KLINGER Ballostar KHE Guida
wT 2575/11
Page 1
Mounting and treatment instructions for
KLINGER
BallostarKHE ball valves
Split body design, DN 15 – 200 and NPS ½“ – 8“
Edition: 06/2006
Rev.: 02/2008
Fluid Control GmbH
Am Kanal 8-10
A-2352 Gumpoldskirchen / AUSTRIA
Tel.: +43(0) 2252 / 600 0
Fax: +43(0) 2252 / 600 359
e-mail: [email protected]
Homepage: www.klinger.kfc.at
7 20 21 13
17
18
19
14
5
6 4 1 15 22 2 16
3
8
12
11
9
10
1 Body
2 Flanged end piece
3 Operating stem
4 Ball
5 Sealing element
6 Sealing ring
7 Stopper
8 Loading ring
9 Stuffing box
10 Slip ring
11 Antistatic disc
12 Fem. support ring
13 Hand lever
14 Secondary graphite sealing
15 Hex screw
16 Hex nut
17 Stuffing box nut
18 Belleville washer
19 Washer
20 Hex screw
21 Washer
22 Supporting ring
wT 2575/11
Page 2
Table of contents
Page 3 Functional principle
Page 4, 5, 6 Mode of operation
Page 7, 8 Instructions for treatment, tightening torques and wrench sizes
Page 8 Material code
Page 9 Designation of parts and materials
Page 10 Type overview
Page 11 Type overview sealing elements
Page 12 Type overview stuffing boxes
Page 13 Components of labyrinth stuffing box
Page 14, 15 Dismantling & assembling of valve
Page 16 Installation of valve, mounting of actuator
Page 17, 18 Operating torques
Page 19 Initiating operation and safety instructions
wT 2575/11
Page 3
FUNCTIONAL PRINCIPLE
Because of the ELASTIC SEALING SYSTEM, the KLINGER Ballostar®KHE ball valve is absolutely
leak tight at high, but also at extremely low pressures. The required contact forces between sealing ring
and ball are created by the differential pressure in the ball valve. For the FLOATING BALL sealing
principle it is important that the shut-off device is freely moveable. The sealing rings perform two
functions at the same time: They guide the ball and absorb bearing forces.
FORCE FLOW
The forces which are absorbed by the sealing rings increase with larger nominal diameters (DN, NPS).
Therefore the floating ball design is only used for small sized ball valves. To achieve a high service life
and to reduce the operating torques for pivot movements, the floating ball design is only used for sizes
up to DN 125. For larger sizes lower costs in production face the significant higher costs for increasing
the moment of force to surmount the high operating torques. The increased amount of friction caused by
high loading pressures additionally leads to a low service life and a poor number of shifting cycles.
wT 2575/11
Page 4
MODE OF OPERATION
The sealing system of the bore consists of:
-A pre-stressed elastic sealing element made of stainless and acid resistant steel with a
KFC-sealing ring (Standard) and a U-Sleeve made of K-Flon located at the pitch of the body
and the flange end piece.
-An inelastic sealing ring located in a chambered groove in the body
-The ball between sealing element and sealing ring
Basically KLINGER Ballostar®KHE ball valves can be pressurized in both directions. In consequence of
the different design of the two sealing components two operating conditions depending on the mounting
direction are possible:
1.) The elastic sealing element respective the flange end piece is mounted upstream:
The fluid pressure presses the ball against the downstream located sealing ring. At the same time, the
upstream located sealing element is pressed against the ball. Because of the elasticity of the KLINGER
sealing system two sealing areas are permanently available in the bore.
For standard applications KLINGER recommends this situation of installation as preferred mounting
direction. This recommended direction is additionally marked with an arrow on the valve body.
Occurring forces:
F1…Fluid force acting on ball
F2…Fluid force acting on
sealing element
Fv…Spring force of sealing
element
F1+F2+Fv…Total force, which
acts onto the sealing ring
wT 2575/11
Page 5
2.) Inelastic sealing ring respective body flange is mounted upstream:
The fluid pressure acts against the preloading force of the elastic sealing element located
downstream.
