Spirax Sarco Spira-trol KE73 Bedienungsanleitung

IM-S24-25

Issue 1 - 2008

3.563.5275.210

Series K

DN125, DN150 and DN200 Control Valves

Installation and Maintenance Instructions

1. Safery informations

2. Operation

3. Installation and commisioning

4. Maintenance

5. Spares

The PED Directive 97/23/EC is repealed and replaced by the new

PED Directive 2014/68/EU with effect from 19 July 2016.

ATTENZIONE

Lavorare in sicurezza con apparecchiature

in ghisa e vapore

Working safely with cast iron products on steam

Informazioni di sicurezza supplementari - Additional Informations for safety

Lavorare insicurezza conprodotti

in ghisa per linee vapore

I prodotti di ghisa sono comunemente presenti

in molti sistemi a vapore.

Se installati correttamente, in accordo alle

migliori pratiche ingegneristiche, sono dispositivi

totalmente sicuri.

Tuttavia la ghisa, a causa delle sue proprietà

meccaniche, è meno malleabile di altri materiali

come la ghisa sferoidale o l’acciaio al carbonio.

Di seguito sono indicate le migliori pratiche

ingegneristiche necessarie per evitare i colpi

d'ariete e garantire condizioni di lavoro sicure

sui sistemi a vapore.

Movimentazione in sicurezza

La ghisa è un materiale fragile: in caso di

caduta accidentale il prodotto in ghisa non è

più utilizzabile. Per informazioni più dettagliate

consultare il manuale d'istruzioni del prodotto.

Rimuovere la targhetta prima di effettuare la

messa in servizio.

Working safely with cast iron

products on steam

Cast iron products are commonly found on steam

and condensate systems.

If installed correctly using good steam

engineering practices, it is perfectly safe.

However, because of its mechanical properties,

it is less forgiving compared to other materials

such as SG iron or carbon steel.

The following are the good engineering prac-

tices required to prevent waterhammer and

ensure safe working conditions on a steam

system.

Safe Handling

CastIronisa brittlematerial.If theproduct isdropped

during installation and there is any risk of damage

the product should not be used unless it is fully

inspectedand pressuretested bythe manufacturer.

Please remove label before commissioning

Vapore

Steam

Flusso

Flow

Esempi di esecuzioni corrette ( ) ed errate ( ) sulle linee vapore:

Steam Mains - Do's and Dont's:

Flusso

Flow

Prevenzione dai colpi d’ariete - Prevention of water hammer

Scarico condensa nelle linee vapore - Steam trapping on steam mains:

Intervalli di 30÷50 m. intervals

Pendenza - Gradient 1:100

Vapore

Steam Gruppo di scarico

Trap set

Condensa - Condasate

Pendenza - Gradient 1:100

Gruppo di scarico

Trap set

Gruppo di scarico

Trap set

Condensa - Condasate

Vapore

Steam

Prevenzione delle sollecitazioni di trazione

Prevention of tensile stressing

Evitare il disallineamento delle tubazioni - Pipe misalignment:

Installazione dei prodotti o loro rimontaggio post-manutenzione:

Installing products or re-assembling after maintenance:

Evitare l’eccessivo serraggio.

Utilizzare le coppie di serraggio

raccomandate.

Do not over tighten.

Use correct torque gures.

Per garantire l’uniformità del carico e dell'allineamento,

i bulloni delle ange devono essere serrati in modo

graduale e in sequenza, come indicato in gura.

Flange bolts should be gradually tightened across

diameters to ensure even load and alignment.

Dilatazioni termiche - Thermal expansion:

Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una

consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione.

Examples showing the use of expansion bellows. It is highly recommended that expert advise is

sought from the bellows manufacturer.

