KIRLOSKAR VALVES Precision and Durability with Customised Solutions
KIRLOSKAR BROTHERS LIMITED
Kirloskar Brothers Limited, with over ten decades of immense experience and unfailing customer satisfaction, has become the name to reckon with for the supplies of pumps, valves and complete pumping solutions in India and across the globe. KBL is the first Valve manufacturing company in India accredited with ISO 9001certificate. The quality and performance of Kirloskar valves is facilitated by : ! One of the Asia's largest Hydraulic Research Centre ! In-house integrated foundries ! Dedicated valve manufacturing facility at Kondhapuri, near Pune, India ! Latest machines and modern automated test rigs
KBL is among the largest manufacturers of Butterfly Valves in India with current size range up to 3600 mm and capacity to manufacture up to 4500 mm. The plant has the capacity to design and develop valves with customised solutions conforming to various National and International Standards such as IS/BS/EN/AWWA etc. KBL is the first valve manufacturing company to introduce Sluice Valves in India and to have successfully carried out Flow Test on a very large size Butterfly Valve (2200 mm) in-house.
KBL offers CE marked EN 593 Butterfly valves and BS 5163 Sluice valves along with other industrial valves. It has successfully carried out proof of design test upto 2600 mm size Butterfly valves as per AWWA C-504.
Valve Manufacturing Plant, Kondhapuri, Near Pune India.
“Yamuna”, the Global Headquarters of Kirloskar Brothers Limited, has been designed to reflect the four principle tenets of the Kirloskar Group - Concern for the Environment, Comfort of our People, Commitment to Technology and Innovation and Continued respect for our Heritage. The corporate office has been awarded the prestigious LEED Platinum rating for green building. The structure that is spread over 3 acres of land and houses 500 employees is able to save up to 50% of energy and 30% of water purely by use of technology and effective design. “Yamuna” uses water-cooled VRV air conditioning system with sensors for monitoring CO2 levels and optimizing intake of fresh air. The structure has photovoltaic panels to generate electricity and meeting 2.6% of power consumption. “Yamuna” has maximum use of glass panels along walls that allow natural light inside the building, thereby saving on electricity. Most of the illuminating lights have CFL fixtures that are extremely energy efficient. The structure also uses other energy efficient gadgets like LCD monitors etc. The facility derives a substantial amount of water from the recharge pits by rainwater harvesting.
YAMUNA - The Global Headquarters Kirloskar Brothers Limited
RESILIENT SEATED BUTTERFLY VALVES AS PER API 609/ EN 593 (BS 5155) WAFER & LUGGED WAFER TYPE
Widely used in Process and General Industries, Power, Building and Construction and Marine sectors
Special Features !
Top plate double drilled to fit ISO 5211 dimensions and standard secondary bolt circle dimensions
!
Unique centre-lock seat design virtually eliminates any seat movement during the seating and un-seating of the disc
!
Unique stem retention system to provide blow-out proof stem and easy assembly and disassembly of valve
Constructional Features Body Heavy duty one piece wafer and lugged wafer body designed to withstand specified pressures Disc Nylon coated high strength disc with hand polished disc edge and hubs ensures excellent corrosion resistance to several chemical media Body Seat Heavy duty square grooved seat design with moulded O-ring seals to serve as flange gasket Stem One piece stem with close tolerances double D drive eliminates the need for disc screws or taper pins Journal Bearing Heavy duty bearing absorbs the forces acting on the stem/disc assembly due to line pressure
Precision and Durability with Customised Solutions
MATERIAL OF CONSTRUCTION
Valve Body
Disc
Seat
Stem
Cast Iron
Ductile Iron (Nylon 12 coated)
EPDM
SS 410
Ductile Iron
SS 316
Buna N
SS 316
Carbon steel
Viton* Silicone
* Viton is registered trademark of E.I. Dupont
TECHNICAL SPECIFICATIONS
APPLICATIONS
Design and Manufacturing Standard
Suitable for variety of liquids in Process and General Industry, Water Works, Power Plants, Sewage Plants, Chemical and Petrochemical Plants etc. for tight shut off and flow control
API 609/ EN 593 (BS 5155) Testing Standard API 598/ EN 12266-1 Size Range 50 mm to 600 mm Pressure Rating 50 mm to 600 mm : PN 10 50 mm to 300 mm : PN 16 Operation Manual Hand Lever (Up to 200 mm) Manual Gearbox (250 mm and above) Electrical and Pneumatic Actuators with accessories and Manual Override End Connection To suit ANSI # 125 / 150
Precision and Durability with Customised Solutions
GENERAL DIMENSIONS / MOUNTING DETAILS
Dimensions
*Face to face dimension “B” generally conforming to API 609 Category A / BS EN 558 - 1 20 / ISO 5752 Series 20 / MSS SP 67 / ASME B 16.10 All dimensions are in mm
Precision and Durability with Customised Solutions
BUTTERFLY VALVES AS PER EN 593 (BS 5155) / AWWA C 504
Widely used by Municipal and Water Supply Authorities, Thermal Power Plants, Nuclear Power Plants, Hydel Power Units and other Government and Industrial users
Special Features !
