSS..................................................................89

Index ..................................................................................................................................................... 90

Glossary

6 of 94

0570.82/17-EN

Glossary

Equipment and Protective Systems Intended for

Use in Potentially Explosive Atmospheres

Regulations 2016

The product regulations Equipment and Protective

Systems Intended for Use in Potentially Explosive

Atmospheres Regulations 2016 lay down rules to

be met by equipment and protective systems

intended for use in potentially explosive

atmospheres in the United Kingdom (except

Northern Ireland).

Pressure Equipment (Safety) Regulations 2016

(PER)

The Pressure Equipment (Safety) Regulations 2016

set out the requirements to be met by pressure

equipment intended to be placed on the UK

market (except Northern Ireland).

Pressure Equipment Directive 2014/68/EU (PED)

The 2014/68/EU Directive sets out the

requirements to be met by pressure equipment

intended to be placed on the market in the

European economic area.

1 General

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0570.82/17-EN

1 General

1.1 Principles

This operating manual is valid for the type series and variants indicated on the front

cover.

The operating manual describes the proper and safe use of this equipment in all

phases of operation.

In the event of damage, immediately contact your nearest KSB sales organisation

responsible 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 specialist

technical personnel.

1.3 Other applicable documents

Table1: Overview of other applicable documents

Document Contents

Type series booklet Description of the valve

Flow characteristics Information on Kv values and zeta values

General assembly drawing1) Sectional drawing of the valve

Sub-supplier product literature2) 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-references

Step-by-step instructions

Note

Recommendations and important information on how to handle

the product

1.5 Key to safety symbols/markings

Table3: Definition of safety symbols/markings

Symbol Description

!DANGER

DANGER

This signal word indicates a high-risk hazard which, if not avoided,

will result in death or serious injury.

!WARNING

WARNING

This signal word indicates a medium-risk hazard which, if not

avoided, could result in death or serious injury.

1If included in agreed scope of supply; otherwise refer to the type series booklet.

2If included in agreed scope of supply

1 General

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0570.82/17-EN

Symbol Description

CAUTION

This signal word indicates a hazard which, if not avoided, could

result in damage to the machine and its functions.

General hazard

In conjunction with one of the signal words this symbol indicates a

hazard which will or could result in death or serious injury.

Electrical hazard

In conjunction with one of the signal words this symbol indicates a

hazard involving electrical voltage and identifies information about

protection against electrical voltage.

Machine damage

In conjunction with the signal word CAUTION this symbol indicates

a hazard for the machine and its functions.

2 Safety

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0570.82/17-EN

2 Safety

!DANGER

All the information contained in this section refers to hazardous situations.

In addition to the present general safety information the action-related safety

information given in the other sections must be observed.

2.1 General

▪This operating manual contains general installation, operating and maintenance

instructions that must be observed to ensure safe operation of the system and

prevent personal injury and damage to property.

▪Comply with all the safety instructions given in the individual sections of this

operating manual.

▪The operating manual must be read and understood by the responsible specialist

personnel/operators prior to installation and commissioning.

▪The contents of this operating manual must be available to the specialist

personnel at the site at all times.

▪Information and markings attached directly to the product must always be

complied with and kept in a perfectly legible condition at all times. This applies

to, for example:

– Manufacturer

– Type designation

– Nominal pressure

– Nominal size

– Flow direction arrow

– Year of construction

– Valve body material

▪The operator is responsible for ensuring compliance with all local regulations not

taken into account.

▪The design, manufacture and testing of the valve are subject to a QM system to

DINENISO9001 as well as the current regulations and directives for pressure

equipment.

▪Bear in mind that valves exposed to creep-rupture conditions have a limited

service life and have to meet the applicable regulations stipulated in the

technical codes.

▪In the case of customised special variants, further restrictions may apply with

regard to the operating mode and service life. Refer to the relevant sales

documentation for applicable limitations.

▪The operator is responsible for any eventualities or incidents which may occur

during installation performed by the customer, operation and maintenance.

2.2 Intended use

▪Only operate valves which are in perfect technical condition.

▪Do not operate the valve in partially assembled condition.

▪Only use the valve for fluids specified in the product literature. Take the design

and material variant into account.

▪Only operate the valve within the operating limits described in the other

applicable documents.

▪The valve's design and rating are based on predominantly static loading in

accordance with the codes applied. Consult the manufacturer if the valve is

subjected to dynamic loads or any other additional influences.

▪Consult the manufacturer about any other modes of operation not described in

the product literature.

▪Do not use the valve as a foothold.

2 Safety

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0570.82/17-EN

2.2.1 Prevention of foreseeable misuse

▪Never exceed the permissible application and operating limits specified in the

data sheet or product literature regarding temperature, etc.

▪Observe all safety information and instructions in this manual.

2.3 Personnel qualification and training

▪All personnel involved must be fully qualified to transport, install, operate,

maintain and inspect the product this manual refers to and be fully aware of the

interaction between the valve and the system.

▪The responsibilities, competence and supervision of all personnel involved in

transport, installation, operation, maintenance and inspection must be clearly

defined by the operator.

▪Deficits in knowledge must be rectified by means of training and instruction

provided by sufficiently trained specialist personnel. If required, the operator can

commission the manufacturer/supplier to train the personnel.

▪Training on the valve must always be supervised by specialist technical personnel.

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

▪Non-compliance with these operating instructions will lead to forfeiture of

warranty cover 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 chemical

effects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.5 Safety awareness

In addition to the safety information contained in this operating manual and the

intended use, the following safety regulations shall be complied with:

▪Accident prevention, health regulations and safety regulations

▪Explosion protection regulations

▪Safety regulations for handling hazardous substances

▪Applicable standards, directives and laws

2.6 Safety information for the operator/user

▪Actuator-operated valves are intended for use in areas which cannot be accessed

by unauthorised persons. Operation of these valves in areas accessible to

unauthorised persons is only permitted if appropriate protective devices are

fitted at the site. This must be ensured by the operator.

▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,

cold or moving parts, and check that the equipment functions properly. Do not

touch rotating parts.

▪Do not remove any protective equipment (e.g. contact guards) during operation.

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

▪Contain any leakage of hazardous fluids (e.g. explosive, toxic, hot) so as to avoid

any danger to persons and the environment. Adhere to all relevant laws.

▪Eliminate all electrical hazards. (In this respect refer to the applicable national

safety regulations and/or regulations issued by the local energy supply

companies.)

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