Spirax Sarco Spira-trol K Series Installation And Maintenance Instructions Manual

Two-port control valves

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3740050/10

IM-S24- 42 CTLS Issue 10

Spira-trol

K and L Series

Two-port Control Valves

Installation and Maintenance Instructions

1. Safety information

2. General product information

3. Installation and

commissioning

4. Maintenance:

DN15 - DN100

5. Maintenance:

DN125 - DN300

6. Spare parts

IM-S24- 42

CTLS Issue 10

Printed in France

Table of Contents

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Summary of Contents for Spirax Sarco Spira-trol K Series

Page 1 3740050/10 IM-S24- 42 CTLS Issue 10 Spira-trol K and L Series Two-port Control Valves Installation and Maintenance Instructions 1. Safety information 2. General product information 3. Installation and commissioning 4. Maintenance: DN15 - DN100 5. Maintenance: DN125 - DN300 6. Spare parts ©...
Page 2 IM-S24- 42 CTLS Issue 10...
Page 3: Safety Information
Groups 1 and 2 of the above mentioned Pressure Equipment Directive.The products’ use on other fluids 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.
Page 4 KE valves Group 1 Group 2 Group 1 Group 2 Product Gases Gases Liquids Liquids DN15 - DN25 DN32 DN40 - DN50 PN40 DN65 - DN100 DN125 - DN200 DN250 DN300 DN200 PN25 DN250 - DN300 DN125 PN16 DN150 - DN200 KE43 DN250 - DN300 DN15 - DN25...
Page 5 KE valves (continued) Group 1 Group 2 Group 1 Group 2 Product Gases Gases Liquids Liquids DN15 - DN25 KE61 PN40 DN32 DN40 - DN50 DN15 - DN25 DN32 DN40 - DN50 PN40 DN65 - DN100 DN125 - DN200 DN250 DN300 DN200 PN25...
Page 6 KE valves (continued) Group 1 Group 2 Group 1 Group 2 Product Gases Gases Liquids Liquids DN15 - DN25 KE71 PN25 DN32 - DN40 DN50 DN15 - DN25 DN32 - DN40 PN25 DN50 - DN80 DN100 - DN125 DN150 - DN200 DN65 - DN125 KE73 PN16...
Page 7 KEA valves (continued) Group 1 Group 2 Group 1 Group 2 Product Gases Gases Liquids Liquids DN15 - DN25 KEA61 ASME 300 DN32 KEA62 DN40 - DN50 DN150 ASME 150 DN200 - DN250 DN300 DN15 - DN25 DN32 DN40 ASME 300 DN50 - DN100 KEA63 DN150 - DN200...
Page 8 LE valves Group 1 Group 2 Group 1 Group 2 Product Gases Gases Liquids Liquids DN15 - DN25 LE31 PN16 DN32 - DN50 LE33 DN65 - DN100 DN15 - DN25 LE43 JIS 10 DN32 - DN65 LE63 KS 10 DN80 - DN100 LEA valves Group 1 Group 2...
Page 9: Protective Clothing
1.9 Tools and consumables Before starting work ensure that you have suitable tools and/or consumables available. Use only genuine Spirax Sarco replacement parts. 1.10 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.
Page 10: Residual Hazards
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.
Page 11 Prevention of waterhammer Steam trapping on steam mains: 30 - 50 metre intervals Steam Trap set Trap set Steam Trap set Condensate Condensate Condensate Steam Mains - Do's and Don'ts: Flow Flow Steam Steam IM-S24- 42 CTLS Issue 10...
Page 12 Prevention of tensile stressing Pipe misalignment: Installing products or re-assembling after maintenance: Do not over tighten. Flange bolts should be gradually tightened across Use correct torque figures. diameters to ensure even load and alignment. Thermal expansion: Guides Axial movement Short Fixing point distance Axial movement...
Page 13: General Product Information
2. General product information 2.1 General description Spira-trol is a range of two-port single seat globe valves with cage-retained seats conforming to either EN (DIN) or ASME standards. These valves are available as follows: DN15 to DN200 (½" to 8") with a choice of three body materials. DN250 and DN300 (10"...
Page 14: Technical Data
2.2 Technical data Plug design Parabolic Metal-to-metal Standard seat Class IV with the option of Class V Leakage Balanced Class IV Soft seal Unbalanced Class VI Equal 50:1 Rangeability Linear 30:1 Fast opening 10:1 DN15 to DN50 (½" to 2") 20 mm (¾") Travel DN65 to DN100 (2½"...
Page 15 Fig. 1 DN125 - DN300 Extended bonnet Fig. 2 DN15 - DN100 KE and KEA with bellows seal (B) and (C) Fig. 3 Fig. 4 DN15 - DN100 DN15 to DN100 KE, KEA and LEA valves KE, KEA, LE and LEA with bellows seal (D) IM-S24- 42 CTLS Issue 10...
Page 16: Pressure/Temperature Limits
F - F Flanged JIS/KS 10. A - D Flanged EN 1092 PN25. Bellows only Maximum operating temperature Bellows B Minimum operating temperature -10 °C Note: For lower operating temperatures consult Spirax Sarco. Steam See relevant actuator Maximum differental saturation Technical Information pressures curve sheet...
Page 17 Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation. When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows must be read in conjunction with the valve pressure/temperature limits shown in table below.
