Ga Hph Bypass Valve

SUPPLIER's (ABFPL's ) REPLY SHEETS NTPC REF.
NO: CC:110:19455 DATE: 31-03-2017

(TANDA II SUPER THERMAL POWER PROJECT) ABFPL REF. NO: C-FOLDER UPLOAD DATE: 21-03-2017
DOC/DWG TITLE: ABFPL's TRANSMISSION NO: C-FOLDER UPLOAD DATE: 13-06-2017

GA DRAWING OF THREE WAY BYPASS VALVES FOR HP HEATER
BYPASS.
DOC/DWG NO: Rev
9562-110-PVM-B-079 03
TDA/12/M/----- ---M24/EA/001
STATUS: CAT II
Sl No. ITEM NTPC COMMENTS ABFPL/KSB REPLY REMARKS

1 Pls furnish connection details for all the valves. NTPC to kindly note that connection details are provided in the sectional drawing of
installation details for all the valves shall also be 3-way bypass valves (page no. 7 &17 of 86).
furnished.
not found.Comment repeated. Installation details is enclosed in revised GAD (page no. 77 of 86).
Asked details shall be part of this document.Pls

furnish the details.Comment repeated.
2 Document shall be vetted by AE. Note and incorporated in revised GAD.
3 Pl. refer following points in MOM: 1. NTPC to please note that orientiation views (side view, front view and view from
1. GA drg. of valves to be included including below) is updated in revised GAD.
orientation views (side view, front view and top view
with dimensions, force and moments, weight etc. Weight of 3-way valve is already provided in GAD.
NTPC to please note that Force and moments are not applicable for 3-Way Valves
as stem is for blocking only and not for operating.
2. For tightmess and seat leak test, MQP ref. no.
to be included. 2. Please note that NTPC MQP ref. no. is updated in revised GAD.
3. Write-up is very brief. Detailed write-up to be

submitted. 3. please note that Write-up is already provided in GAD document (Page no. 67 of
86)
Asked details shall be part of this document.Pls
furnish the details.Comment repeated.
Approval from AE
Alstom Power Systems
(Belfort)
Darchis Julien
Project Engineering Manager
INDEX

1. GENERALARRANGEMENTDRAWING PAGENO. P&IDTAGNO. P&IDREF.NO.

1.1 Automatic3WayValveIntelSide5/8650LAB41AA1109562110PVMF028C
50LAB42AA101

1.2 Automatic3WayValveOutletSide15/86 50LAB81AA1009562110PVMF028C
50LAB82AA100

1.3 Ventvalve 25/8650LAB41AA230/2319562110PVMF028C
50LAB42AA230/231
26/8650LAB81AA230/231
50LAB82AA230/231
29/8650LAB41AA025/026
50LAB42AA025/026

1.4 ChangeOvervalve 31/8650LAB45AA251/2529562110PVMF028C
50LAB46AA251/252

1.5 ManualValve36/8650LAB45AA2019562110PVMF028C
50LAB46AA201
37/8650LAB41AA245
38/8650LAB45AA202
50LAB46AA202
39/8650LAB42AA245

1.6 DumpValve44/86 50LAB41AA2519562110PVMF028C
50LAB42AA251

2. DATASHEET

2.1 Automatic3WayValveIntelSide49/86
2.2 Automatic3WayValveOutletSide51/86
2.3 Ventvalve53/86
2.4 ChangeOvervalve61/86
2.5 DumpValve63/86
3. Writeup67/86
4. InstallationDetails77/86

ANNEXURE 1
Comparison between P355QH1 (1.0571) and ASTM A106 Grade C

Materials:
x P355QH1 acc. EN 10222 (Material No. 1.0571)

x ASTM A106 Grade C (Material No. UNS K03501)
Mechnanical Technologic Properties at Room Temperature:
Min. 0,2% yield Min. tensile Min. braking Min. notch bar
strength Rp0,2 strength Rmax. elongation impact value
/ MPa / MPa A/% J
1.0571 -P355QH1 315 470-630 21 63
A106Gr. C – UNS K03501 275 485 30 -
Chemical Composition:
ASTM A106
P355QH1
Page 1 of 1
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Stückliste / Parts List
3-Wege-Wechselventil / Three-Way-Valve
SN 280 Rev. 0D
3-Way Heater Bypass Valve (ZJSVM) - Inlet Valve
Project: M24 - Tanda TPP Stage-II / India

P.O.-No.: 4101094550
KSB Order-No./Pos.: 9973159108/0100
ABFPL-Document No.: TDA/12/M-------M24/DD/001
SLP/12/M-------M24/DD/001
KSB-Drawing-No.: UG1600531
Pieces
per
Part-No. Valve Material
Equival.
Benennung Designation
ASME-Material
Teile-Nr. Stück/ Werkstoff
Arm.
108 Gehäusekörper casing body 1 1.6368 – 1.4115 A182-F36

131.1 Stutzen connection branch 2 P355QH1* A106-Gr.C
160 Deckel cover 1 1.6368 A182-F36
167 Bügeloberteil upper yoke 1 P250GH A105
188 Befestigungsblech mounting plate 3 S235JR
Odnonie tego technicznego dokumentu zastrzegamy sobie wszelkie prawa
ASTM A 283-Gr. A
192 Stützarm supporting arm 2 S235JR ASTM A 283-Gr. A
Für diese technische Unterlage behalten wir uns alle Rechte vor.
196 Spannplatte locking plate 1 1.6368 A182-F36

