FLOWROX SKW Series, SKF Series Installation, Operation And Maintenance Instructions

These instructions must be read carefully and

understood prior to the installation, use, and servicing

of this product.

N O T E

FLOWROX OY

P.O. Box 338

FI-53101 Lappeenranta, Finland

Tel. +358 (0)201 113 311 Fax +358 (0)201 113 300

E-mail: sales@flowrox.com

www.flowrox.com

SKW / SKF-2015-09-ENG Original document language: English

Installation, operation and maintenance

instructions for Flowrox Slurry Knife Gate

valves SKW DN50 –600 (Wafer) and

SKF DN80 –600 (Flanged)

DISCLAIMER

ALL INTELLECTUAL PROPERTY RIGHTS TO THIS MANUAL (“MANUAL”) BELONG TO FLOWROX OY (”FLOWROX”) WHICH REMAINS THE SOLE OWNER OF THESE RIGHTS. OWNERSHIP OF THESE RIGHTS

ARE NOT TRANSFERRED FROM FLOWROX TO ANYONE IN CONNECTION WITH THIS MANUAL. THIS MANUAL IS INTENDED TO BE USED ONLY BY FLOWROX´S CUSTOMER AND EXCLUSIVELY FOR THE PURPOSES OF THE AGREEMENT UNDER WHICH THIS MANUAL IS DELIVERED TO FLOWROX´S CUSTOMER. WITHOUT THE PRIOR WRITTEN EXPLICIT CONCENT FROM FLOWROX, NO PART OF THIS MANUAL SHALL BE USED, REPRODUCED, COPIED, TRANSLATED,CONVERTED, ADAPTED, STORED IN A RETRIEVAL SYSTEM , COMMUNICATED OR TRANSMITTED BY ANY MEANS, OR FOR ANY COMMERCIAL OR OTHER PURPOSES, INCLUDING , BUT NOT LIMITED TO, SALE, RESALE, LICENS, RENT OR LEASE.

THIS MANUAL PROVIDES INSTRUCTIONS TO CARRY OUT CERTAIN ACTIVITIES AND IS DESIGNED AND MEANT TO GUIDE AND ASSIST PROFESSIONAL AND PROPERLY TRAINED EXPERTS IN PERFORMING THEIR FUNCTIONS. EVERYONE MUST BECOME FAMILIAR WITH ALL INSTRTUCTIONS IN THIS MANUAL BEFORE ANY INSTALLATION, USE, MAINTENANCE, REPAIR OR ANY OTHER ACTIONS OF THE RESPECTIVE GOODS AND/OR SERVICES WHICH THIS MANUAL APPLIES TO. ALL INSTRUCTIONS MUST BE FOLLOWED CAREFULLY. HOWEVER, OBSERVANCE OF ANY PART OF THE INSTRUCTIONS PRESENTED IN THIS MANUAL MAY BE OMITTED IN EVENT WHEN IT IS REQUIRED OR ALLOWED BY LAW

FLOWROX HAS TAKEN EVERY CARE IN THE PREPARATION OF THE CONTENT OF THIS MANUAL, BUT DOES NOT MAKE ANY REPRESENTATIONS, WARRANTIES OR GUARANTEES OR, EXPRESS OR IMPLIED, AS TO THE ACCURACY OR COMPLETENESS OF THIS MANUAL. ALL USERS MUST UNDERSTAND AND BE AWARE THAT UPDATES AND AMENDMENTS WILL BE MADE FROM TIME TO TIME TO THIS MANUAL. ALL USERS ARE OBLIGATED TO FIND OUT AND DETERMINE WHETHER THERE HAVE BEEN ANY APPLICABLE UPDATES OR AMENDMENTS TO THIS MANUAL. NEITHER FLOWROX NOR ANY OF ITS DIRECTORS, OFFICERS, EMPLOYEES, SUBCONTRACTORS, SUB-SUPPLIERS, REPRESENTATIVES OR AGENTS SHALL BE LIABLE IN CONTRACT, TORT OR IN ANY OTHER MANNER WHATSOEVER TO ANY PERSON FOR ANY LOSS, DAMAGE, INJURY, DEATH, LIABILITY, COST OR EXPENSE OF ANY NATURE, INCLUDING WITHOUT LIMITATION INDIRECT, INCIDENTAL, SPECIAL, CONSEQUENTIAL, PUNITIVE OR DIRECT DAMAGES AND/OR LOSSES ARISING OUT OF OR IN CONNECTION WITH THE CREATION, DELIVERY, POSSESSION AND/OR USE OF THIS MANUAL. HOWEVER, NOTHING IN THIS PARAGRAPH IS DEEMED TO EXCLUDE OR RESTRICT ANY LIABILITY WHICH CANNOT BY MANDATORY LAW BE EXCLUDED.

FLOWROX IS THE TRADEMARK OF FLOWROX OY REGISTERED IN FINLAND AND IN OTHER COUNTRIES. ALL OTHER TRADEMARKS, LOGOS, BRANDS AND MARKS DISPLAYED IN THIS MANUAL ARE PROPERTY OF THE RESPECTIVE OWNERS UNLESS STATED OTHERWISE.

