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Clarkson KGF
Instructions Manual
20 pgs679.57 Kb0

Emerson Clarkson series, Clarkson KGF, Clarkson KGF-HP Instructions Manual

CLARKSON SERIES KGF AND KGF-HP SLURRY VALVES
InstallatIon and maIntenance InstructIons
Before installation these instructions must be fully read and understood
1 GENERAL INFORMATION
1. The KGF and KGF-HP are packingless, slurry knife gate valves. 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
INDEX
1. General information ...................................... 1
2. Initial inspection ............................................ 2
3. Installation instructions ................................ 2
4. Operation ....................................................... 5
5. Lockouts ....................................................... 6
6. General maintenance ................................... 7
7. Spare parts ................................................... 8
8. Storage .......................................................... 9
9. Sleeve replacement .................................... 10
10. Gate support replacement .......................... 12
11. Secondary seal replacement ...................... 12
12. Disassembly and assembly instructions ... 13
13. Field replacement of gates ......................... 16
14. Body flushing and discharge ...................... 17
15. Installation instructions for splash
guardbucket ................................................ 18
16. Installation instructions for splash
guardplate ................................................... 18
17. Lifting ........................................................... 18
18. Manual handwheel actuator assembly ...... 19
19. Bevel gear actuator assembly .................... 19
20. Air cylinder actuator assembly................... 20
21. Hydraulic cylinder actuator assembly ....... 20
removable for inspection or replacement while the valve is in service. Refer to Section 13 for gate removal cautions andinstructions.
2. The KGF and KGF-HP are BIDIRECTIONAL (two-way shut-off) product and can be installed without concern over direction of flow. Since they will shut-off equally with in either direction, you will find no arrows or other indicators of a direction of flow or seatside.
3. Clarkson slurry knife gate valves are suitable for on-off service only. They are 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.
© 2017 Emerson. All Rights Reserved.Emerson.com/FinalControl VCIOM-06613-EN 17/08
CLARKSON SERIES KGF AND KGF-HP SLURRY VALVES
InstallatIon and maIntenance InstructIons
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. It is not recommended you remove the retainer flanges. Visually examine the retainer flanges surfaces, looking for tears, irregularities or other damage. Check tightness of retainer flangebolting.
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. The KGF and KGF-HP should be installed with the gate in the open position, exercise caution when applying air to open this valve and ensure that it is locked in the open position when installing in the line.
5. Accessories: if provided, including solenoids, limit switches, etc., are tested for functionality prior to shipment. Examine carefully for damage which may occur during shipment.
6. Refer to lockouts Section 5 for additional cautions on spring cylinders
3 INSTALLATION INSTRUCTIONS
Please take note of the specific installation tagsprovided with each valve.
1. The KGF and KGF-HP are to be installed with the gate in the fully open position with the sleeves inserted into the housing halves.
2. KGF: standard mating flanges 3” (DN80) through24” (DN600) match ASME B16.5/300, sizes30” and larger are per MSS-SP44/300 (see Table 4). Optional drilling to ASME B16.5/150 is available in certain circumstances. Other flange drillings including PN10 or PN16 are available depending on rated pressure of valve.
KGF-HP: standard mating flanges 3”
(DN80) through 24” (DN600) match ASME B16.5/300, sizes30” and larger are per MSS-SP44/300 (see Table 4). Other flange drillings are available depending on rated pressure ofvalve.
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.
FIGURE 1
Operators
Retainer flanges
Sleeves
2
CLARKSON SERIES KGF AND KGF-HP SLURRY VALVES
InstallatIon and maIntenance InstructIons
3. Tables 1 and 2 state the maximum flange bolt tightening torques for standard flange patterns. While the KGF and KGF-HP are provided with flange bolt patterns that match ASME B16.5/150 or ASME B16.5/300 flange bolt patterns, they are not designed to handle the same torque requirements as an all-metal Class150 or Class300 gate valve. The KGF and KGF-HP 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 KGF and KGF-HP are 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. Optimum performance of the valve sleeves may be achieved if the mating pipe I.D. is no larger than +0.25” (6.5mm) of the retainer flange I.D. (Refer to Table 4 for retainer flange dimensions.) Oversized mating pipe I.D. may subject retainer flange and sleeve to additional wear.
7. Listed in Table 4 are the fasteners required for installation.
8. Pipe supports and/or expansion joints should be used to minimize pipe loads onvalves.
9. The elastomer coated retainer flange functions as the gasket for installation into the pipeline, no additional gaskets arerequired.