200 Spindel stem 1 1.4122 + QT N/A - ~420MoV
206 Spindel – oben upper stem 1 1.4122 + QT N/A - ~420MoV
324 Ax.-Rollenlager ax.-bearing 2 St Carbon Steel
350 Kegel disc 1 1.4313V A182-6NM430F
411.1 Dichtring gasket 1 Graphit – P71KL Graphite
411.2 Dichtring gasket 2 Graphit – 1.4541 Graphite-F321 capped
411.3 Dichtring gasket 1 Graphit Graphite
412 O-Ring o-ring 1 NBR 80 NBR
414 Druckplatte disc thrust plate 1 1.6368 A182-F36
452 Stopfbuchsbrille gland cover 1 1.7335 A182-F11
457 Grundring gland ring 1 1.4550-H6 A320-Gr.B8 Cl.1
461.1 Packungsring gland packing 4 Graphit 1,6 Graphite
461.2 Packungsring gland packing 2 BU V901R7K01 Graphite-F316 capped
500.1 Ring ring 1 1.4057 + QT A276-Type 431
500.2 Ring ring 1 1.4550 A182-Gr.F347
500.3 Ring ring 1 1.6368 A182-F36
500.4 Ring ring 1 1.4550 A182-Gr.F347
501.1 Ring – geteilt multiple ring 1 1.6368 A182-F36
544 Gewindebuchse threaded bush 1 CW307G CW307G
547 Führungsbuchse guide bush 1 1.4571 – H6 AISI 316 TI
550.2 Scheibe washer 1 P250GH A105
562.1 Zyl.-Stift cyl.-pin 2 A4 A182-Gr. F316
562.3 Zyl.-Stift cyl.-pin 2 1.4021 + QT A276-Type 420
563.1 Bolzen pin 1 C22 + N A105
563.2 Bolzen pin 1 1.4122 + QT N/A - ~A420MoV
572.1 Schaltstück contact piece 1 1.4057 + QT A276-Type 431
579 Arretierkloben stop log 1 S235JRG2 ASTM A 283-Gr. A
593.1 Kolbenring piston ring 2 1.4057 A276-Type 431
KSB Aktiengesellschaft ECS1S552, Büttner M. / Lautner N. Juli 2016 Page/Blatt 1
Parts List M24-Tanda ZJSVM 9973159108 0100-0D.docx

SN 280 Rev. 0D

P.O.-No.: 4101094550
KSB Order-No./Pos.: 9973159108/0100
SLP/12/M-------M24/DD/001
Pieces
per
Equival.
ASME-Material
Arm.

595 Kolben piston 1 1.4057 + QT A276-Type 431
710 Rohr pipe 1 1.5415 A182-F1
710.2 Rohr pipe 1 P235TR1 A105
723.1 Flansch flange 1 S235JRG2 A283-Gr. A
723.2 Flansch flange 2 1.5415 A182-F1

729 Zwischenflansch intermed. flange 1 P250GH A105
751 Einsatzstück insert 1 1.5415 - H21 A182-F1/Stellited

756 Abstreifer wiper 1 St-A Carbon steel
838 Positionsschalter position switch 3 Siemens 3SE5162-0CE01 N/A
865 Kupplungsstück coupling piece 1 1.4057 + QT A276-Type 431
901.1 6kt.-Schraube hex. head bolt 8 1.7709 + QT A193-B16
902.1 Stiftschraube stud bolt 8 1.7709 + QT A193-B16
904.1 Gew.-Stift threaded pin 2 A4-50 A182-Gr. F316
904.2 Gew.-Stift threaded pin 1 45 H Carbon steel
914.1 Zyl.-Schraube socket head cap screw 8 A4-70 A182-Gr. F316L
914.3 Zyl.-Schraube socket head cap screw 8 8.8 – St. Carbon steel
920.1 6kt.-Mutter hex. nut 8 1.7218 + QT A193-B7
920.5 Mutter nut 1 1.4057 + QT ASTM 431
930.1 Sicherung safety device 8 1.4571 A276-Type 316TI
930.6 Sicherung safety device 2 FSt brun. Spring steel
932 Sicherungsring circlip 1 FSt phosph. Spring steel
934 Schloss lock 1 CuZn Brass
940.1 Passfeder key 1 C45 + C A108-Gr.10450
961 Handrad handwheel 1 St Carbon steel
900 Zyl.-Schraube socket head cap screw 12 4.8 +A2A Carbon steel-Galvan.
550.3 Scheibe washer 12 St+A2A Carbon steel-Galvan.
920.6 6kt.-Mutter Hex. nut 12 8+A2A Carbon steel-Galvan.
* The comparison of the provided material and the pipe material A106 Gr.C is part of the final QA-Doc.

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SN 280 Rev. 0D

P.O.-No.: 4101094550
KSB Order-No./Pos.: 9973159108/2000
SLP/12/M-------M24/DD/001
Pieces
per
Equival.
ASME-Material
Arm.

