CLARKSON SLURRY KNIFE GATE VALVES
KGD
Installation and maintenance instructions for KGD wafer style slurry knife gate valve.
Before installation these instructions must be fully read and understood
INDEX
1. General information ...................................... 1
2. Initial inspection ............................................ 1
3. Installation ..................................................... 2
4. Operation ....................................................... 4
5. Lockouts ........................................................ 5
6. General maintenance.................................... 5
7. Recommended spare parts .......................... 6
8. Storage ........................................................... 7
9. Sleeve installation ......................................... 8
10. Field replacement of the secondary seal .... 9
11. Disassembly and assembly instructions ... 10
12. Actuator adjustment ................................... 11
13. Body flushing and discharge
management ............................................11
14. Installation instructions for splash
guarddrainplate ......................................... 12
15. Lifting ........................................................... 12
Appendix
Manual handwheel actuator ....................... 13
Manual bevel gear actuator ........................ 14
Hydraulic cylinder actuator ........................ 15
Air cylinder actuator ................................... 16
1 GENERAL INFORMATION
1. The KGD is a packingless, slurry knife gate
valve. All the sealing is accomplished by the
elastomeric sleeves in the valve housing.
The sleeves also form the wear section
for the valve. The gate is removable for
inspection or replacement while the valve
is in service. The secondary seal prevents
atmospheric leakage from around the gate.
2. The KGD is a BI-DIRECTIONAL (two-way
shut-off) product and can be installed
without concern over direction of flow. Since
they will shut-off equally in either direction,
you will find no arrows or other indicators
ofa direction of flow or seat side.
3. The KGD is suitable for on-off service only.
Itis not to be used in a throttling application.
4. The style, size, pressure rating and material
selection are the responsibility of the piping
system designer.
5. All valves should be operated within the
design pressure and temperature ranges.
Under no circumstances should the valves
be operated at conditions outside these
parameters. Do not exceed 100% of the
maximum pressure rating of the valve at any
time during its operation. Pressure spikes
beyond the valve’s pressure rating are solely
the responsibility of the user.
6. This manual is applicable to three
generations of KGD sleeves.
A) KGD with secondary seal, equipped with
Mark III sleeves (Mark III, Figure 6).
B) KGD with secondary seal, equipped with
Mark II sleeves (Mark II, Figure 6).
C) KGD with secondary seal, equipped with
Mark I sleeves (Mark I, Figure 6).
2 INITIAL INSPECTION
1. Examine entire valve and report any damage
or discrepancies immediately.
2. Sleeves: visually examine the sleeves
interior, looking for chunking, irregularities
or other damage.
3. Operators: standard manual handwheels
may be shipped loose for field installation,
be sure to fully tighten.
4. Valves are normally shipped with gate in
open position, the recommended position
for installation. Valves supplied with spring
to extend (fail close) cylinder actuators are
shipped with the gate in the closed position.
Gate should be actuated to the open position
prior to installation, exercise extreme
caution when applying air to open this
valve and then ensure that it gate locked in
the open position for installation. Refer to
lockouts Section 5 for aditional cautions on
spring cylinders.
5. Accessories: if provided, including
solenoids, limit switches, positioners,
etc., are tested for functionality prior to
shipment. Examine carefully for damage
which may occur during shipment.
© 2017 Emerson. All Rights Reserved.Emerson.com/FinalControl VCIOM-06600-EN 16/05
CLARKSON SLURRY KNIFE GATE VALVES
KGD
3 INSTALLATION
Please take note of the specific installation
tagsprovided with each valve.
1. The KGD is installed with the gate in the
fully open position with the sleeves inserted
into the body housings.
2. Standard mating flanges NPS 2 - 24
(DN 50 - 600) match ASME B16.5/150, (see
Table 1). Other flange drillings including
PN10, PN16, AS2129 Tables D and E are
available.
3. Table 2 states the maximum flange bolt
tightening torques for standard flange
patterns. While the KGD is provided
with flange bolt patterns that match
ASME B16.5/150 flange bolt patterns, they
are not designed to handle the same torque
requirements as an all-metal Class150
gate valve. The KGD are specialty valves
with a specified maximum flange torque.
Exceeding recommended torque values will
reduce overall valve performance and may
permanently damage the sleeves and or
other components.
4. The KGD is configured for installation in
conventional bolted flange connections.
