DeZurik KGC ES Manual de usuario

DeZURIK, Inc. Sartell, Minnesota USA | Phone: 320-259-2000 | www.dezurik.com | i[email protected]

DeZURIK 2-24”(50-600mm)

KGC ES or HD

Knife Gate Valves

Instruction D10411

June 2019

DeZURIK

Instructions

These instructions are for use by personnel who are responsible for the installation, operation and

maintenance of DeZURIK valves, actuators or accessories.

Safety Messages

All safety messages in the instructions are identified by a general warning sign and the signal word CAUTION,

WARNING or DANGER. These messages indicate procedures to avoid injury or death.

Safety label(s) on the product indicate hazards that can cause injury or death. If a safety label becomes difficult

to see or read, or if a label has been removed, please contact DeZURIK for replacement label(s).

Personnel involved in the installation or maintenance of valves should be constantly alert to potential

emission of pipeline material and take appropriate safety precautions. Always wear suitable protection

when dealing with hazardous pipeline materials. Handle valves which have been removed from service

with suitable protection for any potential pipeline material in the valve.

Inspection

Your DeZURIK product has been packaged to provide protection during shipment; however, items can be

damaged in transport. Carefully inspect the unit for damage upon arrival and file a claim with the carrier if

damage is apparent.

Parts

Replaceable wear parts are listed on the assembly drawing. These parts can be stocked to minimize

downtime. Order parts from your local DeZURIK sales representative or directly from DeZURIK. When ordering

parts please provide the following information:

If the valve has a data plate: please include the 7-digit part number with either 4-digit revision number

(example: 9999999R000) or 8-digit serial number (example: S1900001) whichever is applicable. The

data plate will be attached to the valve assembly. Also, include the part name, the assembly drawing

number, the balloon number and the quantity stated on the assembly drawing.

If there isn't any data plate visible on the valve: please include valve model number, part name, and

item number from the assembly drawing. You may contact your local DeZURIK Representative to help

you identify your valve.

DeZURIK Service

DeZURIK service personnel are available to maintain and repair all DeZURIK products. DeZURIK also offers

customized training programs and consultation services. For more information, contact your local DeZURIK

sales representative or visit our website at DeZURIK.com.

Table of Contents

Description 4

Handling 4

Installation 6

Operation 7

Lubrication 7

Packing 7

Adjustment 7

Drawings 8

Packing Replacement 9

Removing the Old Packing 9

Installing the New Packing 10

Reassembling the Valve 11

Seat Replacement 11

Reassembling the Valve 12

Replacing the Gate 12

Purge Port Option 13

Troubleshooting 15

DeZURIK

2-24” KGC ES or HD KNIFE GATE VALVES

June 2019 Page 3 D10411

D10411 Page 4 June 2019

DeZURIK

2-24” KGC ES or HD KNIFE GATE VALVES

Description

KGC knife gate valves have a stainless steel body and gate, and an all-metal or resilient-faced seat.

The KGC knife gate valve is available in 2-48" (50-1200mm) sizes. This manual covers the 2-24” (50-

600mm) sizes. A choice of several actuators and accessories is available.

Handling

The points below are for reference purposes only, use safe and proper lifting and support tech-

niques. DO NOT lift valves with any adjoining pipe or other equipment attached. Lift with

properly rated lifting equipment. Follow jurisdictional safety requirements.

Suggested lifting points are as shown below to lift valve assemblies that are in a horizontal orientation.

Eye bolts in flange through holes can be used to lift the valve body or, for 2” through 12” valves, a

sling can be strapped around the top of the valve body.

For valves with bevel gear actuators, a sling or chain can a wrapped around the bevel gear actuator

body, between the mounting plate and the input shaft housing. This would be in conjunction with lift-

ing from the valve body as well. See Figure 1.

For valves with pneumatic cylinder actuators, a sling can be wrapped around the cylinder, near the

cylinder head (piston rod end). This would be in conjunction with lifting from the valve body. Utilize

caution to not bump, dent or damage the cylinder tube. DO NOT utilize the cylinder tie-rod ends to lift.

See Figure 2.

Figure 1—Knife Gate Valve with Bevel Gear Actuator,

Horizontal Lifting

Figure 2, Knife Gate Valve with Pneumatic Cylinder Actuator,

Horizontal Lifting

WARNING!

A potential hazard exists with handling valves. Failure to handle valves properly

may cause a valve to shift, slip or fall causing serious injury or death and/or

equipment damage.