If the force of the fluid pressure is higher than the preloading force, the ball lifts from the sealing
ring and only the downstream located sealing element performs the primary sealing function.
Due to the fact that this condition occurs at high differential pressures the surface pressure
between sealing element and ball is high enough to enable an effective sealing.
At high differential pressures the preloading force of the elastic sealing element is high enough
to press the ball against the upstream located sealing ring. A second primary sealing area is
created, which enables an outstanding effective sealing!
High differential pressures: FV-F1 < F1 …ball lifts from upstream located sealing ring
Low differential pressures: FV-F1 > F1 …upstream located sealing ring is in full function
KLINGER Ballostar®KHE ball valves are basically maintenance free and can be pressurized in both
flow directions. The U-sleeve which is drawn onto the supporting ring is completely chambered and
seals the pitch flange against the outside. Additionally ball valves of type KHE have secondary graphite
sealing between body and flange end piece.
Occurring forces:
F1…Fluid force acting on ball
Fv…Spring force of sealing
element
Fv-F1…Total force, which acts
onto the sealing ring and
against fluid pressure
wT 2575/11
Page 6
THE EXTERNAL SEALING SYSTEM
The sealing of the shifting shaft (operating stem) is carried out by a belleville washer supported stuffing
box.
This type of sealing is almost maintenance free and has just little set-off behaviour. Only small
tightening forces are required for leak tightness.
The arrangement of the belleville washer ensures that a constant contact pressure acts against the
stuffing box to compensate alternating temperature- and pressure changes.
WELT OF SEALING RING
The grove in the body prevents floating of the sealing ring in radial direction (1) against the back side (2)
and the bore (3). The ball presses against the sealing ring (4). Therefore the sealing ring can not set
down or flow, because it is surrounded on each side.
wT 2575/11
Page 7
INSTRUCTIONS FOR TREATMENT
KLINGER Ballostarball valves are delivered in OPEN position. To protect them against dirt
contamination and damage the flange ends are covered with plastic caps. We recommend removing the
caps not until you want to install the valve. KLINGER valves should be stored in closed rooms with non-
aggressive ambient atmosphere and where they are protected from moisture and dirt. Furthermore the
maximum temperatures and pressures, specified in the P/T-diagrams, should not be exceeded during
operation. Just under these specified conditions mentioned before our warranty for the determined
duration is valid. Please notice, this warranty does not include valve components that are subjected to
corrosion, erosion and wear during operation
If cover- or shrink foils are used, you have to have to make sure, that the atmosphere within the foil is
free of condensation. For storage in dusty rooms appropriate protective measures are recommended.
To avoid confusion we suggest to name and store parts according to their shipping documents.
The temperature in the storage areas should range between -20° C and +50° C. Fast changes of
temperature should be avoided (creation of condensation- and perspiration water).
Instructions for treatment and application are part of the shipment and should therefore be stored next to
the goods. This makes sure that all necessary information and documentation are passed on.
Changes in documentation which belong to the storage of KLINGER products are timely forwarded by
circular letters.
Damages which can result from inappropriate storage absolve KLINGER from obligations deriving from
guarantee, warranty and product liability.
wT 2575/11
Page 8
KLINGER ball valves are basically MAINTENANCE FREE!
During long periods of non-operating, the valves have to be drained. In case of leakage the screws of
the body have to be retightened. Please check table No.1 for the required torque values!
KLINGER recommends operating the valve minimum six times a year to increase the service life!
Table 1: Tightening torques and wrench sizes (SW)
Tolerances for tightening torques of stuffing box nut: + 10 %
Tolerances for tightening torques of body screws: ±10 %
Screw thread lubricated with special grease paste: MOLYKOTE 1000
Material codes of KLINGER BallostarKHE ball valves
The material codes (m.c.) characterise the materials of body and flange end piece.