Slip on or weld flanges can be used. The
pipeline companion flanges should be
raised or flat face type to insure full sleeve
support and a continuous, unvarying I.D. If
slip-on flanges are used, the pipe should
be cut square and welded in position with
the pipe end matched evenly with the flange
face. Studded flanges are not compatible
with these valves. Use of other flange
connections should be reviewed and verified
by the factory for compatibility prior to
installation.
5. The mating line flanges must be properly
aligned prior to attempting installation.
Never try to make up for misaligned pipe
flanges by the line bolting.
6. Listed in Table 1 are the fasteners required
for installation.
7. Pipe supports and/or expansion joints
should be used to minimize pipe loads on
valves.
8. The face of the Mark III sleeves function as
the gasket for installation into the pipeline,
no additional gaskets are required (refer to
Table 2 notes if not using a Mark III sleeve).
9. Valve is suitable for use in either vertical or
horizontal lines. The valve can be installed
in any position in vertical or horizontal
pipelines. However, valves installed in
an orientation with the actuator below
horizontal may require flushing to prevent
the buildup of solids in the housing and
mayrequire additional actuator support.
CAUTION
Valves are normally shipped with gate in
open position, the recommended position for
installation. Valves supplied with spring to extend
(fail close) cylinder actuators are shipped with
the gate in the closed position. Gate should be
actuated to the open position prior to installation,
exercise extreme caution when applying air to
open this valve and ensure that gate is locked
in the open position for installation. Refer to
lockouts Section 5 for additional cautions on
spring cylinders.
TABLE 1 - BOLTING DIMENSIONS
ASME B16.5/150 flange details
Valve size
NPS DN inch mm inch mm inch mm inch mm
2 50 6 152.4 4¾ 120.7 ⅝ - 11 0 2⅛ 54.0 4 0.56 14.2
3 80 7½ 190.5 6 152.4 ⅝ - 11 0 2¼ 57.2 4 0.56 14.2
4 100 9 228.6 7½ 190.5 ⅝ - 11 4 2¼ 57.2 4 0.56 14.2
6 150 11 279.4 9½ 241.3 ¾ - 10 4 2½ 63.5 4 0.56 14.2
8 200 13½ 342.9 11¾ 298.5 ¾ - 10 4 3 76.2 4 0.56 14.2
10 250 16 406.4 14¼ 362.0 ⅞ - 9 4 3 76.2 8 0.62 15.7
12 300 19 482.6 17 431.8 ⅞ - 9 4 3¼ 82.6 8 0.69 17.5
14 350 21 533.4 18¾ 476.3 1 - 8 4 3¼ 82.6 8 0.69 17.5
16 400 23½ 596.9 21¼ 539.8 1 - 8 4 3¾ 95.3 12 0.69 17.5
18 450 25 635.0 22¾ 577.9 1⅛ - 7 4 3¾ 95.3 12 0.91 23.1
20 500 27½ 698.5 25 635.0 1⅛ - 7 4 4¾ 120.7 16 1.26 32.0
24 600 32 812.8 29½ 749.3 1¼ - 7 4 4¾ 120.7 16 1.19 30.2
* DT = Drill and tapped
Flange diameter Bolt circle diameter Number of thru
Bolt size/
thread
Through bolt hole for bolts or studs DT* bolt hole for studs
holes per valve
Installed face-to-face Number of DT holes
per side of valve
DT bolt hole depth
2
CLARKSON SLURRY KNIFE GATE VALVES
KGD
TABLE 2 - MAXIMUM TIGHTENING TORQUE
Valve size Standard flanging FRP flanges (see note)
NPS DN ft·lb N·m ft·lb N·m
2 50 37 50 25 34
3 80 37 50 25 34
4 100 37 50 25 34
6 150 69 94 40 54
8 200 69 94 40 54
10 250 113 153 65 88
12 300 113 153 65 88
14 350 169 229 100 135
16 400 169 229 100 135
18 450 238 323 140 190
20 500 238 323 140 190
24 600 238 323 200 271
NOTE
Mark II sleeves require the use of a soft elastomer gasket in FRP flange installations.
Gaskets are not required or recommended on Mark I or Mark III sleeves.
Installation notes
A) All slurry knife gate valves are designed and
manufactured to be installed in applications
where no more than 1 g of force In excess
of gravity is applied to the valve in any
direction. This 1 g force can be an effect
of traffic, wind, or earthquake, etc. Valves
should not be used inapplications that
exceed 1 g.