TABLE OF CONTENTS

1 DIRECTIVE CONFORMANCE DECLARATIONS ............................................ 4

1.1 General safety instructions ........................................................................ 5

2 INTRODUCTION .............................................................................. 6

2.1 Applications and purpose of use ................................................................. 6

2.1.1 Restrictions on use for SKW and SKF valves .................................................. 6

2.1.2 Using the valve in explosive conditions ....................................................... 6

2.2 General description ................................................................................. 7

2.2.1 Principle of operation ............................................................................ 7

2.2.2 Mechanical structure ............................................................................. 8

2.3 Technical data ...................................................................................... 11

2.3.1 Product identification ........................................................................... 11

2.3.2 Actuators .......................................................................................... 12

3 TRANSPORTATION, STORAGE AND LIFTING .......................................... 13

4 INSTALLATION ............................................................................. 14

4.1 General ............................................................................................... 14

4.2 Flow direction, support, and valve position ................................................. 15

4.3 Valve installation .................................................................................. 16

4.4 Flushing installation guidelines ................................................................. 17

5 VALVE OPERATION........................................................................ 20

5.1 Commissioning and decommissioning ......................................................... 20

5.2 Flushing .............................................................................................. 20

6 SERVICING AND MAINTENANCE ......................................................... 21

6.1 General maintenance and checks .............................................................. 21

6.1.1 Scheduled maintenance ........................................................................ 22

6.1.2 Spare parts ........................................................................................ 22

6.1.3 Lubrication ........................................................................................ 23

6.2 Changing the secondary seal .................................................................... 24

6.3 Changing the ring sleeves ........................................................................ 25

6.4 Valve dismantling .................................................................................. 26

6.4.1 Removing the actuator, gate, and tower .................................................... 26

6.4.2 Dismantling the valve body .................................................................... 27

6.5 Valve assembly ..................................................................................... 28

6.5.1 Valve body, secondary seal, and gate assembly ........................................... 28

6.5.2 Tower and actuator assembly ................................................................. 29

6.5.3 Testing and adjusting the valve stroke ...................................................... 30

6.5.4 Final assembly and testing ..................................................................... 30

6.6 Troubleshooting .................................................................................... 31

Appendix A: Main measurements of SKW and SKF valves .......................................... 32

1 DIRECTIVE CONFORMANCE DECLARATIONS

FLOWROX OY

Marssitie 1

P.O. Box 338

FI-53101 Lappeenranta

Finland

Tel. +358 201 113 311

hereby declares that the Flowrox Slurry

Knife Gate valve, Wafer (SKW) and Slurry Knife Gate valve, Flanged (SKF)

comply with the following applicable regulations:

Pressure Equipment Directive 97/23/EC (PED):

Valves according to article 3, clause 3 (SEP); no CE-marking for conformity with PED.

European Union Machinery Directive 2006/42/EC and Finnish Government Decree on Machine Safety, 400/2008, Machine Decree (koneasetus):

Annex IIB “partly complete machine”. No conformity with directive when valve is actuated manually.

Atex Directive 94/9/EC:

Conformity to directive declared only if Ex and CE are marked on valve nameplate. In that case a separate Atex declaration is supplied.

Do not operate valve before conformity to machine directive 2006/42/EC has been declared for the complete machine (pipeline) to what the valve is installed as a partly complete machine. Follow the valve installation instructions in this manual. Conformance declarations for accessories (solenoid valve, limit switches etc.) and actuators are supplied separately in component documentation. Risk analysis responsible employee at Flowrox Oy is Jarmo Partanen.

On behalf of Flowrox Oy

In Lappeenranta, 1 September 2015

4

Jukka Koskela

President and CEO

1.1 General safety instructions

Symbol

Description

Risk to personal safety:

Neglecting the safety measures can cause serious injury or death.

Machinery or environmental risk:

Incorrect maintenance or operation of the product can harm the environment or the product.

Read the operation and maintenance instructions:

Read and understand the operation and maintenance instructions before using the product.

DA N GE R

WA R NI NG

N O T E

The symbols in Table 1 are used in this manual to highlight the parts requiring particular attention.

Table 1.Warning and safety signs.

5

Prevent accidents and ensure the valve’s appropriate operation by complying with the installation, safety, and maintenance instructions in this manual. Installation and maintenance of the valve must be carried out by persons with appropriate training. Electrical installation work of the actuator must be performed by a qualified electrician.

Access to the IOM-manual must be guaranteed at all times at the place of operation of the valve. It is required to observe the IOM-manual in all work tasks for the valve.

Use personal protective equipment when performing any checks or maintenance operation for the valve (goggles, helmet, clothing and gloves). Always follow the factory safety regulations.

In case of any discrepancies between translations, the English version shall prevail.

