KLINGER Ballostar KHE Leitfaden

wT 2575/11

Page 1

Mounting and treatment instructions for

KLINGER

BallostarKHE 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

6 4 1 15 22 2 16

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 Ballostarball 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 BallostarKHE 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

NPS

½”

¾”

1”

1 ½”

2”

2 ½”

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

5/8”

7/8”

7/8

15/16”

1 7/16”

1 13/16”

2”

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

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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