Butterfly Valve

APORIS

DN 300-2000

Epoxy-coated

Flanged Ends

Operating Instructions

APORIS - 2

Legal information/Copyright

Operating Instruction APORIS

KSB

All rights reserved. The contents provided 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 KSB's express written consent.

Subject to technical modification without prior notice.

© KSB

APORIS - 3

Table of Content:

1. Technical Description

2. General

3. Safety

4. Transport and Interim Storage

5. Operating Limits / Description of valves

6. Installation

7. Commissioning/Decommissioning

8. Maintenance/Repair

9. Trouble Shooting

10. KSB Service

11. EU declaration of conformity

APORIS - 4

1. Technical Description

Butterfly Valves

Double-offset Butterfly Valves

APORIS

Main applications • Irrigation systems • Cooling circuits • Seawater desalination / reverse osmosis

• Shipbuilding • Water treatment • Water supply systems

Fluids handled • Service water • River, lake and groundwater • Cooling water • Seawater • Drinking water

Operating data Operating properties

Design details Design

• Double-flanged body with short face-to-face length to

EN 558/14,,

• Flanges PN 16,

• Design to EN 593,

• In compliance with EN 12266-1,

• Marked in accordance with EN 19,

• Perfectly tight shut-off in either direction of flow (no

leakage visible to the naked eye),

• Mechanical stop on the valve (DN700 and above),

• Valve certified for drinking water applications to

WRAS (elastomer and coating),

• Manual actuator/gearbox,

Variants

• Limit switches,

• PN10, PN25, PN40 pressure class and flanges, • Pneumatic actuators, • Electric actuators, • Locking device,

Product benefits

• Body with flanged ends, suitable for downstream

dismantling and dead-end service,

• Long-term, reliable shut-off and sealing to atmosphere,

On all enquiries / orders please specify

1. Type

2. Nominal pressure 3. Nominal size

4. Operating pressure

5. Differential pressure

6. Operating temperature 7. Fluid handled 8. Pipe connection 9. Variants

10. Number of type series booklet

Characteristic Value

Nominal pressure PN 16 Nominal size DN 300-2000mm Max. permissible pressure 16 bar Min. permissible temperature 0 °C Max. permissible temperature 85 °C Selection as per pressure/temperature ratings

Body materials Overview of available materials

Material Material number Temperature limit EN-GJS-400-15 JS1030 Up to 85 °C

APORIS - 5

2 . G e n e r a l These operating instructions apply to KSB Double Offset butterfly

valves. Design, manufacturing and testing of the KSB valves are subject to

a Quality Assurance System according to EN ISO. For a specific product configuration as an actuated valve, the

aggregate can be considered as a partly completed machine

according to the machinery directive 2006/42/EC and comply with

the requirements of the directive.

Correct installation and maintenance or repair are mandatory to

ensure trouble free operation of the valves. The manufacturer cannot be made liable for these valves if operating

instructions are not being observed.

ATTENTION The valves must not be operated outside the

permissible operating range. The limits are indicated on the name

plate or currently applicable type leaflet. The pressure-temperature

ratings, in particular, must not be exceeded. Operation of the valves

outside the above-mentioned conditions may result in overloads

which may damage the valves. The type leaflets can be found at www.ksb.com – product catalogue.

Nonobservance of this warning may lead to personal injury

or property damage, e.g.:

- Injury caused by escaping fluids (cold/hot, toxic,

flammable, corrosive or under pressure) - Incorrect operation or

destruction of the valve. The descriptions and instructions in this manual refer to the standard

versions but also apply to the related variants. These operating instructions do not take into consideration: - Incidents which may occur during installation, operation and

maintenance.

- The local safety regulations. lt is the user’s responsibility to ensure

that these are also observed by the installation staff involved. For actuated valves, the specified connection parameters and the installation and maintenance instructions - including the operating

manual for the actuator - must be observed.

ATTENTION Handling a valve requires skilled and experienced

personnel. The personnel in charge of operation, maintenance and installation

of this valve must be aware of the interaction between the valve and

the plant. Operator’s errors concerning the valve may have serious

consequences for the entire plant, e.g.:

- fluid may escape - downtime of the plant/machine - adverse effect/reduction/increase of the efficiency/function of a

plant/machine.

For further questions or in case of damage to the valve, please

contact your KSB Sales Office. For further questions and supplementary orders, especially when

ordering spare parts, please always state the indications of the

marking plate. The specifications (operating data) of the valves are listed in the

technical documentation & type leaflet of the related valve When returning valves to the manufacturer, please refer to section

4.