10. 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 mayrequire additional actuator support.
Installation notes
A) All slurry knife gate valves are designed and
manufactured to be installed in applications where no more than 1g of force In excess of gravity is applied to the valve in any direction. This 1g force can be an effect of traffic, wind, or earthquake, etc. Valves should not be used in applications that exceed 1g.
B) If valve stem or topworks protrude into
walkways or work areas, valve should beflagged per company safety policy.
C) All piping systems should contain
independent support mechanisms and should not utilize the valve as a sole meansof support.
D) Do not install valve over walkways, electrical
or other critical equipment without the use of a splash guard device (refer to section 14) or similar considerations.
FIGURE 2
Retainer flange I.D.
TABLE 1 - MAXIMUM TIGHTENING TORQUE STANDARD CLASS150 FLANGES
Valve size ft·lbs Nm
3 37 50 4 37 50 6 69 64 8 69 64 10 113 153 12 113 153 14 169 229 16 169 229 18 238 324 20 238 324 24 345 467 30 345 467 36 610 827
TABLE 2 - MAXIMUM TIGHTENING TORQUE STANDARD CLASS300 FLANGES
Valve size ft·lbs Nm
3 69 94 4 69 94 6 69 94 8 113 153 10 169 229 12 238 324 14 238 324 16 345 467 18 345 467 20 345 467 24 610 827 30 1000 1355 36 1500 2035
3
CLARKSON SERIES KGF AND KGF-HP SLURRY VALVES
InstallatIon and maIntenance InstructIons
TABLE 3 - BOLTING DIMENSIONS CLASS150 FLANGES
Bolt size/ Valve size Retainer inlet diameter Flange diameter Bolt circle diameter Bolt holes inch/mm inch mm inch mm inch mm UNC inch mm
3” / 80 2.81 71.4 7½ 190.5 6 152.40 4 ⅝-11 3 76.2 4” / 100 3.88 98.6 9 228.6 7½ 190.50 8 ⅝-11 3 76.2 6” / 150 5.81 147.6 11 279.4 9½ 241.30 8 ¾-10 3 76.2 8” / 200 7.75 196.9 13½ 342.9 11¾ 298.50 8 ¾-10 4 101.6 10” / 250 9.81 249.2 16 406.4 14¼ 362.00 12 ⅞-9 4 101.6 12” / 300 11.50 292.1 19 482.6 17 431.80 12 ⅞-9 4½ 114.3 14” / 350 13.25 336.6 21 533.4 18¾ 476.30 12 1-8 4½ 114.3 16” / 400 14.75 374.7 23½ 596.9 21¼ 539.80 16 1-8 4½ 114.3 18” / 450 16.75 425.5 25 635.0 22¾ 577.90 16 1⅛-7 5 127.0 20” / 500 18.50 469.9 27½ 698.5 25 635.00 20 1⅛-7 6 152.4 24” / 600 23.00 584.2 32 812.8 29½ 749.30 20 1¼-7 6½ 165.1 30” / 750 29.00 736.6 38¾ 984.3 36 914.40 28 1¼-7 9 228.6 36” / 900 35.00 889.0 46 1168.4 42¾ 1085.85 32 1½-6 9 228.6
NOTES
• Flange dimensions per ANSI B16.5/150 for 3”-24” and MSS SP44/150 for 30”-36”.
• Type B standard washers are not included in stud lenghts.
• Mating flange thickness assumed to match ANSI B16.5/150 for 3”-24” and MSS SP44/150 for 30”-36”.
• Flange drilled and tapped holes in body over 1” in diameter are normally provided with course threads.
• Stud lengths supplied are minimum for full thread engagement into tapped holes and stud lengths are rounded to nearest 0.5inch.
• Stud lengths are supplied rather than bolt lengths.
• Bolt hole quantity shown below is per side of valve.
no.