Page 18 Bellows only Maximum operating temperature PTFE packing -29 °C Minimum operating Bellows B temperature Graphite packing -50 °C Note: For lower operating temperatures consult Spirax Sarco. See relevant actuator Steam Maximum differental Technical Information saturation pressures sheet curve Maximum cold hydraulic test...
Page 19 Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation. When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows must be read in conjunction with the valve pressure/temperature limits shown in table below.
Page 20 Flanged EN 1092 PN16. F - F Flanged JIS/KS 10. Bellows only Maximum operating temperature Bellows B Minimum operating temperature -10 °C Note: For lower operating temperatures consult Spirax Sarco. See relevant actuator Steam Maximum differental Technical Information saturation pressures sheet curve...
Page 21 Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation. When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows must be read in conjunction with the valve pressure/temperature limits shown in table below.
Page 22 Bellows only Bellows B Maximum operating temperature Pressure bar g Minimum operating -29 °C (-20 °F) 250 284 temperature Note: For lower operating temperatures consult Spirax Sarco. See relevant actuator Maximum differental Steam Technical Information pressures saturation sheet curve Maximum cold...
Page 23 Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C (41 °F), the external moving parts of the valve and actuator must be heat traced to maintain normal operation. When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows must be read in conjunction with the valve pressure/temperature limits shown above.
Page 24 Pressure bar g operating Graphite temperature -50 °C (-58 °F) 200 232 packing Note: For lower operating temperatures consult Spirax Sarco. Maximum See relevant actuator Technical Steam differental Information sheet saturation pressures curve Maximum cold hydraulic 75 bar g (1 087.5 psi g)
Page 25 Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C (41 °F), the external moving parts of the valve and actuator must be heat traced to maintain normal operation. When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows must be read in conjunction with the valve pressure/temperature limits shown above.
Page 26 Bellows only Maximum operating temperature Bellows B Minimum operating -29 °C (-20 °F) Pressure bar g temperature Note: For lower operating temperatures consult 250 284 Spirax Sarco. See relevant actuator Maximum differential Technical Information Steam pressures sheet saturation curve ASME 20.7 bar g...
Page 27 Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C (41 °F), the external moving parts of the valve and actuator must be heat traced to maintain normal operation. When selecting a valve with a bellows sealed bonnet, the pressure/temperature limits of the bellows must be read in conjunction with the valve pressure/temperature limits shown above.
Page 28 300 °C packing Bellows - Option D 300 °C Minimum operating Note: For lower operating temperatures consult Spirax Sarco -10 °C temperature Maximum differential pressures See relevant actuator Technical Information sheet. Maximum cold hydraulic test pressure of: 24 bar g...
Page 29 Screwed BSP Flanged EN 1092 PN16 Steam saturation curve Pressure bar g Note: When the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation. Flanged JIS/KS 10 Steam saturation...
Page 30 Bellows (A - A on the Flanged - Option D 300 °C EN 1092 PN16 chart) Minimum operating Note: For lower operating temperatures consult Spirax Sarco -10 °C temperature Maximum differential pressures See relevant actuator Technical Information sheet. Maximum cold hydraulic test pressure of: 24 bar g For valve operating above 300 °C extended bonnet is recommended for actuator suitability.
Page 31 Flanged EN 1092 PN16 Steam saturation curve Pressure bar g Please note - Bellows sealed valves (Option D) are limited to A - A. Note: When the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
Page 32 LE63 (Carbon steel valve body) 2.11 Pressure/temperature limits Body design conditions PN16 Maximum design pressure 16 bar g @ 50 °C Maximum design temperature 400 °C @ 10.9 bar g Minimum design temperature -50 °C Standard packing PTFE - Option P or N 250 °C chevron PTFE soft seat...
Page 33 Flanged EN 1092 PN16 Steam saturation curve PTFE -28 Graphite -50 Pressure bar g Please note - Bellows sealed valves (Option D) are limited to A - A. Note: When the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