2 INTRODUCTION

Ring sleeve material

NR

NBR

EPDM

Max valve operating

temperature (°C)

-40 to +75

-30 to +100

-40 to +120

2.1 Applications and purpose of use

Flowrox Slurry Knife Gate valves (SKW) and (SKF) are intended for industry medium and slurry applications. They are bi-directional and are installed between flat flanges to shut-off or open flow within instructed temperature and pressure limits.

2.1.1 Restrictions on use for SKW and SKF valves

The valve must not be used to throttle the flow in any way, nor should the gate be left in partially opened or closed position as this will lead to premature failure.

The valve temperature and pressure range must not be exceeded. The temperature ranges are given in Table 2 for standard sleeve materials. Check the pressure class from the valve type plate. Do not use higher pipeline pressure than rated for the valve.

Table 2. Temperature ranges for SKW and SKF valves.

6

2.1.2 Using the valve in explosive conditions

This valve type is not designed for Ex-areas.

For use in explosive conditions the valve must have the required Ex-classification and the grounding cables must be connected to earth. Check actuator, solenoid valve, and limit switch documentation for more information of use in explosive conditions.

2.2 General description

No.

Description

No.

Description

1

Valve body

7

Secondary seal

2

Gate

9

Protective plug (on flushing port)

3

Tower

12

Bottom cover plate

4

Ring sleeve

A

Valve body cavity

2.2.1 Principle of operation

Flowrox SKW and SKF valves are built with a cast or welded body and feature a heavy-duty stainless steel gate as a standard structure. Removable ring sleeves on both sides of the gate provide a bi-directional bubble tight seal.

In the open position the two ring sleeves seal against each other in the centre of the valve, providing a full bore through which the medium can travel. Main components are shown in Figure 1. Closing the valve forces the gate progressively down between the two mating ring sleeves, until it reaches the fully closed position. When the valve is fully closed, the ring sleeves push against both sides of the gate, effectively sealing and completely containing the line pressure. Any medium discharged between the ring sleeves during open/close strokes is collected to the valve body cavity and drained or flushed trough the flushing ports.

The secondary seal is built in the upper part of the body. On every valve stroke, it wipes the gate and lubricates it with silicone grease. Easier actuation and minimum wear are achieved. There is no need to remove the valve from the line when replacing the secondary seal, but in tight or unsafe conditions it is unavoidable.

7

Figure 1. Valve main components.

The valve must not be used to throttle in any way, nor should the gate be left in partially opened or closed position as this will lead to premature failure.

The gate speed may not exceed 25mm/s.

Type

Description

M

Manual actuator

MG

Manual actuator with gearbox

A

Pneumatic actuator

H

Hydraulic actuator

E

Electric actuator

WA RN ING

This valve is intended for on-off operation only. Ring sleeves are easily replaced, and are available in a number of molded elastomer options to suit different conditions.

2.2.2 Mechanical structure

SKW and SKF valves can be delivered with the actuator options shown in Figure 2. Alternative actuators. Manual actuator type depends on the valve size.

8

Figure 2. Alternative actuators

SKW valve part list is shown in Table 3 and the exploded view in Figure 3. Part quantities are

Part

Qty

Description

Part

Qty

Description

1 1 Valve body

10 Bottom cover bolt

2 1 Gate

11 Bottom cover washer

3 1 Tower

12 1 Bottom cover plate

4 2 Ring sleeve (recommended spare part)

13 2 Locking pin

5 Tower mounting bolt

14 1 Clevis 6

Tower mounting washer

15 1 Clevis locking screw

7 1 Secondary seal (recommended spare part)

16 1 Clevis pin

8 4 Grease nipple

17 2 Retaining ring

9 2 Protective plug

18 PTFE sealing strip

not displayed if they are valve size or actuator type dependent.

9

Figure 3.Exploled view of SKW valve

Table 3.SKW valve part list

SKF valve part list is shown in Table 4 and the exploded view in Figure 4. Part quantities are

Part

Qty

Description

Part

Qty

Description

1 1 Valve body

10 Bottom cover bolt

2 1 Gate

11 Bottom cover washer

3 1 Tower

12 1 Bottom cover plate

4 2 Ring sleeve (recommended spare part)

13 2 Locking pin

5 Tower mounting bolt

14 1 Clevis

6 Tower mounting washer

15 1 Clevis locking screw

7 1 Secondary seal (recommended spare part)

16 1 Clevis pin

8 4 Grease nipple

17 2 Retaining ring

9 2 Protective plug

18 PTFE sealing strip

not displayed if they are valve size or actuator type dependent.

10

Figure 4.Exploled view of SKF valve

Table 4.SKF valve part list.

