KSB BOAX-B, Installation & Operating Manual

Page 1: ...Butterfly Valve Installation Operating Manual ...

Page 2: ...ded herein must neither be distributed copied reproduced 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 KSB S A S Gennevilliers Paris France 25 01 2022 ...

Page 3: ...4 Return to supplier 12 3 5 Disposal 13 4 Valve Description 14 4 1 General description 14 4 2 Product information 14 4 2 1 Product information as per Pressure Equipment Directive 2014 68 EU PED 14 4 2 2 EC Machinery Directive 2006 42 EC 14 4 2 3 Product information as per Regulation No 1907 2006 REACH 14 4 3 Marking 14 4 4 Name plate 14 4 5 Design details 15 4 6 Function 16 4 7 Scope of supply 16 ...

Page 4: ...th list of components 30 9 2 Dimensions and weights 32 9 2 1 Dimensions and weights of BOAX S 32 9 2 2 Dimensions and weights of BOAX SF 35 9 2 3 Dimensions and weights of BOAX S SF LP lever 38 9 2 4 Dimensions and weights of BOAX S SF MA manual gearbox 39 9 2 5 Dimensions and weights of BOAX S SF MN and MR manual gearboxes 40 9 2 6 Dimensions and weights of BOAXMAT S and BOAXMAT SF 41 9 3 Flange ...

Page 5: ... 5 Page 17 1 3 Target group This operating manual is aimed at the target group of trained and qualified specialist technical personnel 1 4 Other applicable documents Table 1 Overview of other applicable documents Document Contents Type series booklet Description of the valve General assembly drawing1 Sectional drawing of the valve Sub supplier product literature Operating manuals and other product...

Page 6: ...losion protection This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with the Equipment and Protective Systems Intended for use in Potentially Explosive Atmospheres Regulations 2016 Explosion protection This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with Technical Regulatio...

Page 7: ...g of the valve are subject to a QM system to DIN EN ISO 9001 as well as the current European Pressure Equipment Directive 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...

Page 8: ... 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...

Page 9: ...e cooled down to ambient temperature The pressure in the valve body must have been released and the valve must have been drained When taking the valve out of service always adhere to the procedure described in the manual The actuator must be disconnected from the external source of energy Decontaminate valves which handle fluids posing a health hazard Protect the valve body and the actuating eleme...

Page 10: ...t the valve in the specified position Never attach lifting accessories to the handwheel Observe the information on weights centre of gravity and fastening points Observe the applicable local accident prevention regulations Use suitable permitted lifting accessories e g self tightening lifting tongs For valves with actuators observe the relevant actuator operating manual Transport aids on the actua...

Page 11: ...isposal 11 of 50 8417 8 20 EN Fig 3 Transporting a valve with counterweight in a vertical position Fig 4 Transporting a valve with neck extension in a vertical position Fig 5 Transporting the valve in a horizontal position ...

Page 12: ...ature in the storage room must not exceed 40 C Cover the actuators to protect them from dust and dirt and protect them from mechanical damage If properly stored indoors the equipment is protected for a maximum of 12 months New valves are supplied by our factory duly prepared for storage For storing a valve which has already been operated observe the measures to be taken for shutdown ð Section 6 3 ...

Page 13: ...nd the environment Collect and properly dispose of flushing fluid and any residues of the fluid handled Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posing a health hazard 1 Dismantle the valve Collect greases and other lubricants during dismantling 2 Separate and sort the valve materials e g by Metals Plastics Electronic waste Grea...

Page 14: ...2006 42 EC Annex 1 4 2 3 Product information as per Regulation No 1907 2006 REACH For information as per chemicals Regulation EC No 1907 2006 REACH see https www ksb com ksb en About KSB Corporate responsibility reach 4 3 Marking In accordance with the current European Pressure Equipment Directive PED the valves are marked as shown in the following table Fluids in Groups 1 and 2 Fig 7 Fluids in Gr...

Page 15: ...ll and leak test to EN 12266 1 leakage rate A and ISO 5208 category A Face to face length to ISO 5752 20 and EN 558 1 20 Top flange to ISO 5211 Flange connections to EN ISO PN 6 BOAX S 10 and 16 Marking in accordance with EN 19 Valves manufactured without paint wetting impairment substances Body coating polyurethane 80 μm RAL 2002 orange Standard manual actuation LP lever MA and MR manual gearboxe...

