Operating, Maintenance and Repair Instructions for RMA Ball Valve ...

RMA Kehl GmbH & Co KG 

Oststrasse 17 

77694 Kehl/Rhein, Germany 

Telefon : +49-7851-868-0 

Telefax : +49-7851- 868-113 

Number of sheets : 12 

Operating, Maintenance and Repair Instructions for 

RMA Ball Valve Type "HKSF W100" 

Revision : September 2006 

Technical modifications reserved 

Seite 1 / 12





TABLE OF CONTENTS 

1. Applicable documents 3 

2. Data for intended use 3 

3. Construction / Function 4 

3.1. Ball valve 4 

3.2. Sealant and / or lubrication system 4 

4. References to the storage 5 

5. Unpacking and examination 5 

6. Data to the safe installation 6 

6.1. Preparations 6 

6.2. Handling 6 

6.3. Installation 7 

6.4. Water pressure test 8 

6.5. Leak test 9 

7. Maintenance 10 

8. Repairs 10 

8.1. Preparations 10 

8.2. Repair of the external coating 10 

9. Sketch ball valve with individual parts 11 

Sheet 2 / 12



1. Applicable documents 

If ball valves are equipped with gears, the gear manufacturer’s operating instructions are to be 

respected. 

2. Data for intended use 

The valve is an extremely sturdy, fully welded ball valve for use in piping systems for the shut-off 

position of fluids. 

The valve consists of a body with pipe connections, a spherical stopper, seals and operating spindle. 

The ball valve is a shut-off device and should only be used in the FULLY-OPEN or FULLY- 

CLOSED positions. Flow reduction with a ball valve is prohibited. 

The valve is only in positions FULLY-OPEN or FULLY-CLOSED when the end stops are engaged. 

The permissible operational data (in particular operating temperature and pressure) are to be inferred 

from the marking and the associated data sheets. 

The valve forms a closed system. By the action of the seals the technical tightness is in the long 

term ensured within the operating conditions. 

The fluid existing in the body can be set free over drain or vent ports. In these places danger exists 

form the blow-off pressure and by mixing flammable materials with air causing explosive atmospheres. 

The valve may be used according to its equipment category in the explosion prevention zones 1, 

2 and 3. 

The permissible environment and fluid temperature are considered according to the data of the 

operator within the construction. 



II 2G X 

Letter "X": Since the operating temperature of the valve is determined by the temperature 

of the fluid, the temperature class or largest surface temperature, it 

must be specified by the operator, whereby the safety temperature distances 

from En13463-1 are to be kept. 

Operating temperature °C 1 ) Temperature class 

to 80 T6 

to 95 T5 

to 130 T4 

1 ) Into the table a safety margin was considered by 

5°C (EN of 13463-1 chapter 13.3.3) 

Sheet 3 / 12



3. Construction / Function 

3.1. Ball valve 

The body of the valve is fully welded. 

The ball is supported by a journal at top and bottom (trunnion mounted). 

The sealing system is primarily metallic, secondarily soft. 

On both sides of the ball valve passage are floating arranged seat rings. These can adjust themselves 

as necessary to the ball. This metallic seal is pressed by feathers / springs to the ball, 

contact is pressure-dependent. Ball and seat rings are polished and lapped. 

The fittings comprise a full bore with a smooth round passage and is therefore piggable. 

The ball valve can be equipped with flanges, welding or other specified ends. 

3.2. Sealant and / or lubrication system 

According to customers’ requirements, RMA ball valves can be provided with sealing compound 

systems at the seating rings and / or the spindle sleeve. 

Access is made possible by means of a nipple (e.g. Alemite-Screw AEX 7/8“), either directly at 

the ball valve or through vertically prolonged pipes. 

The systems are pressure-proof up to 1000 bar and are equipped with double-nonreturn valves. 

On request, they are pre-filled with a special sealing grease. 

For these purposes the folowing greases can be used: 

For emergency sealing : Equa- Lube Eighty 

For emergency sealing and greasing : Ceritol.SAS 325 



Sheet 4 / 12



4. References to the storage 

The ball valves should remain during the entire storage time in their original packaging. In order to 

avoid damage, the protective caps at the weld / flange ends are to be left in place until installation. 

The ball valves must always be stored in the FULLY-OPEN Position. 

The valves should be stored in a closed and dry building. 

5. Unpacking and examination 

The ball valves are to be unpacked with the necessary care. After unpacking the ball valves are 

to be examined for transportation damage. The ball valves are supplied in FULLY-OPEN Position 

and with protective caps at both ends. 