B) If valve stem or topworks protrude into
walkways or work areas, valve should
beflagged per company safety policy.
C) All piping systems should contain
independent support mechanisms and
should not utilize thevalve as a sole
meansof support.
D) Do not install valve over walkways, electrical
or other critical equipment without the use
of asplash guard device (refer to Section 14)
or similar considerations.
CAUTION
NOTES
• Flange dimensions per ASME B16.5/150.
• The KGD Body is provided with a combination of
through bolt holes and drilled and tapped (DT)
mating flange bolt holes.
• Length of studs for use in DT holes can be
determined by adding the depth of the DT hole
(includes allowance for height of compressed sleeve
face) shown in chart to the thickness of the mating
flange along with any usedwashers.
• While studs are recommended in DT holes, if bolts
are used, be sure the length does not exceed the DT
bolt hole depth.
• Length of bolts or studs for use in through holes can
be determined by adding the installed face-to-face
(includes allowance for height of compressed sleeve
face) shown in chart to the thickness of the mating
flangealong with any used washers. (For studs, add
both flanges and two sets of nuts and washers).
• Flange drilled and tapped holes in body over 1 inch
(25 mm) diameter are normally provided with course
thread.
Valves are normally shipped with gate in
open position, the recommended position for
installation. Valves supplied with spring to extend
(fail close) cylinder actuators are shipped with
the gate in the closed position. Gate should be
actuated to the open position prior to installation,
exercise extreme caution when applying air to
open this valve and then ensure that gate is
locked in the open position for installation. Refer
to Section 8 storage for additional information.
FIGURE 1
Depth of the
DThole
Body
Sleeve
3
CLARKSON SLURRY KNIFE GATE VALVES
KGD
FIGURE 2 - OPEN POSITION FIGURE 3 - CLOSED POSITION
Open position:
A) Gate positioned above seals.
B) Tight fit between sleeves and the internal
sleeve profile contain the line pressure.
C) No metal parts in contact with slurry.
D) Unobstructed port area eliminates
turbulence, minimizes pressure drop
acrossvalve.
E) No seat cavity where solids can collect
andprevent full gate closure.
4 OPERATION
1. The KGD is suitable for on-off service only.
Itis not to be used in a throttling application.
2. To close the valve and provide isolation,
the actuator (handwheel, bevel gear,
air/hydraulic cylinder or electric motor
actuator) moves the metal gate in a linear
motion between the elastomeric sleeves
to shut off the flow. To open, reverse the
operation and the gate moves up and out
from between the sleeves, opening the
valveport.
3. Matching elastomer sleeves seal against
each under a high compression load
when the valve is open, creating the valve
pressure vessel. When the valve is closed,
the sleeves seal against the gate face,
isolating upstream from downstream.
SeeFigures 2 and 3.
4. As the gate strokes, a gap is created
between the facing sleeves, allowing any
media that could potentially clog or jam the
valve to be purged out from between the
sleeves, and potentially expelled outside the
valve housing to atmosphere.
5. The KGD valve incorporates a built-in
clean-out area at the base of the housing
assembly. The clean-out area may be
enclosed by an optional, removable drain
plate. This drain plate will allow controlled
drainage of any accumulated solids that may
Closed position:
A) Gate travels through sleeves to provide
blindflange shut-off, allowing opportunity
for media to expel to atmosphere.
B) 100% Isolation-bubble tight shut-off results
in absolutely zero downstream leakage.
C) Double-seated design provides
bi-directional flow and shut-off.
D) Controlled stroke prevents gate from
penetrating too far, minimizing stress
onsleeve.
prevent full gate closure. Flush water can
be used to improve the drainage efficiency.
With the drain plate in place, any solids,
slurry, or flush water ejected from the valve
can be handled in a controlled manner. DO
NOT plug or otherwise restrict both ports
of the drain plate as this will prevent proper
operation of the KGD valve. See Section 14
for drain plate installation instructions.
6. All valves should be operated within the
design pressure and temperature ranges.
Under no circumstances should the valves
be operated at conditions outside these
parameters.
NOTE: Actuated Clarkson valves have a maximum
recommended stroke speed of 1 inch (25 mm) per
second. Exceeding this speed can shorten sleeve
life and may void warranty. Optional speed controls
provided by factory will require adjustment in
the field to obtain proper stroke speed against
actual operating conditions. Refer to Section 14
foradditional information on discharge.