D10411 Page 5 June 2019

DeZURIK

2-24” KGC ES or HD KNIFE GATE VALVES

Handling

continued

For valves with handwheel actuators, a sling or chain can be wrapped through the rim of the hand-

wheel. For chainwheel actuators, a sling can be wrapped in the area between the yoke/legs and the

chainwheel/guide assembly. This would be in conjunction with lifting from the valve body as well. See

Figure 3.

Suggested lifting options are as shown below to lift valve assemblies that are in a vertical orientation.

For valves with bevel gear actuators, wrap slings or chains around the top of each leg. Use caution

not to put any side load on the bevel gear input shaft or on the valve’s threaded stem. See Figure 4.

For valves with pneumatic cylinder actuators, wrap slings around the top of each leg. Use caution to

not bump, dent or damage the cylinder tube and avoid any side load on the cylinder piston rod. DO

NOT utilize the cylinder tie-rod ends to lift. See Figure 5.

For valves with handwheel or chainwheel actuators, wrap slings or chains around the top of the each

leg or yoke side. Use caution to not put any side load on the valve’s threaded stem. See Figure 6.

Figure 3, Knife Gate Valve with Handwheel or Chainwheel Actuator, Horizontal Lifting

Figure 4- Knife Gate Valve

with Bevel Gear Actuator,

Vertical Lifting

Figure 5- Knife Gate Valve

with Pneumatic Cylinder

Actuator, Vertical Lifting

Figure 6- Knife Gate

Valve with Handwheel or

Chainwheel Actuator,

Vertical Lifting

Installation

Install the valve between ASME Class 125 or Class 150 pipeline flanges, or other flanges that match

valve end connection. Flange gaskets are required. Before installation, remove foreign material such

as weld spatter, oil, grease, and dirt from the valve and pipeline.

Normal Installations

Install the valve so that the side marked “SEAT” is on the lower pressure side of the valve when the

valve is closed; the pipeline pressure will then help seal the valve in the closed position.

Gravity (Dry) Service Installations

When installing the valve in a vertical pipeline (such as a hopper

bottom, gravity flow, or other dry service application), install the

SEAT side of the valve facing upstream as shown in Figure 1.

Installing the valves with the seat side upstream prevents process

media buildup in the seat and chest area of the valve. This orien-

tation also allows the seat to act as an integral deflection cone,

protecting the seat from wear.

General Guidelines

Observe the following points to prevent distortion of the valve

body and gate when the flange bolts are tightened:

 Align the mating pipeline flanges.

 Select the length of the flange bolts so that the bolts

used in the blind holes near the chest area of the valve

do not bottom out when tightened.

We recommend using studs with

nuts in the blind holes.

 Tighten the flange bolts evenly, in a

crisscross pattern. Refer to Table A

for recommended flange bolt/stud

torques.

Note: Torque ranges are based on ASME

Pressure Vessel Code Calculations and

lab test data. These torques are only for

the listed gasket types. For other gasket

types listed in ASME, consult DeZURIK.

After installing the valve, pressurize pipeline

and ensure the packing is not leaking. If the

packing leaks, adjust the packing as described

on the next page.

D10411 Page 6 June 2019

DeZURIK

2-24” KGC ES or HD KNIFE GATE VALVES

Valve Size

ASME Gasket Types

Rubber with

Soft Fabric

Filler, & 1/8”

Thick Hard

Soft Elastomer

Gasket Shore

Durometer < 75A

2” (50mm) 26 - 29 8 - 9

3” (80mm) 37 - 41 14 - 16

4” (100mm) 26 - 29 11 - 12

6” (150mm) 41 - 45 22 - 24

8” (200mm) 55 - 61 35 - 39

10” (250mm) 56 - 62 40 - 44

12” (300mm) 80 - 88 59 - 65

14” (350mm) 107 - 118 81 - 89

16” (400mm) 103 - 114 79 - 87

18” (450mm) 128 - 141 102 - 112

20” (500mm) 123 - 136 99 - 109

24” (600mm) 188 - 207 155 - 171

Table A: Recommended Flange Bolt/Stud

Torque Range in ft-lbs (non-lubricated)

Figure 1—Vertical Line/

Hopper Bottom

Operation

The gate in the valve is positioned by the valve actuator. The actuator moves the gate over the valve

port in the closed position, and withdraws the gate from the seat in the open position. Refer to the Ac-

tuator Instructions for adjustment and maintenance requirements for the actuator.