2.3 Technical data

Type

Size

(DN)

Actuator

Pressure

class (PN)

-

Flange drilling

Body

material

Gate

material

-

Ring sleeve

material

-

Auxiliaries

SKW = Flowrox Slurry Knife Gate valve, Wafer

SKF = Flowrox Slurry Knife Gate valve, Flanged

50-600

M = handwheel

MG = manual with gearbox

A = pneumatic

AU = pneumatic with pneumatic spring

H = hydraulic

E = electric

10 = 10 bar

2 = DIN PN10

3 = DIN PN16

4 = DIN PN25

5 = DIN PN40

6 = ANSI150

7 = ANSI300

9 = other

0 = Cast iron / Welded steel

2 = AISI 316

4 = other

S = AISI 316

Other on request

COATING: 0 = nothing

NR = natural rubber

NBR = nitrile

EPDM = ethylene propylene diene monomer

R = readiness for inductive limits R1 = AC/DC R2 = DC, PNP R3 = DC, NPN

Z1 = solenoid valve, 24V DC

Z2 = solenoid valve, 220V, 50/60 Hz

Z3 = solenoid valve, 110V, 50/60 Hz

G = Gate guard

2.3.1 Product identification

Flowrox valve type plate is shown in Figure 5.

Figure 5.Valve type plate example.

Table 5.Valve model key table.

11

1. Valve type (see Table 5)

2. Serial number (year, order number,

series size, individual valve number)

3. Customer tag number etc.

4. Nominal diameter, pressure class

Examples: SKW100M10-60S0-NR-G SKF100M10-60S0-NR-G

X = feature that is explained in the valve type plate.

The main dimensions and weight are given in Appendix A of this manual.

12

The gate speed may not exceed 25mm/s.

Valve nominal size

DN 50

DN 80

DN

100

DN

150

DN

200

DN

250

DN

300

DN

350

DN

400

DN

450

DN

500

DN

600

Handwheel revs. to

stroke valve

18

25

28

40

50

60 - - - - - -

Bevel gear revs. to

stroke valve

- - - - - - 120

137

313

350

380

340

WA RN ING

2.3.2 Actuators

Standard actuators:

●

Handwheel / handwheel with gearbox

●

Pneumatic

●

Hydraulic

●

Electric

Manual actuator operation revolutions are shown in Table 6. Valves are closed by turning clockwise.

Pneumatic actuators are with a fixed stroke and do not require external controls to position the gate. The minimum supply pressure for pneumatically operated valves is 6 bars. Air must be clean, waterless, lubricated and comply with ISO 8573-1:2001 Class 3. Use correct sized pneumatic hoses to ensure sufficient air flow. Pneumatic actuator noise level may exceed 85 dB and it is recommended to use ear protectors when working near the valve.

Hydraulic actuators have a minimum supply pressure of 150 bars.

Electric actuators have open/close limit switches preset at the factory. A separate instruction from the actuator manufacturer is always included in the shipment.

Please consult the manufacturer’s instructions on actuator requirements or/and limitations. If actuator is changed or valve needs adjustment, follow the Maintenance instructions.

Table 6.Manually actuated valve operating revolutions.

3 TRANSPORTATION, STORAGE AND LIFTING

Lifting equipment must be used for valves weighing over 25kg.

DA N GE R

Check and document any damage in packages or valves. Contact the transportation company in case of damage. When new or unused valves are sitting idle for long periods, execute the following procedures:

1. Prior to storage, thoroughly drain valves of any liquid.

2. Indoor storage is required. For unfavorable environment, cover the equipment with protective tarpaulin that will allow proper air circulation.

3. Protect the equipment from temperature and humidity extremes and exposure to excessive dust, moisture, vibration and sunlight.

4. It is preferred to store valves with the gate locked in open position.

5. Ensure pneumatic and hydraulic cylinder actuators have appropriate plugs installed in the respective supply ports to prevent contamination of the cylinders.

6. Protect valve ring sleeves from heat, light and exposure to ozone.

7. Cover the flange openings.

8. Do not store any objects on the rubber ring sleeves.

9. Follow actuator instructions for storage.

10. Before start-up, clean the gate and lubricate the valve.

When storing used valves, wash the valve and also the body cavities with fresh water and follow the steps above. For storage periods greater than 36 months, please contact Flowrox as the rubber parts need to be changed before use.

13

Lift the valves securely from the tower (part 3 in Mechanical structure). Bigger valves may have pre-installed lifting eyes which should be used when available. When pre-installed lifting eyes are not available, use soft straps to lift valve as shown in Figure 6.

Do not attach lifting equipment to the valve bore, handwheel, actuator, locking pin holes or gate guards, as they can be damaged.

For valve dimensions and weight, refer to Appendix A.

Figure 6.Valve lifting example.

4 INSTALLATION

Do not put your hands or fingers into the tower or port areas when the valve cycles.

Do not use higher pressure than rated for the valve. Higher pressures can cause serious damage to the valve or harm to operating personnel.

Do not energize the actuator before the valve is properly attached to the pipeline.

Never use the valve with all flushing ports plugged. If the medium is harmful in any way, the flushing port must be piped to a safe location.

DA N GE R

WA RN ING

14

4.1 General

Flowrox gate valves are normally delivered fully assembled and ready for use. Only personnel with appropriate training are allowed to install the valves. If the valve is delivered without an

actuator or accessories, they must be installed in accordance with the manufacturer’s

instructions.

Flowrox gate valves have connections with DIN or ANSI bolt drillings as standard design, but other drillings are also available, such as BS, AS, JIS.