160 Deckel cover 1 1.6368 A182-F36
ASTM A 283-Gr. A

350 Kegel disc 1 1.4313V A182-6NM430F
500.2 Ring ring 1 1.4550 A182-Gr.F347
500.3 Ring ring 1 1.6368 A182-F36
500.4 Ring ring 1 1.4550 A182-Gr.F347
563.1 Bolzen pin 1 C22 + N A105

SN 280 Rev. 0D

P.O.-No.: 4101094550
KSB Order-No./Pos.: 9973159108/2000
SLP/12/M-------M24/DD/001
Pieces
per
Equival.
ASME-Material
Arm.

710 Rohr pipe 1 1.5415 A182-F1



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ZB ZA
SN 280 Rev. 0D
3-Way Heater Bypass Valve (RJSVM) - Outlet Valve

P.O.-No.: 4101094550
KSB Order-No./Pos.: 9973159108/1000
SLP/12/M-------M24/DD/002
Pieces
per
Equival.
ASME-Material
Arm.

160 Deckel cover 1 1.6368 A182-F36
ASTM A 283-Gr. A

350 Kegel disc 1 1.4313V A182-6NM430F
500.2 Ring ring 1 1.4550 A182-Gr.F347
500.3 Ring ring 1 1.6368 A182-F36
500.4 Ring ring 1 1.4550 A182-Gr.F347
563.1 Bolzen pin 1 C22 + N A105
Parts List M24-Tanda RJSVM 9973159108 1000-0D.docx

SN 280 Rev. 0D

P.O.-No.: 4101094550
KSB Order-No./Pos.: 9973159108/1000
SLP/12/M-------M24/DD/002
Pieces
per
Equival.
ASME-Material
Arm.




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06.06.2017
2
ZB ZA
5 -
06.06.2017
2
ZB ZA
SN 280 Rev. 0D

P.O.-No.: 4101094550
KSB Order-No./Pos.: 9973159108/3000
SLP/12/M-------M24/DD/002
Pieces
per
Equival.
ASME-Material
Arm.

160 Deckel cover 1 1.6368 A182-F36
ASTM A 283-Gr. A

350 Kegel disc 1 1.4313V A182-6NM430F
500.2 Ring ring 1 1.4550 A182-Gr.F347
500.3 Ring ring 1 1.6368 A182-F36
500.4 Ring ring 1 1.4550 A182-Gr.F347
563.1 Bolzen pin 1 C22 + N A105

SN 280 Rev. 0D

P.O.-No.: 4101094550
KSB Order-No./Pos.: 9973159108/3000
SLP/12/M-------M24/DD/002
Pieces
per
Equival.
ASME-Material
Arm.




Contractor Identification number Rev. Date Lang. Sheet
TDA/12/M/-------M24/DS/001 0A 25.08.2016 En 2/7
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/001 0A 25.08.2016 En 3/7
TDA/12/M/-------M24/DS/002 0A 29.08.2016 En 2/5
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/002 0A 29.08.2016 En 3/5
TDA/12/M/-------M24/DS/001 0A 25.08.2016 En 4/7
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/001 0A 25.08.2016 En 5/7
TDA/12/M/-------M24/DS/001 0A 25.08.2016 En 6/7
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/001 0A 25.08.2016 En 7/7
TDA/12/M/-------M24/DS/002 0A 29.08.2016 En 4/5
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/002 0A 29.08.2016 En 5/5
TDA/12/M/-------M24/DS/005 0A 25.08.2016 En 2/5
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/005 0A 25.08.2016 En 3/5
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/005 0A 25.08.2016 En 4/5
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/005 0A 25.08.2016 En 5/5
TDA/12/M/-------M24/DS/004 0A 23.08.2016 En 2/5
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/004 0A 23.08.2016 En 3/5
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/004 0A 23.08.2016 En 4/5
____________________________________________________________________________________________

TDA/12/M/-------M24/DS/004 0A 23.08.2016 En 5/5
Feedwater Emergency Bypass Valves
Design and Operating Instructions
Contents:
1. General Description
2. Functional Description
3. Control
4. Basic Drawing of System
5. Design
5.1 Feedwater Emergency Bypass Valves

5.2 Overview Change-Over Valve ZJSVM – Inlet Side
5.3 Overview Change-Over Valve RJSVM – Outlet Side
5.4 Part List for ZJSVM/RJSVM – Main Parts
1 General Description
Preheaters are heat exchangers for heating of feed-water by steam. If the

preheater is damaged, the complete, pressure water part – pump end as well
as boiler – has to be shut off at once. When shutting off the pressure water part
a Bypass has to be released in order to guarantee the continous feed-water
flow to the boiler.
The requirements set forth for the change-over are fulfilled best with valves
controlled by their own medium. This type facilitates a geometric design that is
well matched for the pipeline as well as:
- vibration less changing-over to a Bypass
- tight shutting-off of the preheater within shortest change-over periods
- Emergency control of the shut off preheater to avoid any increased

internal pressure
2 Functional Description
The main valves of the changing-over system consist of a 3-way valve

connected before the preheater and the T- or angle valve (globe type)
connected after the preheater (see basic drawing). It is inevitable that – due to
the common control unit – (e. g. pneumatic operated valve, electric operated
valve or solenoid valve) the main valves controlled by their own medium
change-over simultaneously.
For standard service – flow through the preheater – the 3-way valve is kept in
open position by the pressure difference main pipe / Bypass acting on the disc
and by the travel up power of the stem. Thus the Bypass is closed as well. The
pressure difference corresponds approximately to the pressure drop of the
preheater.
The globe valve connected after the preheater is kept in open position by the
travel up power of the stem.
The changing-over of the valves is effected by means of a piston according to