Page 16: ...tomation options AMTROBOX M limit switch box with MA manual gearbox 4 6 Function Design The butterfly valve consists of the pressure retaining parts i e body 100 actuating shaft 213 the functional unit shaft 210 valve disc 550 elastomer liner 413 and the actuating element Function The valve is actuated via a lever manual gearbox or electric actuator Sealing Valve disc 550 and the actuating shaft a...

Page 17: ...ck any add on parts for in transit damage Do not install damaged valves 5 2 Installation position DANGER Dead end valve High pressure hazard Risk of burns Protect the valve against unauthorised and or unintentional opening A valve installed at the end of a pipeline and closed with a blind flange must not be regarded as a dead end valve Recommended upstream and downstream stabilisation distances Fi...

Page 18: ...age from or rupture of the valve body Connect the pipes to the valve without transmitting any stresses or strains Take structural measures to prevent any piping forces from being transmitted to the valve Avoid mechanical loads beyond normal levels e g piping forces moments and vibrations CAUTION Painting pipes and actuator Valve function impaired Protect stem plastic components and actuator elemen...

Page 19: ... the pipe flanges is within the permissible minimum and maximum diameter limits ð Section 9 3 Page 43 ü Open and close the valve to check that the valve disc rotates freely 1 Move the valve to the open position Open it as far as possible without the valve disc protruding beyond the body 2 Push the pipe flanges as far apart as required to achieve a sufficient clearance between the flange faces and ...

Page 20: ...16 x 110 81 0 8 x M16 x 110 81 0 8 x M16 x 110 125 84 5 8 x M16 x 115 79 5 8 x M16 x 120 79 5 8 x M16 x 120 150 91 5 8 x M16 x 115 81 5 8 x M20 x 130 81 5 8 x M20 x 120 200 92 0 8 x M16 x 125 82 0 8 x M20 x 130 82 0 12 x M20 x 130 250 87 5 12 x M16 x 135 77 5 12 x M20 x 150 72 5 12 x M24 x 150 300 69 5 12 x M20 x 150 67 0 12 x M20 x 160 59 5 12 x M24 x 160 Threaded rods 350 90 0 10 x M20 x 180 12 ...

Page 21: ... Threaded rods 350 90 0 32 x M20 x 55 82 5 32 x M24 x 60 400 100 5 32 x M24 x 60 93 0 32 x M27 x 70 450 105 5 40 x M24 x 60 93 0 40 x M27 x 70 500 108 0 40 x M24 x 60 85 5 40 x M30 x 80 600 107 0 40 x M27 x 70 77 0 40 x M33 x 90 When threaded rods or double ended studs are used at least 1 nut height must be added to the above bolt lengths 5 4 3 Dead end service Table 6 Dead end valve for all nomin...

Page 22: ...m is performed by a trained electrician Observe regulations IEC 60364 and for explosion proof models EN 60079 DANGER Flooding of electrical devices such as actuator control box solenoid valve limit switches etc Danger of death from electric shock Operate electrical devices in flood proof rooms only Do not expose electrical connections to any moisture Voltage and frequency must match the data state...

Page 23: ...pening and closing it several times The actuator has been connected to the power supply in accordance with the actuator s operating manual The piping has been flushed The material pressure data and temperature data of the valve are compatible with the operating conditions of the piping ð Section 6 2 Page 24 The material s chemical resistance and stability under load have been checked 6 1 2 Actuati...

Page 24: ...tor Electric actuators are factory set ready for operation and wired as follows Valve CLOSED travel dependent Valve OPEN travel dependent 6 1 3 Functional test The following functions must be checked 1 Check the shut off function of the installed valve prior to commissioning start up by opening and closing the valve several times 6 2 Operating limits 6 2 1 Ambient temperature Observe the following...

Page 25: ...e in the upper part of the yoke Move the lever in closing direction as required and lock in position with the locking device 6 3 1 2 Valve with manual gearbox Turn the handwheel up to the stop in closing direction Check on the position indicator fitted on top that the valve is actually closed 6 3 1 3 Valve with electric actuator 1 Disconnect the equipment from the power supply 6 4 Returning to ser...