Reserve enough space for safe installation and maintenance. See Appendix A for valve dimensions. Notice that during opening and closing cycles, a small amount of medium is discharged in the valve body cavity; therefore do not install gate valves above walkways or critical components. Flushing and drainage connection must be installed if medium is harmful or corrosive.

If the valve has been stored in the warehouse, lubricate the valve as instructed in the Lubrication chapter.

15

Do not step on a valve installed in horizontal or angled position.

Recommended installation positions

Forbidden installation positions

DA N GE R

Do not install DN250 or larger pneumatically actuated valves in other that vertical position without support. This is to prevent possible distortion of the actuator and valve tower.

WA RN ING

4.2 Flow direction, support, and valve position

The valve does not have an intended flow direction; therefore it can be installed either way in the pipeline.

Proper pipe support must be placed on either side of the valve to support the weight of the pipe. The valve must never be used to support the pipes.

The valve can be installed in any position other than below horizontal. Flushing will not work in installations below horizontal level and it will lead to leaking and nonfunctional valve. See the following Figure 7.

Figure 7. Installation alternatives for SKW and SKF valves.

16

Horizontal installation.

Support is required as shown or otherwise.

Angled installation.

Support is required as shown or otherwise.

Figure 8. Support for pneumatically actuated valves.

4.3 Valve installation

At least the following must be ensured before valve installation:

●

The pipeline is isolated from the process and there is no pressure in it.

●

The pipeline is empty, clean, and cooled down.

●

The pipeline flanges are parallel, concentric and with correct distance.

●

The flange connection bolts size is correct. See Table 7.

●

The valve is in OPEN position.

Follow these Installation steps:

1. Disconnect automatic actuator from power supply if connected.

2. Install the safety guards and required accessories to the valve

3. Lift the valve on place with appropriate lifting equipment.

4. Tighten the flange connection bolts evenly in a crosswise sequence shown in Figure 9. Recommended tightening torque is shown in Table 7.

5. Other than mentioned flange drillings are also available.

Always support DN250 and larger pneumatically actuated valves (Figure 8).

6. Connect automatic actuator to power supply.

7. Connect flushing connection (if applicable).

8. Check that all connections have been fastened and the actuator is installed correctly.

9. Run a few open/close cycles without pressure in the pipeline. Refer to Troubleshooting if the valve does not operate smoothly or without extra force.

Valve size

(DN)

Recommended tightening

torque for flange bolt

Nm (ft-lbs)

Tapped hole

depth in body

(mm)

DIN

Bolt nominal

diameter

ANSI150

Bolt nominal

diameter

50

43 (32)

12

M16

5/8”-11 UNC

80

43 (32)

14

M16

5/8”-11 UNC

100

43 (32)

14

M16

5/8”-11 UNC

150

75 (55)

16

M20

3/4”-10 UNC

200

75 (55)

23

M20

3/4”-10 UNC

250

120 (90)

23

M20

7/8”-9 UNC

300

120 (90)

24

M20

7/8”-9 UNC

350

185 (135)

24

M20

1”-8 UNC

400

185 (135)

30

M24

1”-8 UNC

450

260 (190)

28

M24

1-1/8”-7 UNC

500

260 (190)

42

M24

1-1/8”-7 UNC

600

260 (190)

42

M27

1-1/4”-7 UNC

Never use the valve with all flushing ports plugged. If the medium is harmful in any way, the flushing port must be piped to a safe location.

WA RN ING

Table 7.Valve connection maximum tightening torque and bolt nominal diameter for steel flanges.

17

Figure 9.Flange bolt tightening example.

4.4 Flushing installation guidelines

When valve flushing is required, customers need to provide the plumbing. The valves are shipped with plugs installed in the flushing holes. Contact Flowrox office for process specific instructions.

The concept of flushing is to ensure the valve does not jam due to accumulation of medium solids in the valve body. Flushing line or drain line is also required if the medium is harmful to people, environment or other components nearby. In other cases, the flushing connections can be opened to prevent valve body from clogging up. Reclaim service water is usually clean enough to accomplish the water flush, if clean water is not readily available.

18

Larger diameter valves can have additional flushing connection to ensure proper flushing. Flushing connection are on the sides, bottom or on the face of the valve. Hole sizes are shown in Appendix A. One or more flushing connections are used, depending on the process.

A flow indicator can be installed to the flushing line for easier function check-out.

In flushing example 1 the valve protective plugs (9) are removed or bottom cover plate (12) is removed. The process medium slipping between the gate and ring sleeves during valve operation flows freely out of the valve. If the medium is harmful in any way, the flushing port must be piped to a safe location.

9. Protective plug

12. Bottom cover plate

Figure 10. Flushing example 1.

In flushing example 2 (Figure 11), the water is supplied to one side and drained from the other side of the valve. It is necessary to have a shut-off valve (B) on the upstream or supply side of the flush water line to prevent water running constantly. This can be located anywhere, but is usually near to the valve.