Guide

Guides

Distanza breve

Short distance

Punto di ssaggio

Fixing point

Movimento assiale

Axial movement

Distanza

media

Medium

distance

Tiranti limitatori

Limit rods

Piccolo

movimento

laterale

Small

lateral

movement

Piccolo

movimento

laterale

Small

lateral

movement

Ampio

movimento

laterale

Large

lateral

movement

Ampio

movimento

laterale

Large

lateral

movement

Guide

Guides

Guide

Guides

Guide

Guides

Punto di ssaggio

Fixing point

Tiranti limitatori

Limit rods

Movimento assiale

Axial movement

3.563.5275.210

1. Safety informations

I) The products have been specifically designed for use on water, steam, diathermic oil, air or

condensate which are in Group 2 of the above mentioned Pressure Equipment Directive.

The products’ use on other fluids within Group 2 or fluids within Group 1 may be possible but,

if this is contemplated, Spirax Sarco should be contacted to confirm the suitability of the

product for the application being considered.

II) Check material suitability, pressure and temperature and their maximum and minimum values.

If the maximum operating limits of the product are lower than those of the system in which it

is being fitted, or if malfunction of the product could result in a dangerous overpressure or

overtemperature occurrence, ensure a safety device is included in the system to prevent

such over-limit situations.

III) Determine the correct installation situation and direction of fluid flow.

IV) Spirax Sarco products are not intended to withstand external stresses that may be induced

by any system to which they are fitted. It is the responsibility of the installer to consider these

stresses and take adequate precautions to minimise them.

V) Remove protection covers from all connections before installation.

Safe operation of these products can only be guaranteed if they are properly installed,

commissioned, used and maintained by qualified personnel (see Section 11 on this document) in

compliance with the operating instructions. General installation and safety instructions for pipeline

and plant construction, as well as the proper use of tools and safety equipment must also be

complied with.

1. Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical Information

Sheet, check that the product is suitable for the intended use/application. The products listed

below comply with the requirements of the European Pressure Equipment Directive 97/23/EC

and carry the mark when so required. The products fall within the following Pressure Equipment

Directive categories:

KE73, KE43 DN125 to DN200 valves

Product DN PS Group 1 Group 1 Group 2 Group 2

Gas Liquid Gas Liquid

125 2 SEP 1 SEP

KE73, KE63, KE43 150 16 bar 3 2 1 SEP

200 3 2 1 SEP

125 2 2 1 SEP

KE73, KE63, KE43 150 25 bar 3 2 2 SEP

200 3 2 2 SEP

125 3 2 2 SEP

KE63, KE43 150 40 bar 3 2 2 SEP

200 3 2 2 SEP

3.563.5275.210 3

2. Access

Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting

to work on the product. Arrange suitable lifting gear if required.

3. Lighting

Ensure adequate lighting, particularly where detailed or intricate work is required.

4. Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some previous time.

Consider: flammable materials, substances hazardous to health, extremes of temperature.

5. Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of

temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.

6. The system

Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.

closing isolation valves, electrical isolation) put any other part of the system or any personnel at risk?

Dangers might include isolation of vents or protective devices or the rendering ineffective of

controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system

shocks.

7. Pressure systems

Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double

isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume

that the system has depressurised even when the pressure gauge indicates zero.

8. Temperature

Allow time for temperature to normalise after isolation to avoid danger of burns.

9. Tools and consumables

Before starting work ensure that you have suitable tools and/or consumables available. Use only

genuine Spirax Sarco replacement parts.

10. Protective clothing

Consider whether you and/or others in the vicinity require any protective clothing to protect against

the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects,

and dangers to eyes and face.

11. Permits to work

All work must be carried out or be supervised by a suitably competent person.

Installation and operating personnel should be trained in the correct use of the product according

to the Installation and Maintenance Instructions.

Where a formal 'permit to work' system is in force it must be complied with. Where there is no

such system, it is recommended that a responsible person should know what work is going on

and, where necessary, arrange to have an assistant whose primary responsibility is safety.

Post 'warning notices' if necessary.

3.563.5275.210

12. Handling

Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing,

pulling, carrying or supporting a load by bodily force can cause injury particularly to the back. You

are advised to assess the risks taking into account the task, the individual, the load and the

working environment and use the appropriate handling method depending on the circumstances

of the work being done.

13. Residual hazards

In normal use the external surface of the product may be very hot. If used at the maximum

permitted operating conditions the surface temperature of some products may reach temperatures

of 232°C (450°F).