3 . Safety This manual contains basic instructions to be complied with during

operation and maintenance. lt is therefore vital for the fitter and the

operator/user to read this manual before installing/commissioning

the valve. Also, this manual must always be available at the site

where the valve is installed. lt is not enough to observe the general instructions listed in the

section ”safety”, the specific safety instructions listed in the other

sections should also be observed.

3.1 Safety Symbols in these Operating Instructions Safety instructions put forth in this instruction manual, the

nonobservance of which would involve the risk of personal injury,

they are specially marked with the general hazard symbol:

in accordance with ISO 3864-B.3.1. or

with the electric voltage warning sign:

In accordance with ISO 3864-B.3.6. Safety instructions the nonobservance of which would involve hazard

to the valve and jeopardize its operation have been marked with the

word

ATTENTION

lnstructions directly attached to the valve, (e.g. nominal pressure)

must be complied with and maintained in a legible condition.

3.2 Qualification of personnel and training The personnel for operation, maintenance, Inspection and

installation must be adequately qualified for the work involved. The

personnel responsibility, competence and supervision must be

clearly defined by the user. lf the personnel in question is not already

in possession of the required know-how, appropriate training and

instructions must be provided. lf deemed necessary, the

manufacturer/supplier will provide such training and instructions at

the user’s request. In addition, the user is responsible for ensuring

that the contents of these operating instructions are fully understood

by the personnel involved.

3.3 Danger or nonobservance of the safety

instructions Nonobservance of the safety instructions may lead to personal injury

and danger for both the environment and the valve itself.

Nonobservance of these safety instructions will also forfeit the user’s

warranty. Such noncompliance could result in for example: - failure of essential functions of the valve/plant - failure of prescribed maintenance and repair practices - hazard to people by electrical, mechanical or chemical effects - hazard to the environment due to leakage of hazardous substances 3.4 Safety Consciousness The safety instructions contained in this manual, the applicable

national accident prevention regulations and any of the user’s own

applicable internal work, operation or safety instructions must be fully

complied with.

3.5 Safety Instructions for the User/Operator Any hot or cold parts of the valve (e.g. body or handle or

actuator) that could cause a hazard must be protected by

the user against accidental contact.

Leakage of hazardous substance (e.g. flammable, corrosive,

toxic, hot) must be drained so as to avoid all danger to people or the

environment. All relevant laws must be observed. Electrical hazards must be effectively prevented. (For details, please

refer to the IEC 364 or equivalent national standard and/or local utility energy supply regulation

APORIS - 6

3.6 Safety lnstructions for Maintenance, Inspection and Installation work

3.6.1 General

On an actuated valve the operating instructions of the valve must be strictly followed as well as those of the operating

instructions of the actuators, the limit switch or automation boxes.

The user is responsible for ensuring that all maintenance, inspection and installation work is carried out by authorized,

adequately qualified staff who are thoroughly familiar with this instruction manual.

Any work on a valve may only be performed when the valve is un-pressurized and has cooled down to 60°C.

Any work on actuated valves may only be done after that the actuator has been disconnected from its energy supply.

The procedure described in the operating instructions to shut down the actuator must be observed. Valves in contact with

hazardous media must be decontaminated. Immediately following completion of the work, all safety relevant and protective

devices must be reinstalled and/or re-enabled. Prior to recommissioning, refer to the points listed under section 7 Commissioning.

3.6.2 End of line installation

Please refer to §5.6 NB: A valve fitted at the end of a pipe with a blind flange downstream is not to be considered as an end of pipe service.

3.6.3 Locking device

Please refer to §5.7 This option could be used in order to lock the valve in full open or full close position and to remove the actuator from the valve.

Do not operate the valve when the locking device is engaged.

3.7 Unauthorized Modification and Manufacturing of Spare Parts The equipment shall not be altered or modified in any way prior to consultation with the manufacturer. Genuine spare parts

and accessories authorized by the manufacturer will ensure operational safety. The manufacturer cannot be held responsible

for damage resulting from the use of non-genuine parts or accessories.

3.8 Inadmissible Modes of Operation Operational safety and reliability of the valve supplied is only warranted for its designated use as defined in section 2 ”General”

of the operating instructions. The limits stated in the technical documentation must not be exceeded under any circumstances.

4. Transport and Interim Storage

4.1 Transport

The valves in the as-supplied condition are ready for operation.

ATTENTION For transport and storage, the valves must always be maintained in the semi-closed position and be packed in

cardboard, crate or case with suitable protection (desiccant, thermowelded barrier).