Rigid and sturdy design with minimum loss of head across the valve
!
Compact, light weight, low operating torques
!
Eccentric seat geometry results in less wear and tear and longer life
!
Self cleaning and non jamming seat design
!
Gas tight shut-off
!
Self energizing seating design
!
Combined ‘O’ ring and ‘U’ cup seating on shaft
!
Through flow disc design for large size Butterfly Valves
Constructional Features Body Wafer/ Double flanged short/ long valve body designed to withstand specified pressures. Disc Streamlined Single/ Double eccentrically mounted disc to ensure complete shut-off Body Seat Ring Accurately machined to close tolerances to achieve tight shut off Shaft Stub type design, sealing with unique combination of ‘O’ Ring and ‘U’ Cup Seal to prevent leakage from drive end side Clamping Ring Unique clamping ring design ensures controlled and uniform seat compression and facilitates easy replacement of seal Journal Bearing Low friction self lubricated journal bearings for supporting shaft outside fluid flow. Precision and Durability with Customised Solutions
MATERIAL OF CONSTRUCTION
Valve Body
Disc
Body Seat Ring
Disc Seal
Clamping Ring
Shaft
Cast Iron
Cast Iron
Bronze (LTB2)*
Nitrile Rubber
Carbon (Fab) Steel
SS AISI 410
2% Ni Cast Iron
2% Ni Cast Iron
SS AISI 304
EPDM Rubber
SS AISI 304/CF 8
SS AISI 431
Cast Steel
Cast Steel
SS AISI 316
SS AISI 316/CF8M
SS AISI 304
SG (Ductile) Iron
SG (Ductile) Iron
SS AISI 316L
SS AISI 316L/CF3M
SS AISI 316
Fab. Steel
Fab. Steel
SS AISI 410
Duplex SS
SS AISI 316L
SG Ni Resist
SG Ni Resist
SS AISI 431
SS CF 8
SS CF 8
Duplex SS
SS CF 8M
SS CF 8M
Duplex SS
Duplex SS
Duplex SS
Super Duplex SS * up to 500mm NB
TECHNICAL SPECIFICATIONS
APPLICATIONS
Manufacturing and Testing Standard
Suitable for variety of liquids in water works, power plants, sewage plants, process industries, chemical and petrochemical plants etc. for tight shut-off and control. Ideally suited for isolating as well as throttling.
EN 593 (BS 5155) / AWWA C-504 Size Range 80 mm to 3600 mm Pressure Rating EN 593 (BS 5155) : PN6, PN10, PN16 and PN25 AWWA C-504 : Class 25, 75, 150 & 250 Higher pressure classes are also available against customized requirement
Accessories (Optional) Extension shafting and floor stand Disc locking arrangement at Non Driving End Chain and chain wheel arrangement By-pass arrangement (on pipeline - across the valve)
Operation Manual Hand Lever (Up to 150mm)
Integral Valve foot Manual Quarter Turn Worm Gearbox Electrical Actuator Electro - Hydraulic Actuator Pneumatic Actuator End Connections
Protective Coatings for Body / Disc Epoxy Painting (standard) Corrocoating Ebonite and EPDM Lining
Wafer / Double Flanged Flanges drilled to IS/ EN / AWWA/ ANSI/ DIN or as per customer requirement
Precision and Durability with Customised Solutions
GENERAL DIMENSIONS / MOUNTING DETAILS 80 mm to 500 mm BUTTERFLY VALVES
M
F1
N
F
O
O
S
S
DISC CLAMPING RING DISC SEAL ADAPTOR PLATE/ DE COVER
WASHER
O-RING
BEARING BUSH
BEARING BUSH
SPACER NDE COVER
SPLIT THRUST RING O-RING
BODY SEAT RING VALVE BODY
GASKET
SLEEVE
DRIVE END
NON DRIVE END
BODY SEAT RING
SHAFT SEALING ARRANGEMENT
SHAFT SEALING ARRANGEMENT
ARRANGEMENT
Dimensions as per EN 593 Nominal Size 80 100 150 200 250 300 350 400 450 500
M (approx) 125 145 200 210 260 300 330 360 400 450
Face to face F1 114 127 140 152 165 178 190 216 222 229
F 64 64 76 89 114 114 127 140 152 152
All dimensions are in mm
F: Wafer Long Type (Basic Series 16)
F1: Double Flanged Short Body Type (Basic Series 13)
Precision and Durability with Customised Solutions
N (approx) 90 115 160 170 215 260 280 300 335 375
GENERAL DIMENSIONS / MOUNTING DETAILS 600 mm to 3000 mm BUTTERFLY VALVES N
M
F1/F2
O S
DISC COVER
.