19

12. Bottom cover plate

A. Flush water supply B. Shut-off valve C. Drain line

Figure 11. Flushing example 2.

20

5 VALVE OPERATION

5.1 Commissioning and decommissioning

Before the valve is operated within the pipeline, ensure that it has been installed in accordance with this manual and applicable safety regulations.

The following must also be ensured:

●

Parameters on the type plate are suitable for the process and environment

●

The valve is used for the purpose specified at the time of sales

●

Required gate guards and other accessories are installed

●

Possible explosive conditions have been taken into account

When a valve is decommissioned, dispose the valve parts and electric/pneumatic/hydraulic devices (actuators) according to the local regulations and the instructions given by the part or device manufacturer. Collect and dispose dangerous process media, so that people and environment are not endangered. Follow the local regulations.

5.2 Flushing

Follow these operation instructions, when valve flushing is installed.

Flush Fowrox gate valves at least after every 20 cycles to keep the body clear of solids, depending on application and process. If slurry solids are present in the process, the flushing sequence needs to be initiated each time the valve is operated.

It is important to open the water supply valve a moment before the valve is operated. The flushing water is then left on for the entire cycle and for a minimum of 10 seconds after the cycle. To improve flushing, the water should be left on until clean flushing water is exhausting through the drain line.

6 SERVICING AND MAINTENANCE

Depressurize, empty and cool down the valve before any maintenance work. Valve surface can be hot. Isolate the valve completely from the process and follow the factory safety regulations.

Crush hazard. Keep your hands and feet clear of moving parts. Lock the gate before any maintenance work.

De-energize actuators before maintenance. Especially pneumatic actuators equipped with a mechanical spring can cause injury to people and equipment if cylinder actuates unintentionally.

Lifting equipment must be used for valves weighing over 25kg.

Do not step on a valve installed in horizontal or angled position.

DA N GE R

6.1 General maintenance and checks

21

Only personnel with appropriate training are allowed to service the valves. For actuator service instructions consult the manufacturer’s documentation supplied with the valve.

Check the condition of the valve regularly. When the valve is tight and it actuates flawlessly, lubricating is the only mandatory maintenance task. Periodic inspections should be done as valves may wear over time depending on conditions and process.

6.1.1 Scheduled maintenance

Maintenance task

Frequency & advice

Do a leakage inspection

Regularly. Refer to Troubleshooting.

Lubricate valve

After every 50 cycles. More often if valve is operated rarely. Refer to chapter

6.1.3.

Lubricate the actuator stem

Every six months. Read the manufacturer’s instructions.

Run an open/close cycle

Suggested once a month for smooth and reliable operation.

Examine the flushing and drainage

Every two months

Clean the gate

Every two months. Reduces the ring sleeve and gland packing wear.

Examine the gate for erosion

Every two months.

Examine the valve for erosion and wear

Every six months.

Part

Part number

Quantity/valve

Ring sleeve 4 2

Secondary seal 7 1

Sealing kit for hydraulic or pneumatic actuator

-

1

Include the valves in your factory maintenance program. Maintenance tasks and service intervals are offered as a guideline in Table 8. Schedules will vary with applications.

Table 8.Maintenance schedule.

22

6.1.2 Spare parts

To ensure correct and quick delivery of spare parts, the order must contain at least the following information:

●

Valve type number as in type plate (example: SKW100M10-60S0-NR-G)

●

Spare part name and quantity (example: Ring sleeve, 2 pieces)

You can order the spare parts from Flowrox offices, distributors or agents. Contact information is available at http://www.flowrox.com

It is recommended to keep the spare parts of Table 9 available at your factory warehouse. Part numbers refer to Mechanical structure.

Table 9.Spare part list.

23

Do not use hydrocarbon based grease. Use silicone based lubricants such as DOW# 111, DOW 4, DOW 44, GENERAL ELECTRIC COMPOUND G661, AND RHONE POULENE RHODORSIL III

Valve nominal size

DN 50

DN 80

DN

100

DN

150

DN

200

DN

250

DN

300

DN

350

DN

400

DN

450

DN

500

DN

600

Lubricant per valve

(cm3)

35

40

60

65

105

240

480

490

550

620

1090

1470

WA RN ING

6.1.3 Lubrication

Flowrox gate valves have grease nipples on both sides of the valve body (Figure 12). Valves are lubricated when assembled - therefore first lubrication should not be required unless the valves have been in stock for a longer time. For dry material handling, lubrication might be limited or forbidden.

Hydrocarbon based greases cannot be used to lubricate these valves as the elastomer ring sleeves will swell and disintegrate.

Lubricate both sides of the valve approximately every 50 cycles, or after long periods of infrequent cycling. Grease volume requirement is shown in Table 10. Please notice that even when the lubricant is inert it may disturb a sensitive process. Acceptable lubricants include: DOW# 111, DOW 4, DOW 44, GENERAL ELECTRIC COMPOUND G661 AND RHONE - POULENE RHODORSIL III.

1. Valve body

2. Gate

3. Tower

5. Tower mounting bolt

6. Tower mounting washer

7. Secondary seal

8. Grease nipple

Figure 12. Grease nipples on valve body.