ATTENTION To prevent damage, do not hang the valve by its handle or disc or actuator.After delivery or prior to installation,

the valve should be checked for damage during transit.

4.2 Interim Storage

The valves must be stored in such a way that correct operation is assured even after prolonged storage.

This comprises:

- Storing at 5° from the closed position - Suitable measures against contamination, frost and corrosion (e.g. by using thermowelded plastic bags with desiccant,

protection caps and plugs onto threaded holes) - Temperature from +5°C to +50°C - To protect the seals ( elastomer parts) against direct sunlight and/or UV - Dry and aerated place, clean, without any contact with sand or other debris

APORIS - 7

5. Operating limits / description of valves

5.1 Marking

Marking of the identity plate Example

1 – Valve type model

2 – Nominal Diameter

3 – Valve PN

4 – Maximum allowable pressure

5 – Maximum allowable pressure at end of line of for downstream dismantling

6 – Maximum allowable temperature

7 – Pipe flange drilling pattern

8 – Internal material code

9 – Month and year of production

10 – Equipment serial number

5.2 Drawings and documents

Type DN (mm) PS (bar) Leaflet No.

APORIS 16 300 - 2000 16 8123.5

Part No. Name of parts

100 Body

176 Bottom

210 Shaft

213 Operating shaft

310 Plain bearing

411 Gasket

412 O-ring

550 Disc

72-3 Tightening flange

901 Hexagon head screw

940 Key

970 Identity plate

1

2 3

4 / 5 / 6

7

8

9 10

Preferred flow direction

APORIS - 8

5.3 Cavitation

APORIS is a Double Offset Butterfly Valve to be used as a shut off valve and on/off position. In case it is

requested to control the flow, please, call your nearest KSB sales Company giving all related technical information.

Do not operate the valve under cavitation conditions.

5.4 Flow Velocity

Following limits should be observed with fully open position: Pressure rating PN 16: 4.0 m/s

5.5 Maximum temperature and pressure

Pressure rating PN 16: 16 bar at 85°C 5.6 End of line installation

Use as end of line and downstream dismantling at ambient temperature of standard range.

NB: A valve fitted at the end of a pipe with a blind flange downstream is not to be considered as an end of pipe service.

Valves

Gas or liquids* Liquids

Hazardous

(Group 1)

Non hazardous

(Group 2)

Hazardous

(Group 1)

Non hazardous

(Group 2)

APORIS All sizes : not

authorized

All sizes : not

authorized

All sizes : not

authorized

All sizes :

ΔPS = 10 bar max

PS: Differential pressure * Liquids whose vapour pressure at the maximum allowable temperature is greater than 0.5 bar

above normal atmospheric pressure (1013 mbar)

5.7 Optional accessories

Locking device It is possible to lock the position of the disc in full open or full close position by means of locking device.

This locking device is fixed on the body instead of the bottom rep. 176.

Locking device engaged Locking device disengaged

Do not operate the valve when the locking device is engaged.

APORIS - 9

6 Installation

6.1 General

ATTENTION To avoid leakage, deformation or rupture of the body, the piping should be laid out in such a way that no

thrust or bending forces act on the valve bodies when they are installed and operational. The pipeline must be coplanar and

aligned and tension-free for the valve

ATTENTION Sealing faces of the flanges must be cleaned and undamaged.

lf construction work is still in progress, non-mounted valves must be protected against dust, sand and building

material etc.(cover with suitable means). Do not use valve handles and gear hand wheels as footholds!

Valves and pipes used for high (> 60 °C) temperatures must either be fitted with a protective insulation, or there

must be warning signs fitted showing that it is dangerous to touch these valves.

lf a valve is used as end-valve in a pipe, this valve should be protected against unauthorized or unintentional opening to prevent personal injury or damage to property.

For drinking water installation make sure to use approved material for lubricant, cleaning, painting, etc.

If a valve is used as end-of-line on a pipe, this valve should be protected against unauthorized or unintentional

opening to prevent personal injury or damage to property.