the blowing-out principle. The compression volumes ZB facing the valve disc
are connected to the control line. When the control valve is opened (opening
order given either by the level controller in the preheater or by the control
panel) the compression volumes ZB (Volume below the inner piston) are
relieved from pressure, and both valves are closed. The preheater is shut off
and simultaneously the feed-water flow is changed over to the Bypass.
For Bypass operation – the control valve being in open position yet – the
pressure of the enclosed feedwater may increase in the preheater. In this case
both valves open slightly like a safety valve and relieve the preheater.
Is the control valve closed, the 3-way valve remains only closed when the
pressure in the preheater is reduced in comparison with the feedwater pressure
(pressure reduction required approx. 10 – 12 %). Thus the valves cannot be
opened when the preheater is pressureless or with low pressure only; an
abrupt increase of pressure in the preheater-pipes is not possible!
For opening both valves – start of the preheater – the preheater and the supply
valve must be filled from the pump side via a filling line and be put to pump
pressure. Both valves open automatically when the pressure compensation is
attained, the control valve being in closed position. Shall the valves be
operated at earlier at a very low pressure (< 100 bar) in open position, the
compression volume ZA (Upper volume on the inner piston) has to be relieved
from pressure; this is effected via the corresponding blow out pipe (Aeration
Valve).
Both isolation valves of the preheater can be blocked in closed position by the
handwheel-locking system. The pressure difference preheater Æ bypass must
not exceed 50 bar.
It is useful to effect blocking after the change-over action, the control valve
being in open position.
Attention: The valve (angle-, T- or globe-) connected after the preheater

may be blocked only after having blocked the 3-way valve (observe the
behaviour of pressure in the preheater after blocking). The control valve
can be closed after the blocking actions.
At low system pressures the discs can be actuated manually by means of the
locking device.
3 Control
In order to achieve the required acting times, different control methods are
applicable. With the standard method – direct blow out (ZB) of the piston
spaces by means of a control valve – very short acting times are achieved (see
basic drawing), with throttle periods of time between 1 and 5 seconds are
feasible. The control valve can be actuated electrically, electromagnetically or
pneumatically. Observe the special instructions for the control valves!
Slow change-over times will help to reduce or to prevent possibly occurring

pressure surges (Water hammer).
Pressure Release at Connection ZB by Pneumatic Change-Over Valve (Pilot Valve)
leads into switching to Bypass-Operation
4 Basic Drawing of System
5 Design
5.1 Feedwater Emergency Bypass valves
The valve bodies (100) and the fitting covers (160.1) are hammer-forged.
These parts are sealed against each other and connected via a pressure-seal
bonnet. The nozzles (131.1/ 2/ 3) are hammer-forged, too. The 2-way valve
differs from the T-valve with regard to the inserted piece (751) by the second
seat, by the staggered dimensions of the connection branches at the Bypass
and by the resulting increased overall height.
The cover (160.1) contains the inserted piece (751) with the second valve seat
facing the Bypass, the working cylinder and the stem guide near the disc.
Cover and inserted piece are screwed up. The screws (914.1) are secured
against loosening.
The stem (209) is guided in bushes (547, 457) at good distance of which are
imbedded in the cover or in the inserted piece. The working piston itself is not
in contact with the cylinder walls; the mutual sealing is guaranteed by floating
piston rings (593.2).
Stem and disc (350) are screwed up. The screwed connection is not rigid; the
disc can be adapted to the inclination of the seat. A special, well-proved safety
device prevents the stem / disc from distortion. Sealing between inserted piece
and body is effected via piston rings.
The complete functional unit can be withdrawn from the body after loosening of
the self-sealing bonnet and unscrewing of the control lines (see disassembly,
observe safety prescriptions!).
The yoke (192) with the hand-locking system (550, 563, 961) is – completely
separate from the functional unit – mounted on the body. Any position of the
locking stem can be blocked; the stop (563) has to be secured with a lock
(934). Limit switches (814) may be fixed at the yoke; they signalize the given
position of the main stem (209).
The valve seats are hard-faced, the inner surfaces of the stem guide bushes as
well. The wall of the working cylinder is stellited. Buffering is provided between
the chrome-layer and the basic material.
The materials of the individual components are specified on the parts listed
enclosed – according to the item numbers.
5.2 Automatic Change-Over Valve ZJSVM – Inlet Side
5.3 Automatic Change-Over Valve RJSVM – Outlet Side
5.4 Part List for ZJSVM/RJSVM - Main Parts

Installation, Commissioning and Maintenance Manual

for
KSB Change-Over Valves, Type ZJSVM/RJSVM
1 General Instructions
These operating instructions apply to the ZJSVM changeover valve and the corresponding RJSVM non-return valve, made by KSB, as described
in section 5, unless reference is made to other operating manuals in individual cases.
Only correct installation, maintenance or repair will ensure smooth operation of the valves, the manufacturer shall not accept any liability if the
instructions set forth in this manual are not complied with.
The design, manufacture and testing of KSB valves are subject to a QM-System to DIN EN ISO 9001 as well as the European Pressure
Equipment Directive 97/23/EC. Compliance with these requirements, however, is based on normal, static loading, e.g.
- Flow velocities typical of the fluid handled