Used Materials:
DIN ANSI
Carbon steel: GS – C25N 1.0619 WCB
Stainless steel: G-X 6Cr NiMo 1810 1.4408 CF8M
1) Approval in cryogenic temperature range acc. to pressure-/temperature-diagram wT 2455/2 (13.05.96)
(Application limits acc. to AD-Merkblatt W 10 – technical sheet for the acceptance of facilities)
Size
DN
NPS
15
½”
20
¾”
25
1”
32
40
1 ½”
50
2”
65
2 ½”
80
3”
100
4”
125
-
150
6”
200
8”
Tightening torque of
stuffing box nut 5 15 15 25 25 20 20 40 40 40 o.r. o.r.
Tightening torque of
body screws 9 20 20 40 60 60 80 110 120 o.r. o.r.
SW of stopper screws 8 10 10 13 13 13 13 19 19 19 o.r. o.r.
SW of body screws 10 13 13 17 19 22 19 24 24 24 o.r. o.r.
SW of stuffing box nut:
DIN-version
ANSI-version
16
5/8”
22
7/8”
22
7/8
24
15/16”
24
15/16”
36
1 7/16”
36
1 7/16”
46
1 13/16”
46
1 13/16”
50
-
50
2”
65
2 9/16”
SW of operating stem 8 11 11 14 14 17 17 22 22 27 27 36
o.r. = on request
Symbol Body/end piece Internal parts Colour/surface treatment
VIII Carbon steel Without copper alloy black - phosphated
Xc Stainless steel Stainless steel blanc - pickled
wT 2575/11
Page 9
DESIGNATION OF PARTS AND MATERIALS
Materials
Pos. Parts of the standard version m.c. VIII m.c. Xc
1 Body 1.0619 (WCB) * 1.4408 (CF8M) **
2 Flange end piece 1.0619 (WCB) * 1.4408 (CF8M) **
3 Operating stem 1.4104 1.4571
4 Ball 1.4401(316)****
5 Sealing element *** Xc - KFC
6 Sealing ring *** KFC
7 Stopper 1.4301
8 Fem. support ring 1.4404
9 Labyrinth stuffing box* K – Flon / 4401 / Graphite
10 Slip ring KFC-25
11 Antistatic disc 1.4401
12 Loading ring 1.4404 plasma-nitrated
13 Hand lever 1.4006/Vinyl blue
14 Hexagon screw 8.8-A2L A4-70
15 Hexagon nut 8-A2L A4
16 Stuffing box nut 1.4404
17 Belleville washer 1.4310
18 Washer A4
19 Hexagon screw A4-70
20 Supporting ring Sint D10/Sint C39 1.4404 (316L)
21 Secondary body sealing Graphite
22 Socket head screw A4-70
23 Hexagon nut A4
19
18
7
16
12
17
8
11
9
13
22
23
14 1 10 3 6 4 20 5 21 15 2
* Zn/Fe phosphated
** pickled
*** Standard design
**** beginning with DN65: 1.4408
(CF8M)
wT 2575/11
Page 10
TYPE OVERVIEW
There are three different types of KHE ball valves available: KHE-FK, KHE-FL and KHE-CL
The valves are differed by:
- Overall length (EN 558-1 or ANSI 16.10 and basic series)
- Type of flange connection: a) KHE-FK and KHE-FL ball valves are delivered with flanges
acc. to EN 1092-1
b) KHE-CL ball valves are equipped with flanges acc. to ANSI B 16.5
- Pressure range (PN16, PN40 or Class 150, Class 300)
KHE-FL, long overall length acc. to EN 558-1, basic series 1 (DIN 3202-1F1)
KHE-FK, short overall length acc. to EN 558-1, basic series 27 (DIN 3202-1F4)
KHE-CL, short pattern acc. to ANSI B 16.10
Further information, as product features, dimensions, equipment and fields of application can be
gathered from the product catalogue.
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