Table 10.Volume of grease required per unit.

24

Crush hazard. Keep your hands and feet clear of moving parts.

Do not use hydrocarbon based grease. Use silicone based lubricants such as DOW# 111, DOW 4, DOW 44, GENERAL ELECTRIC COMPOUND G661, AND RHONE POULENE RHODORSIL III

DA N GE R

WA RN ING

6.2 Changing the secondary seal

Follow these instructions if you are to change the secondary seal while the valve is installed to a pipeline. The actuator, tower, and gate are removed as one package to get more work space. Refer to Changing the ring sleeves or Valve dismantling if further service is required as well.

Part numbers refer to Mechanical structure.

1. Depressurize and drain the pipeline.

2. Stroke the valve to fully OPEN position and put the locking pins (13) on place.

3. Disconnect automatic (electric, pneumatic or hydraulic) actuator from power supply to prevent injuries.

4. Remove the bolts (5) that attach the tower (3) to the body (1). Lift the actuator, tower (3) and gate (2) off as one package. The secondary seal (7) might come up with the gate (2).

5. Remove the secondary seal (7).

6. Clean the space for the secondary seal (7).

7. Apply recommended silicon lubricant to any inner contours and outside of the new secondary seal (7) and push it in the sealing slot. If the secondary seal has a sealing lip, place it towards valve bore.

8. Apply recommended silicon lubricant on the chamfered edge of the gate (2).

9. Lower the actuator, tower and gate package on the body and fasten with bolts (5).

10. Lubricate valve grease nipples (8) as instructed in Lubrication.

11. Reconnect automatic actuator to power supply and remove locking pins (13).

12. Run a few test strokes before the pipeline is pressurized.

25

Do not disconnect a pressurized valve from the pipeline in any case!

Lifting equipment must be used for valves weighing over 25kg.

Do not use hydrocarbon based grease. Use silicone based lubricants such as DOW# 111, DOW 4, DOW 44, GENERAL ELECTRIC COMPOUND G661, AND RHONE POULENE RHODORSIL III.

DA N GE R

WA RN ING

6.3 Changing the ring sleeves

To change the ring sleeves, the valve needs to be removed from the pipeline. Refer to Valve dismantling if further service is required as well. Part numbers refer to Mechanical structure.

1. Depressurize and drain the pipeline.

2. Stroke the valve to fully OPEN position and put the locking pins (13) on place.

3. Disconnect automatic (electric, pneumatic or hydraulic) actuator from power supply to prevent injuries.

4. Disconnect flushing pipelines from the valve if flushing is installed.

5. Remove the flange connection bolts and lift the valve to a suitable working surface.

6. Lift the ring sleeves (4) out from the valve body and inspect for visible damage such as cuts, slits or erosion grooves. Depressions and evident flat spots are also to be taken as signs of damage.

7. Check if the gate (2) is damaged and needs to be replaced.

8. Clean the valve body (1).

9. Apply a thin layer of recommended silicone based lubricant to the sealing lip and to the outer face of the new ring sleeves. Insert the sleeves into the valve body centering the ring sleeve within the bore.

10. Leave the valve to OPEN position until it is installed and follow the storage instructions if the valve is placed in stock.

6.4 Valve dismantling

Follow these instructions if you are to do full overhaul on the valve. Part numbers refer to Mechanical structure.

6.4.1 Removing the actuator, gate, and tower

1. Remove the valve from the pipeline as instructed in the earlier chapter 6.3.

2. Install locking pins (13) between the gate (2) and tower (3).

3. Remove the tower mounting bolts (5) bolts and lift the actuator, gate (2) and tower (3) off.

4. To detach the gate (2) from the actuator stem, remove retaining ring (17) and the clevis pin (16) from the clevis (14).

26

Figure 13. Removing the clevis pin.

5. Clean the gate (2) and inspect it for deep scars and transformations. Replace the gate if it’s damaged to prevent accumulation of damage to the secondary seal (7) and ring sleeves (4).

6. Use a marker to mark the height of the clevis (14) on the cylinder shaft. The position is needed in valve assembly.

7. Remove the clevis locking screw (15) and the clevis (14).

8. Remove the bolts from between the actuator and tower (or adapter plate if equipped). Lift the actuator off the tower.

9. Refer to actuator manufactures’ instructions for actuator sealing replacement or other maintenance work.

6.4.2 Dismantling the valve body

1. Disassemble the valve with the instruction above to the point where the actuator, gate (2) and tower (3) have been removed from the valve body (1).

2. Remove the ring sleeves (4) from the valve body and inspect for visible damage such as cuts, slits or erosion grooves. Depressions and evident flat spots are also to be taken as signs of damage. Change ring sleeves if damaged.

3. Remove the secondary seal (7).

4. Remove bottom cover plate (12).

5. Remove grease nipples (8).

27

Figure 14. Dismantled valve body.