- Typical temperature gradients
Other than normal operating conditions (temperature, pressure, special corrosive, chemical or abrasive influences, ...) must be specified fully
and clearly in the purchase order, so that the valve manufacturer can prepare and suggest suitable measures.
Such measures may, for example, influence
- Material selection
- Wall thickness
- Seal selection
- Protection of valve areas prone to wear
- Prevention of excessive pressures and temperatures
- Special designs for controlled operation, etc.
Valves exposed to creep-rupture conditions have a limited service life and have to meet the applicable regulations stipulated in the technical
codes.
Caution
The valves must not be operated outside the permissible operating range. The application limits are indicated on the name plate or in the
applicable type series booklet. The pressure / temperature ratings, in particular, must not be exceeded. Operation of the valves outside the
above-mentioned conditions will result in overloads the valves cannot withstand.
Non-observance of this warning may cause personal injury and damage to property, for example:
- Injuries resulting from fluid leakage (cold / hot, toxic, under pressure, ...)
- Impairment of the valve’s function or its destruction.
The descriptions and instructions set forth in this manual refer to the standard models but are also applicable to variants.
These operating instructions do not take into account:
- Any eventualities and events which might occur during installation, operation and maintenance,
- Local regulations; the operator must ensure that such regulations are strictly observed by all, including the personnel called in for installation.

Caution
The valve must only be operated by skilled personnel.
Incorrect operation of the valve may have a substantial impact on the entire system, for example:
- Leakage of the fluid handled

- System / machine brought to a standstill
- Impairment / reduction / increase of the system’s / machine’s function / effect
For any queries and repeat orders, in particular for purchasing spare parts, please specify the type series / variant details, the order number, as
well as the year of construction, if possible.
1

2 Safety
These operating instructions contain important information which must be observed during installation, operation and maintenance.
In addition to the general safety instructions laid down in the Chapter ”Safety”, also the special safety instructions provided in other sections must
observed.

2.1 Symbols used in these Operating Instructions
The safety instructions contained in this manual whose non-observance might cause hazards to persons are specially marked with the general
hazard sign, namely
Safety sign in accordance with DIN 4844 - W 9.
The electrical danger warning sign is Safety sign in accordance with DIN 4844 – W 8.
The word Caution
is used to introduce safety instructions whose non-observance may lead to damage to the valve and its accessories and its / their functions.
Instructions attached directly to the valve (e. g. nominal pressure) must always be complied with and be kept in a perfectly legible condition at all
times.
2.2 Non-Compliance with Safety Instructions
Non-compliance with safety instructions can jeopardize the safety of personnel, the environment and the valve itself. Non-compliance with
these safety instructions will also lead to forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
- Failure of important valve / system functions,

- Failure of prescribed maintenance and servicing practices
- Hazard to persons by electrical, mechanical and chemical effects,
- Hazard to the environment due to leakage of hazardous substances.
2.3 Safety Awareness
It is imperative to comply with the safety instructions contained in this manual, the relevant national health and safety regulations and the
operator’s own internal work, operation and safety regulations.

2.4 Safety Instructions for the Operator / User
Any hot or cold valve components (e. g. body components or handwheel) that could pose a hazard must be equipped with a guard by the
operator.
Guards which are fitted to prevent accidental contact with moving parts (e.g. coupling) must not be removed whilst the unit is operating.
Leakages (e.g. at the stem seal) of hazardous fluids handled (e.g. explosive, toxic, hot) must be contained so as to avoid any danger to persons
and the environment. All relevant laws must be heeded.
Electrical hazards must be eliminated. (For details please refer to VDE regulations and the safety regulations, laid down by the local energy
supply companies, for instance).
2

2.5 Safety information for maintenance, inspection and installation work

The operator is responsible for ensuring that all maintenance, inspection and installation work be performed by skilled personnel.
Before removing the valve from the pipeline or before repair or maintenance work at the valve itself, i.e.
- Removing the bonnet (160) from the body (108)

- Removing mating flange (723.2) and blind flange (724)
- Removing the gland flange (452) to replace the packing rings or the packing
- Removing the yoke (723.1) or loosening the intermediate flange (729),
the complete valve must be depressurized and the temperature must be cooled down below the fluid’s vaporization temperature (also in the gland
packing chamber) to prevent any risk of scalding.
Work on valves must be carried out only during standstill.
Immediately following completion of the work, all safety-relevant and protective devices must be re-installed and / or re-activated.
Please observe all instructions set out in S ection 7 Commissioning / Start-up before returning the valve to service.

2.6 Unauthorized Modification and Manufacture of Spare Parts
Modifications or alterations of the valve supplied are only permitted after consultation with the manufacturer. Original spare parts and accessories
authorized by the manufacturer ensure safety. The use of other parts can invalidate any liability of the manufacturer for resulting damage.

2.7 Unauthorized Modes of Operation
The warranty relating to the operating reliability and safety of the valve supplied is only valid if the equipment is used in accordance with its
designated use as described in Section 2 General of this manual. The limits stated in the documentation must not be exceeded under any
circumstances.
3

3 Transport and Storage

The valves are delivered ready for operation, the obturator plug is in ’closed’ position and the line connection ports are closed with suitable
material (Caps, plugs, covers).

3.1 Transport
Suitable precautions shall be taken to prevent damage during transport.

Caution
The valves must never be suspended by the handwheel or by the actuator, if any.
Valves shall be transported by means of ropes attached to the connection ports and yoke arms, taking into account the center of gravity.
Use any lifting lugs provided.