Lubrication

The valve does not require lubrication. If applicable, ensure that valve threaded stems are maintained

with proper lubrication. Refer to the Actuator Instructions for lubrication requirements for the actuator.

Packing

The gate packing is contained and compressed by the packing gland. See Figure 2 for component

identification.

Note: The packing gland is slightly loosened prior to shipping. This is done to increase the life of the

packing during extended storage.

Adjustment

If packing leaks, tighten the adjustment nuts on top of the packing gland. Tighten the nuts evenly and

gently just enough to stop the leak. Over tightening will cause excessive operating forces, and will de-

crease the life of the packing.

June 2019 Page 7 D10411

DeZURIK

2-24” KGC ES or HD KNIFE GATE VALVES

Figure 2—Component Identification

D10411 Page 8 June 2019

DeZURIK

2-24” KGC ES or HD KNIFE GATE VALVES

Drawings

Removable Seat Detail

Bolt (A5)

Nut (A7)

Washer (A6)

Gate (A3)

Packing Gland (A4)

Packing (A2)

Packing Cord (A8) (if supplied)

Packing (A2)

Anti Extrusion Ring (A9)

(if supplied)

Body (A1)

Seat (A10)

Packing Replacement

Removing the Old Packing

1. Relieve the pressure in the pipeline and close the valve.

2. If the actuator is powered, disconnect and lock out power to prevent accidental operation of the ac-

tuator.

3. Remove the two screws and nuts near the top of the gate and disengage the stem from the gate by

stroking the actuator (not the valve) to the open position.

4. Remove the gland nuts (A7), bolts (A5) and packing gland (A4).

5. Remove the used packing (A2), anti-extrusion ring (A9) if supplied and packing cord (A8) if sup-

plied, from the packing chamber.

June 2019 Page 9 D10411

DeZURIK

2-24” KGC ES or HD KNIFE GATE VALVES

WARNING!

Pipeline pressure can cause personal injury or equipment damage. Relieve pipe-

line pressure before removing gate stem and packing gland nuts.

WARNING!

Accidental operation of power actuator can cause personal injury or equipment

damage. Disconnect and lock out power to actuator before servicing.

Installing the New Packing

Packing (A2) strip length and quantity are shown in Table B. Ensure the inside and outside edges of

each ring are packed against the gate and packing chamber, so that each strip is compressed flat

and evenly. DeZURIK provides extra packing in their packing kits, but do not try to put more packing

into a layer than shown in Table B. If packing is for low pressure applications (40psi [2.7 bar]) contact

DeZURIK.

Do not compress the packing any more than

needed to stop leaks.

1. Ensure the gate (A3) is fully closed and cen-

tered in the body before packing.

2. If used, place the anti-extrusion ring (A9) or

scraper ring in the bottom of the packing

chamber.

Note: Ensure that the anti-extrusion ring fits

tightly around the gate and that there is approxi-

mately 1/32-1/16" clearance around the packing

chamber.

3. Assemble and pack the rings one at a time,

with the ends together, but not overlapped

Note: Stagger the joints, on the long side of the

packing chamber. For packing rings, we recom-

mend using a square-ended wood or plastic tool,

driven by a hammer or mallet. Do not use a

sharp tool to pack the rings.

4. For packing systems with the packing cord (A8), assemble and pack one row of packing (A2) and

then insert the packing cord (A8). Assemble and pack the last row of packing. See detail below:

Figure 3—Packing Ring Detail

D10411 Page 10 June 2019

DeZURIK

2-24” KGC ES or HD KNIFE GATE VALVES

Valve Size Square

Size

Length,

inches Quantity Qty

Cord

2” (50mm)

3/8”

7.50

4 w/o

anti-ext

ring or

cord

3 w/o

cord

2 with

cord

3” (80mm) 9.50

4” (100mm) 11.50

5” (125mm) 13.50

6” (150mm) 15.50

8” (200mm) 20.00

10” (250mm)

1/2”

25.00

12” (300mm) 29.00

14” (350mm) 32.00

16” (400mm) 36.75

18” (450mm)

5/8”

41.25

20” (500mm) 45.25

24” (600mm) 53.50

Table B: Packing Ring and Packing Cord

Length & Quantity

Standard

Anti-Extrusion

Ring

(A9) if supplied

Packing (A2)

Packing

Cord

(A8)

Packing (A2)

Scraper

Ring

(A9)

Scraper

Ring

Packing

Cord

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