The preferred flow direction of operation is indicated by an arrow on the body. Anyway, the valve is designed to

work, to be waterproof and resist to the pressure in both directions. 6.2 Recommended distance upstream and downstream of the valve

6.2.1 Recommended minimum distance between the position of the valve and of the T-piece or elbow

Also valid for valve placed at pump discharge

APORIS - 10

6.2.2 Downstream of a control valve or a plunger valve or a flowmeter

- Minimum 10XDN

6.2.3 Flanging dimensions

The dimensional compatibility of the flange gasket must be checked to ensure the connection quality, according to the

dimensions defined hereunder:

Size Ø 1 Ø 2

300 369 308

400 479 403

500 608 503

600 719 606

700 793 703

800 900 803

900 1000 903

1000 1111 1003

1200 1327 1203

1400 1529 1403

1600 1749 1603

1800 1949 1804

2000 2149 2004

6.3 Installation Position

Valves sizes DN ≤ 600 may be installed in:

Horizontal Position Vertical Position

Ø 2 Ø 1

APORIS - 11

Valves sizes DN > 600 should be installed in horizontal position because: - The weight of the disc and shafts is borne by the two bearings, - the pivot bearing is relieved, - it is a guarantee of long valve life, especially in the case of fluids containing solids, where sold particles tend to accumulate

on the bottom of the pipe ( during the closing, the reduction in cross-section causes a local increase in velocity which

results in a "sweeping" or "cleaning" of the liner). Note: please ask your nearest KSB Sales Office for special design in case of mandatory installation of a valve > 600mm in

vertical position. 6.4 Recommendation for installation

Before assembling

− Verify that pipeline flanges are free from metallic chips and weld splatter − Verify that pipeline flanges are located on the same centerline, in parallel and that flange holes are aligned. Verify

the distance between flanges. − Verify that nothing hinders the complete moving of the disc during opening or closing − Protect the valve against any dirty or debris caused by the construction works − Verify that there are not damages caused by the piping cleaning/washing process.

Never suspend the valve by its disc or handle or actuator. − Verify that all seals and gasket are cleaned and without any damage − Verify that there are not external forces transmitted to valve body

During assembling

− Use appropriate lifting devices checking the load capacity and dimensions − Use hexagon bolts and nuts with washers from flange to flange suitable for the operating and environment

conditions applying the tightening torque according to the standards of reference ( i.e. EN 1591) − Fasten the bolts evenly crosswise − Do not over-tighten the bolts of the flanges to avoid cracks − Avoid any damage to the liners or gaskets − Any paint repair must follow the paint Data Sheet − Do not pull the pipeline towards the valve or vice-versa

6.5 Actuated valves

Electrical cables may only be connected by qualified personnel.

The applicable electrical regulations (e.g. IEC and national standards), also for equipment in hazardous locations,

must be observed. All electrical equipment such as actuator, switchboard, magnetic valve drive, limit switch etc.

must be installed in flood proof dry locations. Voltage and frequency must match the valves stated on the identity

plate.

APORIS - 12

6.6 Handling

Handling means may be necessary to install large sizes valves.

They must be used as shown.

7 Commissioning/Decommissioning

7.1 Commissioning 7.1.1 General

Prior to commissioning the valve, the pressure, temperature and material data stated on the valve should be compared to

the actual operating conditions in the piping system to check whether the valve can withstand the loads occurring in the

system.

Possible pressure surges (water hammer) must not be exceed the highest admissible pressure. Adequate

precautions should be taken. In new pipe systems and especially after repair work, the system should be flushed with the

valves fully open to remove solids, e.g. weld beads, which may damage the seats. 7.1.2 Operation

The position of the disc is indicated by the pointer of the actuator or by handle lever. The valves are closed by turning in the

clockwise direction (top view) and opened in the counter clockwise direction.

7.1.3 Functional Check

The following functions should be checked: before commissioning, the shut-off-function of the valves should be checked by

repeated opening and closing.

7.1.4 Actuated valves

Adjustable end stops and torque limiter are pre-adjusted in factory. The customer may have to complete the adjustment on

site during the commissioning, if necessary.

Verify gears and actuators Operating Manual issued by its manufacturer

7.2 Decommissioning During extended shutdown periods, liquids liable to change their condition due to polymerization, crystallization,

solidification etc. must be drained from the piping system. If necessary, the piping system should be flushed with the valves

fully open.

Correct Correct Correct

FORBIDDEN

FORBIDDEN

APORIS - 13

8 Maintenance/Repair 8.1 Safety Instructions Maintenance and repair work may only be carried out by skilled and qualified personnel. For all maintenance and repair work, the safety instructions listed below and also the general notes in section 2 must be

observed. Always use suitable spare parts and tools, even in case of emergency, otherwise correct operation of the valves

cannot be assured.

8.2 Valve removal from piping and actuator disconnecting Identify the valve by identity plate.

Place the disc at 10° from closing position so that the disc will not exceed from face to face.