After delivery and prior to installation, check the valve for potential damage acquired in transit.

3.2 Storage
Storage / interim storage of the valves must ensure that even after a prolonged period of storage the valves’ function is not impaired. The
following requirements must be met:
- Storage is performed with the valve in closed position (to protect the seat / disc contact faces against damage)
- Measures are taken to protect the valves against dirt, humidity, frost and corrosion (e.g. by using foils or caps; indoor storage).
4

4 Installation

4.1 General
Responsibility for positioning and installing the valves always lies with the engineering company, construction company or operator/user.
Planning and installation errors may impair the reliable function of the valves and pose a substantial safety hazard. For this reason it is
particularly important to observe the following:
Caution
The piping shall be laid in such a way as to prevent detrimental thrust or torsional forces from being transmitted to the valve bodies in
installed and operating condition, to avoid leakage, deformation or excessive stresses on the valve body.
Caution
The caps on the connection ports shall be removed immediately prior to installation.
When painting the pipelines and valves, do not apply paint to the bolts, stems and plastic components (valve function will be impaired). If
construction work is still in progress, the valves must be protected against dust, sand and building material (cover with suitable material).
Do not use valve’s handwheel as footholds.

For safety reasons, valves and piping systems operated at high (> 50°C) or low (< 0°C) temperatures must be insulated, or a warning sign must
point out the risk of personal injury involved when touching the hot or cold components.
Valves with external moving elements must be fitted with protective covers, or other suitable measures must be taken to prevent accidents.
To prevent any damage to the seat/disc interface during transport and storage, the valves are delivered in closed position.
4.2 Installation Position
The best installation position is with the stem pointing vertically upwards.
4.3 Welding instructions

Responsibility for welding the valves into the piping and for any heat treatment required lies with commissioning company or the plant
operator.
Caution
When welding valves with butt or socket weld ends into the piping or when performing welding jobs on a pipeline after the valves have been
installed (pipeline installation) make sure that no contamination enters the valve body and stays there, to prevent damage to the seat/disc
interface or stem guiding elements.
Caution
When welding the valve into the pipeline, take special precautions, e.g. welding in several steps, to prevent the temperature in the middle of the
valve body from rising above 80 - 100 °C and distorting the valve.
Caution
For welding, the valve must be open (intermediate position).
Caution
To prevent tarnishing at the inside it is recommended to supply shielding gas at the welding surfaces from the body side.
Caution
The welding cable (Opposite pole) must not be attached to functional valve elements, to prevent scorching.
5

Caution
Welding instructions, such as pre-heating, the quality of filler metal and the secondary treatment of welds, must be observed.
6

5 Operation / Commissioning, Start-up / Shutdown

(Also refer to Section 4 Installation)
5.1 Operation / Commissioning / Start-up
5.1.1 General
Prior to commissioning / start-up compare the material, pressure and temperature data on the valves with the operating conditions of the piping
to check the material’s chemical resistance and stability under load.
Surge pressure (water hammer), which might occur, must not exceed the max. permissible pressure, therefore safety measures are required to
be taken.
In new systems and particularly after repair, the complete piping system must be thoroughly flushed with the valves fully opened so that particles
and / or welding beads that might damage the seat/disc interface are removed.
If the piping system is cleaned by means of a pickling procedure, responsibility for the compatibility of the pickling media used and the pickling
procedure itself lies with the pickling company.
For commissioning or after particular operating conditions (repairs at the feed water heater, switching errors) the feed water heater line must be
opened. If pressurized, the feed water heater valves must only be opened after the pressure has been released. By-pass lines and valves
must be provided. For low pressures, a start-up control valve or line is provided, which serves to support the opening of the changeover valve
in this direction. On the non-return valve, the blind flange can also be replaced by a control valve line.
Manual actuation at the coupling can also be provided (e.g. a handwheel), which allows opening against a differential pressure of up to 30
bar.
Caution
Prior to opening the valve, make sure the relevant precautionary and safety instructions are heeded!
Caution
The shut-off element consisting of handwheel, yoke and upper stem allows the feed water heat line valve to be locked in position. This
means the valve plug (350) either remains in the upper (open) position or in the lower position (feed water heater closed). The valve must
not be locked against full operating pressure (more than 30 bar on request). Always lock the change-over valve upstream of the feed water
heater before locking the non-return valve downstream of the feed water heater.
To prevent damage to the valve material or joint seals, the usual start-up and shutdown velocities must be adhered to.
The control valves and electrical limit switches must be checked for reliable functioning. Make sure that the valve is easy to actuate.
Before putting the valve into operation, remove pin (563.2) from the coupling piece (865), put stem (206) into top position (by turning the
handwheel) feed pin (563.2) through disc (550.2) into the upper yoke (167) and secure it with lock (934). This ensures that the valve can be
actuated properly via the control valves.
5.1.2 First Tests and Adjusting
The functional reliability of installed valves must be checked by opening and closing them repeatedly.
If the valve is in unpressurized condition, this can be done manually by coupling the stems (200 and 206) as described in section 5.4 and
moving them by turning the handwheel.
The functional reliability can also be checked by means of process fluid control via the control valves. Make sure that stem (206) is locked
in top position with pin (563.2). Check the correct contact setting of the limit switch and adjust if required.
Once the limits of the main valve have been reached, the control valves must be closed again to prevent unnecessary water loss and
blasting wear.
In closing direction, the valve can also be actuated with the handwheel when in operation. To do so, pull pin (563.2) out of the perforated
disc (550.2) of the locking arrangement. The stems (200 and 206) must not be coupled. In this case, make sure that the non-return valve
downstream of the feed water heater is always closed last.
5.1.3 Functional Test
KSB recommends checking the following functions:
Check the shut-off function of the installed valves prior to commissioning / start-up by opening and closing them several times.
7