Page 26: ...d Risk of injury Observe all relevant laws When draining the fluid take appropriate measures to protect persons and the environment Decontaminate valves used in fluids posing a health hazard NOTE Before removing the valve from the piping ensure that the pipe has been taken out of service and released for repair maintenance work NOTE All maintenance work service work and installation work can be ca...

Page 27: ...until the temperature of the fluid in all the valve s chambers is lower than the fluid s vaporisation temperature WARNING Unqualified personnel performing work on the valve Risk of injury Always have repair work and maintenance work performed by specially trained qualified personnel Always observe the safety instructions and information ð Section 7 Page 26 In the event of damage you can always con...

Page 28: ... level assembly surface 7 3 3 Assembling the valve 7 3 3 1 General information Safety regulations CAUTION Improper reassembly Damage to the valve Reassemble the valve in accordance with the general rules of sound engineering practice Use original spare parts only Tightening torques Use an appropriate tool to tighten the fasteners crosswise 7 3 3 2 Mounting the actuator ü All dismantled parts have ...

Page 29: ...seat area Flush valve dismantle if necessary and remove foreign matter Gearbox is blocked Deblock replace Electric actuator is not connected or damaged Connect to power supply Replace actuator Unfavourable flow conditions and restricted movement Change installation position Leakage at the seat disc interface Valve not fully connected Fully connect valve Liner and disc damaged or worn Replace liner...

Page 30: ...0 EN 9 Related Documents 9 1 General assembly drawing with list of components DN 20 25 DN 32 80 DN 100 150 Fig 13 Sectional drawings of BOAX S SF DN 20 to DN 150 DN 200 DN 300 DN 250 Fig 14 Sectional drawings of BOAX S SF DN 200 to DN 300 ...

Page 31: ... chromium 1 4029 6k 310 1 Plain bearing 200 600 Steel with reinforced PTFE coating 310 2 Plain bearing 200 600 Steel with reinforced PTFE coating 310 3 Plain bearing 200 600 Steel with reinforced PTFE coating 310 4 Plain bearing 350 600 Steel with reinforced PTFE coating 400 Gasket 500 600 Polypropylene 412 O ring 250 600 EPDM 413 Liner 20 600 EPDM XU 20 600 High grade nitrile K 550 Valve disc 20 ...

Page 32: ...cuments 32 of 50 8417 8 20 EN 9 2 Dimensions and weights 9 2 1 Dimensions and weights of BOAX S DN 20 50 DN 65 80 DN 100 DN 125 150 DN 200 DN 250 DN 300 DN 350 450 DN 500 DN 600 Fig 16 Sectional drawings of BOAX S ...

Page 33: ... 70 164 82 F05 40 9 12 21 55 11 2 2 80 46 138 70 170 88 9 F05 40 9 12 21 71 17 2 8 100 52 150 70 191 103 F05 40 11 14 24 90 23 4 4 125 56 234 70 204 5 117 3 F05 40 11 14 24 119 35 5 6 150 56 260 95 224 130 F07 42 17 22 25 144 46 7 8 200 60 322 95 252 161 F07 42 17 22 25 196 69 11 9 250 68 394 133 275 197 F10 38 19 25 249 92 17 8 300 78 462 158 290 231 F12 28 5 22 29 297 111 32 0 350 78 538 183 338...

Page 34: ... Table 11 Bolt circle diameter mm DN Bolt circle diameter Ø K PN 6 PN 10 PN 16 20 25 75 85 85 32 90 100 100 40 100 110 110 50 110 125 125 65 130 145 145 80 150 160 160 100 170 180 180 125 200 210 210 150 225 240 240 200 280 295 295 250 335 350 355 300 395 400 410 350 460 470 400 515 525 450 565 585 500 620 650 600 725 770 ...

Page 35: ...ed Documents 35 of 50 8417 8 20 EN 9 2 2 Dimensions and weights of BOAX SF DN 20 65 DN 200 PN16 DN 150 DN 200 PN 10 DN 100 125 DN 80 DN 600 DN 500 DN 350 450 DN 300 DN 250 Fig 18 Sectional drawings of BOAX SF ...