DISC CLAMPING RING
BEARING BUSH
O-RING
DE COVER U SEAL CAP
BEARING BUSH
SPACER
DISC SEAL
GASKET
BODY SEAT RING
U SEAL RETAINING
U CUP SEAL
SPACER
SPLIT THRUST RING
BUSH
NDE COVER
DRIVE END
NON DRIVE END
SHAFT SEALING ARRANGEMENT
SHAFT SEALING ARRANGEMENT
VALVE BODY
BODY SEAT RING ARRANGEMENT
Dimensions as per EN 593
Face to face
Nominal Size 600 700 750 800 900 1000 1100* 1200 1300* 1400 1500* 1600 1700* 1800 2000 2100 (Fab)* 2200 2400 2600 (Fab)* 3000 (Fab)*
F1 267 292 312 318 330 410 440 470 500 530 565 600 635 670 760 565 590 890 660 950
F2 390 430 450 470 510 550 590 630 670 710 750 790 830 870 950 990 1030 1110 1190 1350
M
N
475 550 575 595 650 700 775 780 900 955 990 1075 1100 1150 1290 1460 1500 1630 1660 1950
435 515 535 575 625 675 735 800 860 940 1010 1035 1120 1170 1310 1380 1475 1560 1635 1800
* Modified. These sizes are not covered in EN 593 standards
Hydraulic Test Pressures - as per EN 593
Nominal Size 50 to 3000
All dimensions are in mm
Rating Bar 6 10 16 F1: Double Flanged Short Body
Hydrostatic Test Pressures in Bar Body Seat 9 6.6 15 11 24 17.6 F2 : Double Flanged Long Body (Optional)
(Basic Series 13) (Basic Series 14) * for 600mm and above sizes support foot can be provided against special request (optional)
Precision and Durability with Customised Solutions
DIMENSIONS AS PER AWWA C-504
Nominal
Face to Face
M
N
Size
F1
(Approx)
(Approx)
80*
127
125
90
100
127
145
115
150
127
200
160
200
152
210
170
250
203
260
215
300
203
300
260
350
203
330
280
400
203
360
300
450
203
400
335
500
203
450
375
600
203
475
435
700*
305
550
515
750
305
575
535
800*
305
595
575
900
305
650
625
1000*
305
700
675
1200
381
900
830
1350
381
950
900
1400*
381
1000
935
1500
381
1050
990
1600*
457
1165
1050
1800
457
1275
1190
2000 (Fab)*
540
1350
1230
2200*
590
1500
1475
2400*
660
1625
1500
2600 (Fab)*
660
1660
1635
3000 (Fab)*
950
1950
1800
F1: Double Flanged Short Body * Modified. These sizes are not covered in AWWA C 504 standards
Hydraulic Test Pressures - as per AWWA C - 504
Nominal Size
Class
80 to 3000
Class - 75 Class - 150
Hydrostatic Test Pressures in Bar Body 10.5 21.0
Seat 5.27 10.5
All dimensions are in mm
Precision and Durability with Customised Solutions
Disc Strength 10.5 21.0
SLUICE VALVES AS PER BS 5163
Widely accepted by Municipal and Irrigation Authorities, Water Supply Authorities, National Thermal Power Plants, Nuclear Power Plants, Hydel Power Units and other Government and Industrial users
Special Features Rigid and sturdy design with minimum loss of head across the valve
=
Assured interchangeability of components
=
Assured parallelism between side flanges
=
Assured equal taper between wedge faces
=
Perfect machining and pressing of body and wedge rings
=
Excellent finish on spindle threads resulting in low friction and smooth operation of valves
=
Long service life and leak-tightness even after thousands of Open / Close cycles
=
Unique spindle with integral forged collar design
=
Constructional Features Valve Body Designed for minimum pressure drop with sufficient thickness to withstand torsional forces and piping loads Dome Bolted to valve body to withstand specific pressures Wedge Solid, strong, tapered on both sides and precisely machined Spindle Designed for smooth operation and low torques Body/ Wedge Rings Renewable and precisely machined to close tolerances
Precision and Durability with Customised Solutions
MATERIAL OF CONSTRUCTION
Body / Wedge / Dome
Body / Wedge - Ring
Spindle
Stem Nut
Cast Iron
Bronze (LTB2)
High Tensile Brass
Bronze LTB2
SG (Ductile) Iron
SS AISI 410
SS AISI 410
High Tensile Brass
2% Ni Cast Iron
SS AISI 304
SS AISI 304
Cast Steel
SS AISI 316
SS AISI 316
WCB
SS AISI 316 L
SS AISI 316 L
SG Ni Resist
SS AISI 431
SS AISI 431
CS 8 CS 8 M CS 3 M
TECHNICAL SPECIFICATIONS