The gland packing (461) shall be checked for leakage when it is subjected to full operating pressure and temperature for the first time. Re-
tighten the nuts (902.2/920.2) at the gland flange (452) evenly, if necessary.
On valves in pressure seal design, the hexagon head bolts (901.1) pre-loading the bonnet (160) and the inserted joint ring (411.1) must
always be tight enough under operating conditions to avoid leakage, which might be caused by the bonnet sinking as a result of low
pressure inside the body.
Caution
Before retightening the nuts at the gland flange (920.2), open the valve by two full handwheel turns to prevent stress or distortion.
5.2 Shutdown
In the event of prolonged shutdowns, KSB recommends draining from the piping fluids which change their physical condition due to changes
in concentration, polymerization, crystallization, solidification, etc. If required, flush the piping with the valves fully opened.
8

6 Servicing / Maintenance
6.1 Safety Instructions

Repair and maintenance work must only be performed by competent personnel taking into account the relevant health and safety
regulations.
It is imperative that the below safety instructions and the general information on safety as per Section 3 be observed for all servicing and
maintenance work to be performed.
Caution
Always use suitable spare parts and tools, even in emergencies, to ensure proper functioning of the valves.
6.1.1 Valve Dismantling
Proceed as follows to dismantle the valve:
- Unscrew nuts (920.3) and disconnect flanges (723.2) from the control lines. Unscrew bolts (902.3).
- Unscrew limit switch (815)
- Unscrew contact piece (572) from coupling piece (865)
- Unscrew nuts (920.1) and remove the yoke
- Loosen bolts (901.1) until locking plate (196) releases segmental ring (501.2). Remove segmental ring and lift off locking plate (196)
- Lift off thrust plate (414) and remove segmental ring (501.1) by pushing a mandrel through the drilled holes in the body.
- Pull the complete trim with stem (200), valve plug (350), bonnet (160) and inserted piece (751) out of the body
- Unscrew grub screw (904.2) and remove coupling (865) from stem (200)
- Remove gland bolts (902.2, 920.2).
- Loosen screws (914.2) and pull out bonnet (160) from inserted piece (751) via stem (200)
- Remove grub screw (904.3) and unscrew piston (595)
- Pull stem (200) together with valve plug (350) out of inserted piece (751)
- Undo screws (914.1)
- Unscrew valve plug (350) from stem (200), remove ring (500.1) with parallel pins (562.1)
Valve pressure must be released and the valve must be allowed to cool down such that the temperature is below the fluid’s vaporization
temperature in all areas in contact with the fluid in order to effectively prevent any risk of scalding.
Never open a valve under pressure (Danger to life!)
Any fluid residues which may have collected in the valves shall be collected and properly disposed of.
Prior to any transport, flush and drain the valve thoroughly.
6.2 Maintenance
This valve has been designed to be largely maintenance-free. The materials of the sliding parts have been selected for minimum wear. It is
generally sufficient to conduct checks every 6 to 12 months. If there are any leakages at the gland packing, the gland nuts (920.2) must be
retightened. Do not tighten nuts on one side only. If the leakage continues after the nuts (920.2) have been retightened, a new gland
packing must be mounted.
If there are any leakages at the seat, which are usually caused by foreign matter or its indentation marks, regrinding is required if the
permissible values are exceeded.
If there are any leakages at the joint ring (411.1) of the bonnet, replace it with a new one.
6.3 Valve Reassembly
Valve reassembly shall be effected in reverse order to dismantling.
To maintain functional reliability, new sealing elements and gland packings shall be used whenever the valve is reassembled.
After reassembly and prior to commissioning / start-up, the valves shall be subjected to a leak test.
9

7 Trouble-Shooting

7.1 General
KSB valves are robust in design. Nevertheless, malfunctions e.g. caused by maloperation, lack of maintenance or improper use cannot be
ruled out completely.
All repair and maintenance work shall be performed by competent personnel using suitable tools and original spare parts, whereby KSB
recommends to have this work performed by their service personnel.
In any case, the safety instructions in Sections 2 and 5 must be complied with.
7.2 Faults > Remedies
7.2.1 Leakage at the Seat
Possible reasons:
Contaminations/solids in the fluid

Erosion, corrosion, abrasion
Excessive loads from pipeline forces or thermal stresses
Measures:
> Rework the seat / disc contact faces at the discs and body using a suitable reseating tool after the valve has been dismantled. The re-
seating process shall be continued until the contact faces exhibit a uniform bright surface.
7.2.2 Leakage at the Pressure Seal Bonnet
Possible reasons:
Joint ring has settled as a result of high temperature fluctuations

Impermissible pressure loads
Poor joint ring resistance to temperature and fluid handled
Measures:
> Re-tighten the hex. nuts (901.1), as described in 5.1.3

> Replace the joint ring (411.1)
7.2.3 Leakage at the Gland Packing
Possible reasons:
Worn packing material

Poor maintenance
Poor packing resistance to temperature and fluid handled
Measures:
> Re-tighten the gland packing at the nuts (920.2) of the gland cover (452). Make sure that the friction forces at the stem do not increase too
much
> Replace the packing rings of the gland packing (461.1/461.2): Undo the nuts (920.1/920.2) and lift off the gland cover (452). Clean the
gland packing chamber carefully before inserting new packing rings. Split packing rings shall be inserted in such a way that the cut edges
are offset by 120°- 180°
This manual is an extract from KSB Doc. No. 0570.83-10
10

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SUPPLIER's (ABFPL's ) REPLY SHEETS NTPC REF.