Page 36: ... F05 40 9 12 21 55 11 3 0 80 10 16 46 178 70 170 88 9 F05 40 9 12 21 71 17 4 5 100 10 16 52 210 70 191 103 F05 40 11 14 24 90 23 5 5 125 10 16 56 236 70 204 5 117 3 F05 40 11 14 24 119 35 9 0 150 10 16 56 260 95 224 130 F07 42 17 22 25 144 46 11 0 200 10 60 312 95 252 156 F07 42 17 22 25 196 69 24 0 200 16 60 322 95 252 161 F07 42 17 22 25 196 69 25 0 250 10 68 396 133 275 198 F10 38 19 25 249 92 ...

Page 37: ...OAX SF Fig 19 Connection for BOAX SF Table 13 Bolt circle diameter Ø K DN PN 10 PN 16 20 75 75 25 85 85 32 100 100 40 110 110 50 125 125 65 145 145 80 160 160 100 180 180 125 210 210 150 240 240 200 295 295 250 350 355 300 400 410 350 460 470 400 515 525 450 565 585 500 620 650 600 725 770 ...

Page 38: ...mm mm kg 3 kg 3 20 25 165 163 1 156 70 1 1 20 165 163 1 156 70 1 3 25 165 163 1 156 70 1 3 32 165 167 1 178 70 1 5 2 6 40 165 185 1 178 70 1 8 2 6 50 165 189 6 183 70 2 1 3 1 65 165 216 1 209 70 2 8 3 6 80 165 222 1 215 70 3 4 5 1 100 230 253 253 70 5 2 6 3 125 230 256 266 70 6 2 9 8 150 330 298 298 95 9 1 12 3 200 330 326 326 95 13 2 25 3 250 460 374 374 133 20 1 41 3 3 The weights given refer to...

Page 39: ... BOAX S BOAX SF mm mm mm kg 4 kg 4 20 25 MA12 140 198 60 2 1 20 MA12 140 195 60 2 5 25 MA12 140 198 60 2 5 32 MA12 140 202 60 2 4 3 5 40 MA12 140 220 60 2 7 3 5 50 MA12 140 225 60 3 0 4 0 65 MA12 140 251 60 3 7 4 5 80 MA12 140 257 60 4 3 6 0 100 MA12 140 285 70 5 9 7 0 125 MA12 140 299 70 7 1 10 5 150 MA25 225 355 95 10 8 14 0 200 MA25 225 383 95 14 9 27 0 250 MA25 225 406 133 20 8 42 0 4 The weig...

Page 40: ...2 BOAX S BOAX SF mm mm mm mm mm mm kg 5 kg 5 150 MN25 46 140 38 41 200 318 9 7 12 9 200 MR25 62 184 66 64 225 403 18 9 32 0 250 MR25 62 184 66 64 225 426 24 8 46 0 300 MR50 74 184 77 76 225 453 42 0 56 0 350 MR50 74 184 77 76 225 501 70 0 80 0 400 MR100 86 233 88 88 350 595 95 0 116 0 450 MR100 86 233 88 88 350 625 125 0 175 0 500 MR100 86 233 88 88 350 677 160 194 0 600 MR200 120 270 108 117 350 ...

Page 41: ...SF bar mm mm mm mm mm kg 6 kg 6 20 25 10 16 AQ1L 67 85 83 60 104 277 3 1 20 10 16 AQ1L 67 85 83 60 104 277 3 5 25 10 16 AQ1L 67 85 83 60 104 277 3 5 32 10 16 AQ1L 67 85 83 60 108 281 3 4 4 5 40 10 16 AQ1L 67 85 83 60 126 299 3 7 4 5 50 10 16 AQ3L 67 85 83 60 131 304 4 0 5 0 65 10 16 AQ3L 67 85 83 60 157 330 4 7 5 5 80 10 16 AQ7L 67 85 83 60 163 354 5 8 7 5 100 10 16 AQ7L 67 85 83 60 191 382 7 4 8 ...