Manufacturing and Testing Standard BS 5163
ACCESSORIES (Optional)
Position Indicator
=
External By-pass arrangement
=
=
Size Range
=
Repacking (Back Seat) arrangement
50 mm to 600 mm
=
Pressure Rating PN 10 & PN16
=
Operation
Thrust bearing arrangement (200 NB and above sizes)
=
Channel and Shoe arrangement - Renewable
=
(300 NB and above sizes)
Manual Hand wheel
=
Manual Gearbox
=
Electrical Actuator
=
=
=
=
End Connections Flanges drilled to IS/ EN / AWWA/ ANSI/ DIN or as per customer requirement
Locking arrangement Extension shafting and Headstock Drain Plug Chain and Chain Wheel arrangement
=
=
Applications
Protective Coatings for Body / Wedge / Dome Epoxy Painting (standard)
=
Clear water having turbidity upto 5000 ppm and temperature upto 45° C.
=
Corrocoating
=
Valves can also be supplied upto 180° C working temperatures with special design, subject to working pressure limitations
=
Precision and Durability with Customised Solutions
GENERAL DIMENSIONS / MOUNTING DETAILS 50 mm to 300 mm BS 5163 SLUICE VALVES
O
O O
BS 5163 Sluice Valves, Sizes 50 - 300 mm VALVE SIZE 50 65 80 100 125 150 200 250 300
A DIA. 50 65 80 100 125 150 200 250 300
A1 DIA. 99 118 132 156 184 211 266 319 370
B PCD 125 145 160 180 210 240 295 355 410
C DIA. 165 185 200 220 250 285 340 405 460
D 4 4 8 8 8 8 12 12 12
E DIA. 19 19 19 19 19 23 23 28 28
F
G
G1
178 190 203 229 254 267 292 330 356
20 20 22 24 26 26 30 32 32
3 3 3 3 3 3 3 3 4
H1 MAX. 420 435 415 560 625 675 790 900 1000
M 160 160 188 238 280 318 445 483 572
All dimensions are in mm
Precision and Durability with Customised Solutions
Wt.Kgs. Approx. 24 25 27 48 67 76 135 195 281
GENERAL DIMENSIONS / MOUNTING DETAILS 350 mm to 600 mm BS 5163 SLUICE VALVES
O
O O
Part No.
DESCRIPTION
100 110 115 135 140 146 168
Valve Body Wedge Spindle Spindle Nut Body Face Ring Wedge Face Ring Dome
BS 5163 Sluice Valves, Sizes 350 - 600 mm VALVE SIZE 350 400 450 500 600
A DIA. 350 400 450 500 600
A1 DIA. 429 480 548 609 720
B PCD 470 525 585 650 770
C DIA. 520 580 640 715 840
D 16 16 20 20 20
E DIA. 28 31 31 34 37
F
G
G1
381 406 432 457 508
36 38 40 42 48
4 4 4 4 5
H1 MAX. 1125 1200 1320 1420 1620
L DIA. 50 50 55 55 60
M
P
626 706 776 886 990
50 65
Wt.Kgs. Approx. 440 515 650 1020 1260
Hydraulic Test Pressures
Nominal Size
Rating (Bar)
50 to 600
10 16
Hydrostatic Test Pressures in Bar Body 15 24
All dimensions are in mm
Precision and Durability with Customised Solutions
Seat 10 16
BALL VALVES AS PER EN ISO 17292 (BS 5351) FULL BORE & REDUCED BORE
Widely used in Process and General Industries, Power, Chemical, Petrochemical plants, Marine and Building and Construction sectors
Special Features Top flanged is designed as per EN ISO 5211 for direct mounting of actuators and gear operators
=
Body joint sealing is provided by a reinforced graphite gasket to withstand high temperatures and is contained in a precision-machined groove for extended sealing life
=
Double “V” stem packing in graphite is loaded with the gland assembly to ensure positive and trouble free sealing
=
Adjustable packing gland bolts are provided to ensure easy access to adjust packing with the actuator in place
=
Constructional Features Body Flanged, two piece design in cast construction Ball Floating design with stainless steel ball with superior finish and sphericity ensures extended seat life and low operating torques Seat Seat is contoured to ensure that all stresses due to the line pressure are counterbalanced and that the extrusion of the seat into the body cavity due to sealing forces is eliminated Stem Heavy duty stem in stainless steel designed to provide positive engagement with all types of valve operators Stem Bearing Heavy duty reinforced PTFE bearing is provided to absorb side and thrust load hence reducing stem torques and protect stem packing from deformation