Page 34 (450 °F) Minimum Note: For lower operating temperatures -29 °C (-20 °F) operating temperature consult Spirax Sarco Maximum differential pressures See relevant actuator Technical Information sheet. Maximum cold hydraulic test pressure of: 21 bar g (300 psi g) IM-S24- 42 CTLS Issue 10...
Page 35 Screwed NPT Flanged ASME class 125 Pressure psi g Steam saturation curve 13.7 Pressure bar g Note: When the process fluid temperature is sub-zero and the ambient temperature is below +5 °C (41 °F), the external moving parts of the valve and actuator must be heat traced to maintain normal operation. Flanged JIS/KS 10 Pressure psi g Steam...
Page 36 150 chart) Note: For lower operating temperatures Minimum -28 °C (-20 °F) operating temperature consult Spirax Sarco Maximum differential pressures See relevant actuator Technical Information sheet. Maximum cold hydraulic test pressure of: 29.5 bar g (428 psi g) For valve operating above 300 °C (572 °F) extended bonnet is recommended for actuator suitability.
Page 37 Flanged ASME class 150 Pressure psi g Steam saturation curve 19.6 Pressure bar g Please note - Bellows sealed valves (Option D) are limited to A - A. Note: When the process fluid temperature is sub-zero and the ambient temperature is below +5 °C (41 °F), the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
Page 38 (572 °F) LEA63 chart) -28 °C (-20 °F) Note: For lower operating temperatures Minimum operating temperature consult Spirax Sarco -50 °C (-58 °F) Maximum differential pressures See relevant actuator Technical Information sheet. Maximum cold hydraulic test pressure of: 28.4 bar g (413 psi g) For valve operating above 300 °C (572 °F) extended bonnet is recommended for actuator suitability.
Page 39 Flanged ASME class 150 Pressure psi g 1000 Steam saturation curve PTFE -29 Graphite -50 18 19.6 Pressure bar g Please note - Bellows sealed valves (Option D) are limited to A - A. Note: When the process fluid temperature is sub-zero and the ambient temperature is below +5 °C (41 °F), the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
Page 40: Installation
3. Installation Note: Before actioning any installation, observe the 'Safety information' in Section 1. Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet, check that the product is suitable for the intended installation: Check materials, pressure and temperature and their maximum values. Do not exceed the performance rating of the valve.
Page 41 4. Maintenance : DN15 to DN100 Note: Before actioning any installation, observe the 'Safety information' in Section 1. Warning for all stainless steel valves The 316 type stainless steel used in the construction of these products particularly for screwed or close fitting parts, is very susceptible to galling or cold welding.
Page 42 Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions covering Spirax Sarco actuators. Unscrew the gland nut (18). Undo and remove the bonnet nuts (27) or the bolt if it is the LE valve.
Page 43 PTFE Graphite 3 mm Fig. 8 Fig. 9 Scarf joint Fig. 10 IM-S24- 42 CTLS Issue 10...
Page 44 4.5 Removal and refitting of the valve plug/ stem assembly and seat Lift out the seat retaining cage (5) followed by the seat (6). Remove the seat back gasket (7) and discard. Clean all components, including the seat recess in the valve body. Examine the seat and plug/stem assembly for damage or deterioration and renew as necessary.
Page 45 4.6 Refitting the bonnet Caution: The following must be carefully followed to enable the correct reassembly of the control valve, and the subsequent test that is required to ensure that the plug moves freely inside the valve seat: Fit new bonnet gasket. Ensure the plug stem is fully extended without the upper stem threads making contact with stem seals on the top of the bonnet.
Page 46 Using a spanner lightly and After each tightening Firmly and briskly push the evenly tighten each bolt or nut sequence lift the stem fully. stem fully down. by 45°, following the sequence illustrated in Figure 5, page 37. Repeat Steps 5, 6 and 7 until the bonnet nuts or bolts have an even tension. Continue Steps 5, 6 and 7 but use a torque wrench set at 10% of maximum required torque setting.
Page 47: Bellows Sealed Valves
Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions covering Spirax Sarco actuators. Remove the lock-nut (3). Loosen the gland nut (18). Remove the 4 bonnet nuts (27).