The entire valve must be unpressurized and must have cooled down sufficiently so that the temperature of the

medium is lower than 60 °C, to prevent scalding. Opening pressurized valves will cause danger to life and limb toxic or highly flammable substances or liquids whose

residues may cause corrosion by interaction with the air humidity were handled by the valve, then the valve should be

drained and flushed or vented. lf necessary, wear safety clothing and a face guard/mask. Depending on the installation

position, any liquid remaining in the valve may have to be removed. Prior to possible transport, the valves must be flushed and drained carefully. lf you have any questions please contact your

KSB Sales Office.

lf actuators powered by an external source of energy (electric, pneumatic, hydraulic) need to be removed from the valves or dismantled, the energy supply must be shut down prior to starting any repair work. Remove the valve from the piping with its actuator. Do not damage the liner during removal the valve from the pipe.

Therefore, pull apart the pipe flanges to allow sufficient clearance. Identify the mounting position of the actuator Disconnect the actuator and take care of all bolting parts.

Before reassembling the actuator, please apply sealant joint between butterfly valve top flange and actuator.

8.3 Inspection and Operation Intervals The valve must be inspected at least once a year regarding its tightness, smooth operation and corrosion protection.

The disc seal, O-ring and gaskets must be replaced at any signal of wear or tear or whenever necessary in function of the

operating conditions and inspections reports. Use always KSB original Spare parts

8.4 Spare parts Use the relevant spare parts included in the kits. Please refer to leaflets.

All constitutive parts of kit and flange gaskets must be replaced.

During mounting / dismantling of the valve, the operations must be respected step by step as defined in section 8.5

to prevent injuries and material damages.

During the tests, closing and opening valves, care must be taken that no operator interferes with the disc travel.

8.5 Valve disassembly and re-assembly See manual of maintenance reference:

Reference Manual of maintenance

APORIS 16 8123.81

8.6 Cleaning and Lubrication Whenever replacing the disc seal, O-rings and gaskets please remove any dirty or debris and apply approved lubricants for

application with drinking water according to the local regulations.

APORIS - 14

9 Trouble Shooting

All repair and Service work must be carried out by qualified personnel using suitable tools and genuine spare parts.

Problem Cause Remedial action

Valve makes noise

Unfavorable installation position causing unfavorable flow around or inside the valve (e.g. installed too closely downstream of an elbow etc.)

Change installation position

Valve operating beyond its design limits

Check design and/or operation data, change flow resistance in the valve.

Valve cannot be operated

Foreign matter jammed in the seat area

Flush valve, dismantle, if necessary, and remove foreign matter

Gear blocked Undo block

No electrical connection of electric actuator Establish electrical connection

Unfavorable flow and impairment of movement Change installation position

Leaks in the body seat

Valve not completely closed Close valve completely

Valve seal damage or worn Replace seal Cavitation in Valve

Valve operating beyond its design limits Butterfly valve not suitable for use as

control valve, replace valve by a more suitable valve type, or change operating

Operational data changed conditions

Leaks at the body

Deterioration of seals Replace seals

High external forces Replace the body; check water hammer High operation forces Seat of the valve polluted by deposits

Flush valve , dismantle, if necessary, and clean seat area

Valve is dry in pipeline, no medium present

Valve can be operated more easily when wet

10. KSB Service

For any additional information or assistance please contact your nearest KSB Service or KSB Sales Office. The Address,

emails and phone contacts are available at web site www.ksb.com

APORIS - 15

11 EU declaration of conformity 11.1 EU declaration of conformity APORIS

Hereby we,

KSB SAS

Zone industrielle Gagnaire Fonsèche

24490 LA ROCHE CHALAIS

Registered office: 92635 GENNEVILLIERS CEDEX

Declare that the valves listed below comply:

With the requirements of the Pressure Equipment Directive 2014/68/EU

Description of the valve types: Butterfly valves

APORIS 16 PS 16 bar DN300-2000

As per harmonized standards: EN593, EN12266-1, EN12516-2, EN12516-4

And other standards: EN1563

Conformity Assessment Procedure: Module H

PED Classification: Dangerous liquids: Yes: according to table 9

Gas: No

Production site: 24490 LA ROCHE CHALAIS

FRANCE

Name and address of the notified body Bureau Veritas S.A. Newtime

52 Boulevard du Parc Ile de la Jatte 92200 Neuilly sur Seine

FRANCE

Number of Notified Body 0062

Signature Michel DELOBEL Rev 1 – 11-2017

Quality Manager

APORIS - 16

812

3.8

2/0

4 E

N

16.0

5.2

01

8

KSB S.A.S

4, allée des Barbanniers 92635 Gennevilliers Cedex (France)

Tél. : +33 (1) 41 47 75 00

www.ksb.com