Precision and Durability with Customised Solutions
MATERIAL OF CONSTRUCTION
Body
Ball
Stem
Seat
WCB
CF8
SS 304
PTFE
CF8
CF8M
SS 316
CF8M
CF3
SS 304L
CF3
CF3M
SS 316L
CF3M
CA15
SS 410
LCB
SS 316
CA15
SS 304
TECHNICAL SPECIFICATIONS
APPLICATIONS
Design and Manufacturing Standard
Suitable for variety of liquids in Process and General Industry, Power Plants, Sewage Plants, Chemical and Petrochemical Plants etc. for tight shut off and flow control
EN ISO 17292 (BS 5351)
=
Size Range 15 mm to 300 mm
=
Pressure Rating Class 150 and Class 300
=
Operation Manual Hand Lever (Up to 100 mm)
=
Manual Gearbox (150 mm and above)
=
Electrical and Pneumatic Actuators with accessories and Manual Override
=
End Connections As per ASME B16.5 - 2003 Class 150 / 300
=
End-to-End Dimensions Valve end-to-end dimensions as per ASME B 16.10/ API 6D
=
Precision and Durability with Customised Solutions
GENERAL DIMENSIONS / MOUNTING DETAILS
Full Bore Class 150
Full Bore Class 300
All dimensions are in mm
Precision and Durability with Customised Solutions
GENERAL DIMENSIONS / MOUNTING DETAILS
Reduced Bore Class 150
Reduced Bore Class 300
All dimensions are in mm
Precision and Durability with Customised Solutions
SPECIAL COATINGS Kirloskar Brothers Limited specializes in providing various types of protective coatings for valves such as Epoxy Painting, Corrocoating, Ebonite and EPDM Lining for drinking / portable and sea water
Kirloskar Corrocoat Range of High Performance Protective Coatings Kirloskar Brothers Limited in association with Corrocoat Ltd., U.K., brings you advanced technology glass flake filled coating systems to suit a wide range of application needs Plasmet ZF has been specially developed to satisfy the demand for a rust tolerant coating requiring minimal surface preparation yet offering long term resistance to corrosion
=
Plasmet ZX is to be applied as a top coat over ZF and other epoxy based primers where decorative appearance and chemical resistance is necessary. It is used mainly in atmospheric conditions
=
Plasmet ZE is a versatile, high performance glass flake filled epoxy system developed for application directly on to metal substrates or on to an inhibitive primer system such as ZF
=
Plasmet ECP is a clear coating system for coating or priming masonry and concrete substrates. It is suitable for application to damp surfaces, which for operation reasons cannot be dried out prior to application
=
Polyglass High Performance Coating System The polyglass range of materials was originally developed to create a spray- applied protective coating which offers all the performance advantages of a flake glass filled system, together which improved ease and speed of application
=
Precision and Durability with Customised Solutions
REFERENCES
2400 mm manually operated Butterfly Valve,
2600 mm Butterfly Valve for National Thermal Power Corporation,
Brihan Mumbai Municipal Corporation, Mumbai, India
Sipat – I & Barh – I, India
1800 mm motorized Butterfly Valve for
2200 mm Butterfly Valve for Sohar Sea Water Intake Pipeline Project, Oman
Massachusetts Water Resources Authority, Boston, USA
Proof of design test as per AWWA C - 504 Kirloskar Brothers Limited have successfully carried out proof of design test on rubber seated butterfly valves as per AWWA C - 504
Valve size tested
This covers size range
Pressure class
No. of cycles
2600 mm
1200 mm & above
CL - 75
1000 (one thousand)
2200 mm
1200 mm & above
CL - 75
1000 (one thousand)
1400 mm
1200 mm & above
CL - 75
1000 (one thousand)
800 mm
600 mm to 1050 mm
CL - 150
5000 (five thousand)
450 mm
75 mm to 500 mm
CL - 150
10000 (ten thousand)
300 mm
75 mm to 500 mm
PN 16
10000 (ten thousand)
Precision and Durability with Customised Solutions
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