NO: CC:110:19455 DATE: 31-03-2017

DOC/DWG TITLE: ABFPL's TRANSMISSION NO: C-FOLDER UPLOAD DATE: 13-06-2017

Sl No. ITEM NTPC COMMENTS ABFPL/KSB REPLY REMARKS

Asked details shall be part of this document.Pls

2 Document shall be vetted by AE. Note and incorporated in revised GAD.

3. Write-up is very brief. Detailed write-up to be

Comparison between P355QH1 (1.0571) and ASTM A106 Grade C

x P355QH1 acc. EN 10222 (Material No. 1.0571)

Mechnanical Technologic Properties at Room Temperature:

3-Way Heater Bypass Valve (ZJSVM) - Inlet Valve

Project: M24 - Tanda TPP Stage-II / India

108 Gehäusekörper casing body 1 1.6368 – 1.4115 A182-F36

196 Spannplatte locking plate 1 1.6368 A182-F36

KSB Aktiengesellschaft ECS1S552, Büttner M. / Lautner N. Juli 2016 Page/Blatt 1

Parts List M24-Tanda ZJSVM 9973159108 0100-0D.docx

3-Way Heater Bypass Valve (ZJSVM) - Inlet Valve

Project: M24 - Tanda TPP Stage-II / India

593.2 Kolbenring piston ring 2 1.4057 A276-Type 431

723.2 Flansch flange 2 1.5415 A182-F1

751 Einsatzstück insert 1 1.5415 - H21 A182-F1/Stellited

KSB Aktiengesellschaft ECS1S552, Büttner M. / Lautner N. Juli 2016 Page/Blatt 2

Parts List M24-Tanda ZJSVM 9973159108 0100-0D.docx

3-Way Heater Bypass Valve (ZJSVM) - Inlet Valve

Project: M24 - Tanda TPP Stage-II / India

108 Gehäusekörper casing body 1 1.6368 – 1.4115 A182-F36

196 Spannplatte locking plate 1 1.6368 A182-F36

KSB Aktiengesellschaft ECS1S552, Büttner M. / Lautner N. Juli 2016 Page/Blatt 1

Parts List M24-Tanda ZJSVM 9973159108 2000-0D.docx

3-Way Heater Bypass Valve (ZJSVM) - Inlet Valve

Project: M24 - Tanda TPP Stage-II / India

593.2 Kolbenring piston ring 2 1.4057 A276-Type 431

723.2 Flansch flange 2 1.5415 A182-F1

751 Einsatzstück insert 1 1.5415 - H21 A182-F1/Stellited

KSB Aktiengesellschaft ECS1S552, Büttner M. / Lautner N. Juli 2016 Page/Blatt 2

Parts List M24-Tanda ZJSVM 9973159108 2000-0D.docx

3-Way Heater Bypass Valve (RJSVM) - Outlet Valve

Project: M24 - Tanda TPP Stage-II / India

108 Gehäusekörper casing body 1 1.6368 – 1.4115 A182-F36

196 Spannplatte locking plate 1 1.6368 A182-F36

KSB Aktiengesellschaft ECS1S552, Büttner M. / Lautner N. Juli 2016 Page/Blatt 1

Parts List M24-Tanda RJSVM 9973159108 1000-0D.docx

3-Way Heater Bypass Valve (RJSVM) - Outlet Valve

Project: M24 - Tanda TPP Stage-II / India

595 Kolben piston 1 1.4057 + QT A276-Type 431

751 Einsatzstück insert 1 1.5415 - H21 A182-F1/Stellited

838 Positionsschalter position switch 3 Siemens 3SE5162-0CE01 N/A

KSB Aktiengesellschaft ECS1S552, Büttner M. / Lautner N. Juli 2016 Page/Blatt 2

Parts List M24-Tanda RJSVM 9973159108 1000-0D.docx

3-Way Heater Bypass Valve (RJSVM) - Outlet Valve

Project: M24 - Tanda TPP Stage-II / India

108 Gehäusekörper casing body 1 1.6368 – 1.4115 A182-F36

196 Spannplatte locking plate 1 1.6368 A182-F36

KSB Aktiengesellschaft ECS1S552, Büttner M. / Lautner N. Juli 2016 Page/Blatt 1

Parts List M24-Tanda RJSVM 9973159108 3000-0D.docx

3-Way Heater Bypass Valve (RJSVM) - Outlet Valve

Project: M24 - Tanda TPP Stage-II / India

595 Kolben piston 1 1.4057 + QT A276-Type 431

751 Einsatzstück insert 1 1.5415 - H21 A182-F1/Stellited