Page 42: ...0 16 AQ5 180 96 74 110 100 126 412 11 2 12 0 50 10 16 AQ5 180 96 74 110 100 131 417 11 5 12 5 65 10 16 AQ5 180 96 74 110 100 157 443 12 2 13 0 80 10 16 AQ5 180 96 74 110 100 163 449 12 8 14 5 100 10 16 AQ10 180 96 74 110 100 191 477 14 4 15 5 125 10 16 AQ10 180 96 74 110 100 205 491 15 6 19 0 150 10 16 AQ15 180 96 74 110 100 224 510 17 8 21 0 200 10 16 AQ15 248 117 86 138 100 252 569 24 9 37 0 250...

Page 43: ...for valve body type 4 Table 19 Pipe flange dimensions mm DN NPS Ø2a Ø2b Ø3 Ø6 C1 C2 20 32 27 46 0 4 5 25 1 37 34 15 55 0 4 5 32 1 46 43 31 67 0 8 5 40 1 54 49 32 77 1 5 50 2 63 61 33 86 1 3 5 65 2 80 77 55 107 1 6 5 80 3 93 89 71 121 2 7 5 100 4 116 115 90 141 3 5 125 8 141 5 140 119 171 3 2 5 150 6 170 57 169 144 196 4 7 10 200 8 2227 220 196 250 6 10 250 10 276 57 273 249 306 8 1 10 300 12 327 5...

Page 44: ...20 DN 32 600 ISORIA 25 PN 25 DN 32 1000 MAMMOUTH PN 6 10 20 25 DN 1050 4000 KE Plastomer PN 10 DN 40 600 KE Elastomer PN 10 DN 40 300 DANAÏS MTII PN 25 50 Class 150 300 DN 50 600 DANAÏS 150 PN 25 Class 150 DN 50 1200 TRIODIS 150 PN 20 Class 150 DN 50 1200 TRIODIS 300 PN 50 Class 300 DN 80 1200 TRIODIS 600 PN 100 Class 600 DN 150 1000 DANAÏS CRYO PN 10 20 Class 150 DN 50 1200 DANAÏS CRYO AIR PN 10 ...

Page 45: ...quids Gases8 Hazardous9 Yes No Yes No Yes No Yes No Group 1 2 1 2 1 2 1 2 Table10 8 9 6 7 8 9 6 7 Type of liner XV XA XC K VC EG CC NB NH SK Y CB Table 21 For ISORIA 20 ISORIA 25 and MAMMOUTH valves Valves ISORIA 20 ISORIA 25 and MAMMOUTH Fluid handled Liquids Gases8 Liquids Gases8 Hazardous9 Yes No Yes No Yes No Yes No Group 1 2 1 2 1 2 1 2 Table10 8 9 6 7 8 9 6 7 Type of liner XV XA XC K VC EG C...

Page 46: ...9 Yes No Yes No Yes No Yes No Group 1 2 1 2 1 2 1 2 Table10 8 9 6 7 8 9 6 7 Type of liner XV XA Y CB F Production sites La Roche Chalais Dalian and Burgos Name and address of the notified body responsible for approval and surveillance Bureau Veritas Services SAS 8 cours du Triangle 92800 Puteaux FRANCE Identification number of the notified body 0062 The EU Declaration of Conformity was issued in o...

Page 47: ...s have been carefully drained cleaned and decontaminated inside and outside prior to dispatch placing at your disposal We herewith declare that this product is free from hazardous chemicals and biological and radioactive substances No special safety precautions are required for further handling The following safety precautions are required for flushing fluids fluid residues and disposal We confirm...

Page 48: ...tion 18 Fluids in Group 1 14 Fluids in Group 2 14 Function 16 I Installation position 17 Insulation 22 Intended use 7 K Key to safety symbols markings 6 M Maintenance 26 N Noise characteristic 16 O Operating limits 7 24 Other applicable documents 5 P Partly completed machinery 5 Piping 18 Preservation 12 R Return to supplier 12 Returning to service 25 S Safety 7 Safety awareness 8 Scope of supply ...

Page 49: ......

Page 50: ...KSB S A S 4 allée des Barbanniers 92635 Gennevilliers Cedex France Tél 09 69 39 29 79 www ksb com fr fr 8417 8 20 EN ...