thread Stud length (see note)
TABLE 4 - BOLTING DIMENSIONS CLASS300 FLANGES
Bolt size/ Valve size Retainer inlet diameter Flange diameter Bolt circle diameter Bolt holes inch/mm inch mm inch mm inch mm UNC inch mm
3” ⁄ 80 2.81 71.4 8¼ 209.6 6⅝ 168.30 8 ¾-10 3½ 88.9 4” ⁄ 100 3.88 98.6 10 254.0 7⅞ 200.00 8 ¾-10 3½ 88.9 6” ⁄ 150 5.83 148.1 12½ 317.5 10⅝ 269.90 12 ¾-10 3½ 88.9 8” ⁄ 200 7.86 199.6 15 381.0 13 330.20 12 ⅞-9 4 101.6 10” ⁄ 250 9.80 248.9 17½ 444.5 15¼ 387.40 16 1-8 4½ 114.3 12” ⁄ 300 11.50 292.1 20½ 520.7 17¾ 450.90 16 1⅛-7 5½ 139.7 14” ⁄ 350 13.30 337.8 23 584.2 20¼ 514.40 20 1⅛-7 5½ 139.7 16” ⁄ 400 14.75 374.7 25½ 647.7 22½ 571.50 20 1¼-7 6 152.4 18” ⁄ 450 17.00 431.8 28 711.2 24¾ 628.70 24 1¼-7 6 152.4 20” ⁄ 500 18.50 469.9 30½ 774.7 27 685.80 24 1¼-7 7 177.8 24” ⁄ 600 23.50 596.9 36 914.4 32 812.80 24 1½-6 7½ 190.5 30” ⁄ 750 29.00 736.6 43 1092.2 39¼ 996.95 28 1¾-5 10 254.0 36” ⁄ 900 35.00 889.0 50 1270.0 46 1168.40 32 2-4.5 11 279.4
NOTES
• Flange dimensions per ANSI B16.5/300 for 3”-24” and MSS SP44/300 for 30”-36”.
• Type B standard washers are not included in stud lenghts.
• Mating flange thickness assumed to match ANSI B16.5/300 for 3”-24” and MSS SP44/300 for 30”-36”.
• Flange drilled and tapped holes in body over 1” in diameter are normally provided with course threads.
• Stud lengths supplied are minimum for full thread engagement into tapped holes and stud lengths are rounded to nearest 0.5inch.
• Stud lengths are supplied rather than bolt lengths.
• Bolt hole quantity shown below is per side of valve.
no.
thread Stud length (see note)
4
CLARKSON SERIES KGF AND KGF-HP SLURRY VALVES
InstallatIon and maIntenance InstructIons
FIGURE 3 - OPEN POSITION FIGURE 4 - CLOSED POSITION
Open position
A) Gate positioned above seals, out of flow. B) Matching elastomer sleeves seal against
each other under a high compression load. C) Sleeves act as pressure vessel. D) No metal parts in contact with slurry. E) Unobstructed port area eliminates
turbulence, minimizes pressure drop
acrossvalve. F) No seat cavity where solids can collect
andprevent full gate closure.
4 OPERATION
1. Clarkson slurry knife gate valves are
suitable for on-off service only. They are
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
valveport.
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.
SeeFigures 3 and 4.
It is normal for the KGF and KGF-HP
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 (refertosection 14).
Closed position
A) Gate travels through sleeves to provide
blindflange shut-off, allowing opportunity for media to expel to atmosphere.
B) 100% Isolation-bubble tight shut-off results
in absolutely zero downstream leakage.
C) When properly installed and maintained,
the KGF is designed to provide man-safeisolation.
D) Double-seated design provides bidirectional
flow and shut-off.
E) Controlled stroke prevents gate from
penetrating too far, minimizing stress onsleeve.
Depending on the pressure rating, some models of the KGF and KGF-HP include a splash guard device as standard. Do not install valve over walkways, electrical or other critical equipment without the use of a splash guard device or similar considerations.
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 KGF and KGF-HP incorporate a built-in clean-out area at the base of the housing assembly. The clean-out area may be enclosed by a removable splash guard device. Depending on the pressure rating, some models of the KGF and KGF-HP include a splash guard device as standard. This splash guard device will allow controlled drainage of any accumulated solids that may prevent full gate closure. Flush water can be used to improve the drainage efficiency. With the splash guard device in place, any solids, slurry, or flush water ejected from the valve can be handled in a controlled manner. See Section14forsplash guard device installation instructions.
5
CLARKSON SERIES KGF AND KGF-HP SLURRY VALVES
InstallatIon and maIntenance 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 recommend stroke speed of1”per second. Exceeding this speed can shorten sleeve life and may void warranty. Speed controls provided by factory will require adjustment in the field to obtain proper stroke speed against actual operating conditions. Refer to Section 14 foradditional inormation on discharge.
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 manually 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 KGF and KGF-HP 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 to the power source. Incorrect phasing of 3-phase wiring may cause valve/motor damage.
5 LOCKOUTS
Open and closed lockout positions are optional on the KGF and KGF-HP. 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 & 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 air
supply 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.
FIGURE 5
brackets
FIGURE 6
Lockout
Secondary seal
6
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