Sheet 5 / 12



6. Data to the safe installation 

6.1. Preparations 

It must be guaranteed that when assembling and disassembly no combustible atmosphere is present 

or develops. 

Before the installation check the size, the pressure and the materials used correspond to the 

specified requirements. 

Impurities, which formed during longer storage times, are to be removed before the installation. 

6.2. Handling 

When lifting the ball valve, the slings must be wrapped around the body only and not around the 

spindle lever. 

Lifting: 



Sheet 6 / 12



6.3. Installation 

Ensure the ball valves are as in the delivered state to weld and / or build into position FULLY- 

OPEN to avoid damage of the ball and the seat rings. 

During the welding procedure the temperature at the body within the range A (see sketch) should 

not exceed 120° C. The valve may be welded only in the FULLY-OPEN position. Only arc welding 

methods may be used. 

After welding and before first operation of the ball valve the line system must be rinsed thoroughly 

to remove impurities for example welding debris (cinder, scale, rust, etc.) which could damage the 

sealing elements. 

The valve must be attached by electrostatically compatable hose and / or tubing systems or be 

connected directly electrostatically conductive (Resistance < 10 6 Ω) with the earth potential. Intended 

electrical interfaces (cathodic corrosion protection) may not be short circuited. 

Outside piping forces and tensions are to be avoided by appropriate line constructions and / or by 

appropriate installation positions. 



Sheet 7 / 12



6.4. Water pressure test 

We recommend to put the ball in FULLY-OPEN position before filling the line with water. 

After filling the line with water, put the ball into HALF-OPEN position to have a pressure before 

and behind the seat rings. 

Immediately after the water pressure test the following is to be done: 

1. The valve is placed into the FULLY-OPEN position. 

2. Drain the valve by the drain connection. If a drain valve is present, open it completely. 

If there is only a vent/drain plug then turn it 2 or 3 turns and wait until the pressure has 

dropped entirely, remove the plug and remove the water. 

When the valve is pressureless, to drain the cavity you have to put pressure into the 

body through the drain valve (Nitrogen, not over the max. design pressure ! ). Then 

close the drain valve, take away the nitrogen connection and open the drain valve to 

remove the water. 

3. Close the drain connection again. 

4. Lubricate the valve through the sealant injectors for the seat rings (not the spindle) to 

remove existing dirt. 

5. Turn the valve once (Close – Open). 

6. Turn the valve into the final FULLY-OPEN position. 



Sheet 8 / 12



6.5. Leak test 

The tightness can be examined with two methods. 

1. Leak test from piping to valve body. 

1. The valve is placed into the FULLY-OPEN or FULLY-CLOSED position. 


If there is only a vent/drain plug then turn it 2 or 3 turns and wait until the pressure 

has dropped entirely, remove the plug. 

3. Check the leakage (a sufficient time is needed to have a pressure balance). 

4. Apply pressure (Nitrogen) into the valve body (pressure balance between valve body 

and pipe line). 





8. Turn the valve into the final FULLY-OPEN or FULLY-CLOSED position. 

2. Leak test from valve body to piping. 

1. The valve is placed into the final FULLY-OPEN or FULLY-CLOSED position. 


If there is only a vent/drain plug then turn it 2 or 3 turns and wait until the pressure 

has dropped entirely, remove the plug. 

3. Apply pressure (Nitrogen) into the valve body (not more than the max. operating pressure). 

4. Check the decrease of pressure (leakage). 

5. Pressurise the valve body to the pressure in the pipe line (pressure balance between 

valve body and pipe line). 





9. Turn the valve into the final FULLY-OPEN or FULLY-CLOSED position. 



Sheet 9 / 12



7. Maintenance 

If the measures as described were accomplished after the water pressure test as under chapter 

6.4, the valve is maintenance-free. The bearings are self-lubricating and wear resistant. The 

gears supplied are greased for life and therefore require no maintenance. 

8. Repairs 

8.1. Preparations 

It must be guaranteed that within the work area no combustible atmosphere is present or develops. 

8.2. Repair of the external coating 

When the external coating PUR for underground (Protegol 32-55) is damaged, it may be repaired 

using the repair kit “ Protegol 32-55L ” which is specially designed and supplied by the manufacturer 

for this purpose. The manufacturer's corresponding technical instructions are to be respected. 

Due to the fast reaction time, the repair kit is supplied in small canisters of 0.5 kg (supplied by 

RMA). 

In case of other coatings, especially for above ground, please ask from case to case. 



Sheet 10 / 12



9. Sketch ball valve with individual parts 



Sheet 11 / 12





Sheet 12 / 12

Operating, Maintenance and Repair Instructions for RMA Ball Valve ...

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