CAUTION
It is normal for the KGD to discharge media
during opening and closing cycles. Some
additional discharge may continue for a time after
completion of the open cycle. This helps prevent
any solids from building up between the sleeves
that would prevent a tight seal when the valve is
fully open or closed. Discharge can be controlled
with the use of a splash guard device (drain plate,
refer to Section 14). Do not install valve over
walkways, electrical or other critical equipment
without the use of a splash guard device or
similarconsiderations.
4
CLARKSON SLURRY KNIFE GATE VALVES
KGD
7. The operator of any valve should have an
understanding of the effects of opening/
closing the valve with regards to its role
in the overall piping system. Operators of
valves under pressure should take caution
to ensure that the valve is in good operating
condition prior to operating it under
pressure.
8. Certain processes contain hazardous and/or
otherwise unstable media. Care should be
taken in these circumstances to ensure the
operator is aware of the specific health and
safety risks associated with that medium.
9. When operating the valve stand clear of any
moving parts such as the stem and/or gate
assembly, use of gloves is suggested when
operating manual valves to minimize the
risk of injury.
10. All manual handwheel operated valves
are designed for hand input. Do not apply
excessive input torque via pipe wrenches,
‘cheater bars’, or other devices. If a manual
handwheel actuated valve is difficult to
operate due to torque requirements, it is
recommended that the valve be supplied
with or converted to a bevel gear, air/
hydraulic cylinder or electric motor
actuator.
11. Electric motor actuated valves should be
left in their factory set condition, unless
the system operating parameters dictate
a change. If changes are necessary, they
should be performed in small increments
using the lightest/lowest setting possible
to achieve the desired performance and
then the valve/actuator function inspected.
Excess torque and/or thrust in the motor
settings may damage or lockup the valve.
12. Clarkson KGD valves are position seated
and should never be torque seated. Do not
use the motor torque settings to seat the
valve.
13. Care should be taken to ensure that
electrical motors are wired correctly.
Incorrect phasing of 3-phase wiring may
cause valve/motor damage.
5 LOCKOUTS
Open and closed gate lockout positions are
standard on the KGD NPS 2 - 16 (DN 50 - 400),
optional on the larger sizes. Optional lockout
pins may be supplied by Emerson or customer
may use their own suitable pin. (Contact factory
for pin specifications).
CAUTION
If lockout pins are used on automated valves, the
open and closed lockout brackets are designed
to resist the normal valve operating thrust. In
order to assure complete lockout compliance, any
double acting air cylinder, hydraulic cylinder or
electric motor actuated valve must be placed in
a ZERO ENERGY STATE by isolating all potential
energy sources including electricity, operator air
supply or hydraulic fluids.
In the case of a single acting spring to close
or spring to open cylinder with the spring
compressed, the mechanical energy cannot
be placed in the ZERO ENERGY STATE. When
compressed, the spring will cause unwanted
gate movement if inlet air pressure is not
maintained on the non-spring side of the
actuator. Specific care must be taken to insert
or remove lockout pins. To insert or remove
lockout pins
- Spring extended (uncompressed): isolate
airsupply from cylinder actuator.
- Spring retracted (compressed): maintain
air pressure on the non-spring side of the
actuator.
Take great care when inserting and removing the
lockout pin. If the gate moves during the insertion
or removal process, injury may occur
6 GENERAL MAINTENANCE
We recommend that all Clarkson products be
inspected at least every 60 days. The following
points should be examined and corrected as
required:
1. Exterior overview: piping system
components are subject to certain levels of
erosion and corrosion. Periodic inspections
should be made as valves/components
may wear over time. Regular inspection
of the housing assembly and gate should
be performed, check for general signs
of corrosion, component wear and/
or damage caused by process media.
Severe applications may require additional
inspection types and/or frequency.
2. Valve stems, extension stems, and stem
nut: look for excessive corrosion, galling
orlack of lubrication. If valve stem requires
lubrication, utilize the grease fitting
provided and pump standard bearing
grease through the yoke hub to lubricate
the stem and stem nut assembly. Additional
lubrication may be applied directly onto
stem or stem threads. (Use material which
meetsASTM 4950 GBLB).
FIGURE 4
5
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