Page 48 4.7.2 Procedure for renewing the bellows (D) assembly: Isolate the valve on both sides. Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions covering Spirax-Sarco actuators. Remove in order: lock-nut (8), gland nut (9), gland nut spacer (19), the anti-rotation pin (16). Caution: care should be taken in removing the valve bonnet since fluid under pressure may be remain inside between the valve body and bellows...
Page 49 5. Maintenance : DN125 to DN300 Note: Before actioning any installation, observe the 'Safety information' in Section 1. 5.1 General Valve parts are subject to normal wear and must be inspected and replaced as necessary. Inspection and maintenance frequency depends on the severity of the service conditions. This Section provides instructions on the replacement of the packing, stem, plug and seat.
Page 50 Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions covering Spirax Sarco actuators. Loosen the gland nut (11). Undo and remove the bonnet nuts (21). Using suitable lif ting equipment, remove the bonnet (2) with the plug and stem assembly (3).
Page 51 5.4 Replacement of graphite gland packings (reference Figure 20) Remove the lock-nut from the stem (20), and withdraw the plug stem assembly (with cage on balanced versions). Withdraw the graphite packing (26) and discard. Remove all metal components, washer (14) and spacers (10) carefully noting how many components have been removed as it will differ on each valve size.
Page 52 5.5 Procedure for removal and refitting of valve plug/stem assembly and seat 5.5.1 Unbalanced valves Using lifting equipment as appropriate, withdraw the plug/stem assembly (3). Lift out the cage (4) followed by the seat (6). Remove the seat back gasket (16) and discard. Clean all the components, including the seat recess in the valve body.
Page 53 Fig. 21 Fig. 22 Balanced IM-S24- 42 CTLS Issue 10...
Page 54 5.6 Refitting the bonnet Fit a new bonnet gasket (15). Using appropriate lifting equipment, carefully lower the bonnet into place over the valve stem. Care must be taken not to damage the new gland packing at this stage. Note: that the actuator mounting hole orientation should be in line with the valve flow axis.
Page 55 Fig. 24 Balanced valve shown Fig. 25 Extended bonnet configuration IM-S24- 42 CTLS Issue 10...
Page 56: Spare Parts
Always order spares by using the description given in the column headed 'Available spares', and state the size and type of valve including the full product description of the product. Example: 1 - PTFE stem seal kit for a Spirax Sarco 1" Spira-trolTM two-port LEA31 PTSUSS.2 Cv 12 control valve.
Page 57 Soft seat arrangement Fig. 26 IM-S24- 42 CTLS Issue 10...
Page 58 Always order spares by using the description given in the column headed 'Available spares', and state the size and t ype of valve including the full product descr iption of the product. Example: 1 - PTFE stem seal kit for a Spirax Sarco 1" Spira-trolTM two-port KEA31B TSUSS.2 Cv 12 control valve.
Page 59 Soft seat arrangement Fig. 27 IM-S24- 42 CTLS Issue 10...
Page 60 Always order spares by using the description given in the column headed 'Available spares', and state the size and type of valve including the full product description of the product. Example: 1 - PTFE stem seal kit for a Spirax Sarco 1" Spira-trolTM two-port LEA31B TSUSS.2 Cv 12 control valve.
Page 61 Soft seat arrangement Fig. 28 IM-S24- 42 CTLS Issue 10...
Page 62 Always order spares by using the description given in the column headed 'Available spares', and state the size and type of valve including the full product description of the product. Example: 1 - PTFE stem seal kit for a Spirax Sarco DN150 Spira-trolTM two-port PTSUSS.2 K v 370 control valve.
Page 63 Total number of spacers DN125 valves = 0 spacer DN150 valves = 1 spacer PTFE sealed DN200 valves DN250 valves = 4 spacers Spacer DN300 DN125 valves = 2 spacers DN150 valves = 3 spacers Graphite sealed DN200 valves DN250 valves = 6 spacers DN300 Exploded view of soft seat arrangement...
Page 64 Always order spares by using the description given in the column headed 'Available spares', and state the size and t ype of valve including the full product descr iption of the product. Example: 1 - PTFE stem seal kit for a Spirax Sarco DN150 Spira-trolTM two-port KE43 PTSBSS.2 Kv 370 control valve.
Page 65 Total number of spacers DN125 valves = 0 spacer DN150 valves = 1 spacer PTFE sealed DN200 valves Spacer DN250 valves = 4 spacers DN300 DN125 valves = 2 spacers DN150 valves = 3 spacers Graphite sealed DN200 valves DN250 valves = 6 spacers DN300 Exploded view of soft seat arrangement...
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Spirax Sarco Spira-trol K Series Installation And Maintenance Instructions Manual

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