Many products are not self-draining. Take due care when dismantling or removing the product

from an installation (refer to 'Maintenance instructions').

14. Freezing

Provision must be made to protect products which are not self-draining against frost damage in

environments where they may be exposed to temperatures below freezing point.

15. Disposal

Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable

and no ecological hazard is anticipated with its disposal providing due care is taken.

16. Returning products

Customers and stockists are reminded that under EC Health, Safety and Environment Law, when

returning products to Spirax Sarco they must provide information on any hazards and the

precautions to be taken due to contamination residues or mechanical damage which may present

a health, safety or environmental risk. This information must be provided in writing including

Health and Safety data sheets relating to any substances identified as hazardous or potentially

hazardous.

3.563.5275.210 5

2. Operation

2.1 General Description

With the development of modern industrial processes, experience has shown that the advantage

of precise control instruments will be lost unless the associated control valves have good operating

and flow characteristics. The range of KE valves have been designed to meet these requirements

and embody a precise characteristic having a high turndown ratio.

2.2 Technical details and ratings

Maximum allowable body pressure at 120°C

SG Iron (KE 73) 25 bar

Carbon Steel (KE 43) 40 bar

Maximum temperatures:

SG Iron 350°C

Carbon Steel 400°C

Refer to appropriate TI sheets for relevant Pressure/temperature Relationships.

2.3 Nomenclature

KE 73 SG Iron Valves

KE 43 Cast Steel Valves

3. Installation and commisioning

3.1. Installation

The valve should be installed in such a position as to allow full access to valve and actuator for

maintenance purposes. Prior to fitting the valve the pipework should be flushed clear to remove

any debris or other particles.

Remove the flange protectors and fit the valve into the pipeline taking notice of direction of flow

arrow on the body.

Care should be taken to prevent any strain being imposed on the valve body due to pipe

misalignement. Tighten flange bolts evenly. Check flange bolts for tightness after 24 hours of

operation.

Care should be taken to ensure that the valve/actuator spindle is not painted or coated with any

other substance.

When carrying out maintenance of the valve care should be taken to avoid damage to the valve

plug, stem and seat.

3.2 Bypass arrangements

It is reccomended that isolating valves be fitted upstream and downstream of the control valve. A

bypass can be fitted around the valve with a manual regulating valve allowing the process to be

controlled whilst the control valve is isolated for maintenance.

3.3 Commissioning

For commissioning instructions refer to the Operation, Installation and Maintenance Instructions,

covering Spirax Sarco Actuators.

3.563.5275.210

4. Maintenance

4.1. Procedure for renewing stem seals (Fig.2.)

a) Isolate the valve.

b) Remove actuator from valve.Refer to Installation and Maintenance Instructions covering Spirax

Sarco Actuators.

c) Remove locknut (1).

CAUTION: Care should be taken in removing the stem seal since fluid under pressure may be

trapped between the isolating valves.

d) Unscrew the bonnet nuts (8) and withdraw the bonnet (12) taking care not to damage the

spindle surface.

e) Unscrew and remove gland nut (2). By mean of a hooked tool in soft metal like brass, remove

the gland ring set (3), the washers (6) and the spring (4).

f) Examine parts for signs of damage or deterioration and renew as necessary. Note that score

marks or scaly deposits on the valve stem (5) will lead to early failure of the seals.

Clean parts taking care to avoid scratching the stem or bore of the packing chamber.

See paragraph 4.3 for renewing valve stem (5).

g) Refit the bonnet and finger tighten the bonnet nuts.

h) Insert washers, spring and new gland ring seals into the packing chamber following the

sequence shown in fig.1, care being taken to avoid damage to the sealing edges.

i) Refit the gland nut (2) and tighten until resistance is felt and unscrew two turns.

j) Ensure that the stem (5) moves freely.

k) Refit valve lock nut (1).

l) Bring the valve back into service

m) Check for leakage at gland.

Chart of Recommended Torques (Nm)

Size Seat Bonnet Nuts Plug Nut & Lock Nut

DN (9) (8) (13/14)

150 270-290 150-160 230-250

200 320-340 110-120 230-250

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