6. Clean the body (1) from the inside and ensure that the bores are flawless.

7. When all valve parts have been cleaned and inspected, continue to Valve assembly.

6.5 Valve assembly

Size

M6

M8

M10

M12

M16

M20

M24

Tightening torques

Nm (ft-lbs)

7 (5)

17 (13)

33 (24)

57 (42)

140 (103)

282 (208)

499 (368)

Do not use hydrocarbon based grease. Use silicone based lubricants such as DOW# 111, DOW 4, DOW 44, GENERAL ELECTRIC COMPOUND G661, AND RHONE POULENE RHODORSIL III

WA RN ING

Follow the general tightening torques in Table 11, when specific tightening instructions are not given in this document or in other supplied documentation. Part numbers in assembly instructions refer to Mechanical structure.

Table 11.General tightening torques (bolt class 8.8, lubrication MoS2).

6.5.1 Valve body, secondary seal, and gate assembly

1. Install the secondary seal (7) in the sealing slot with the possible sealing lip facing towards valve bore. Apply recommended silicon lubricant to any inner contours and outside of the new secondary seal.

2. Install grease nipples (8).

3. Insert a piece of timber in the bore as shown in Figure 15. It is to prevent excessive gate drop before clevis pin is installed.

4. Apply recommended silicon lubricant on the chamfered edge and sides of the gate (2) and slide it through the opening at the top of the valve body until it stands safely on the piece of timber.

5. Continue to the tower and actuator assembly in the next chapter.

28

Figure 15.Detail of timber insert.

6.5.2 Tower and actuator assembly

1. After the valve body and gate have been assembled, lift and fit the tower (3) on the valve body. Install the tower mounting bolts hand tight (5).

2. Tighten the mounting bolts by starting from the middle as shown in the Figure 16.

3. Fit the actuator (and possible adapter plate) on the top of the tower (3) using the correct bolts and nuts.

4. Assemble the clevis (14) to the actuator stem if it was dismounted.

5. Stroke the actuator stem down or lift the gate to fit the clevis pin (16) through the aligning holes of the gate (2) and clevis (14). Secure the clevis pin with the retaining rings (17).

6. Install the bottom cover plate (12) and tighten the bottom cover bolts (10).

7. Continue to test the stroke in the next chapter.

29

Figure 16.Tightening the tower mounting bolts.

30

Crush hazard. Keep your hands and feet clear of moving parts.

DA N GE R

6.5.3 Testing and adjusting the valve stroke

Only personnel with appropriate training are allowed to energize the valves. Check and adjust the valve stroke if you dismantle the valve or assemble a pneumatic or hydraulic actuator. This is not needed with manual actuators. Refer to the electric actuator documentation for specific stroke adjustment instructions.

1. Assemble the valve according to the instructions above.

2. Connect the actuator to power source and stroke the valve to fully OPEN position.

3. Stroke is adjusted correctly if gate (2) can now be locked with the locking pins (13). Otherwise continue to the next step for stroke adjustment. See Figure 17.

4. Measure how much the gate (2) must be adjusted.

5. Disconnect automatic actuator from power supply to prevent injuries.

6. Remove retaining ring (17) from the clevis pin (16) and remove the clevis pin.

7. Push the gate (2) down to get space for the clevis (14) to turn.

8. Loosen the clevis locking screw (15)

9. Rotate the clevis (14) on the stem to adjust it up or down according the dimension measured above.

10. Re-install the clevis and test if the locking pins (13) fit in now. Repeat adjustment if

pin does not fit in place. Continue to the next chapter if valve is adjusted correctly.

Figure 17.Stroke correctly adjusted.

6.5.4 Final assembly and testing

1. Stroke the valve with the actuator to fully OPEN and fully CLOSED position to ensure smooth operation and the correct positioning of the gate.

2. Install the ring sleeves (4).

3. Lubricate valve grease nipples (8) as instructed in Lubrication.

4. Install all removed safety guards and other accessories according to the manufacturer’s instructions.

5. Run a few open/close cycles and leave the valve open. If the valve operates smoothly, it is ready to be installed on the pipeline. Follow the Installation instructions.

6.6 Troubleshooting

Problem

Possible reason

Action

Leakage from bottom cover plate

Loose flushing pipeline connections or bottom cover plate

Check the flushing connection and bottom cover plate tightness

Damaged ring sleeve and/or gate

Check ring sleeves and gate and change as needed

Leakage from flange connection

Flange connection is loose

Tighten the flange connection bolts to correct torque

Flange connection bolts are too long

Measure the bolts and change as needed

Pipeline flanges and valve are misaligned

Check that the flanges are parallel and concentric to valve

Leakage from the secondary seal

Tower mounting bolts loose

Tighten tower mounting bolts

Secondary seal worn out

Replace secondary seal

Valve does not open/close or valve is not tight

Fault in actuator, limit switch or control system

Check and fix actuator operation Clogged up with solids

Clean gate and body cavity. Check or install flushing.

Damaged gate, ring sleeve or secondary seal

Check and change damaged parts

Valve does not open/close smoothly

Insufficient lubrication

Lubricate valve and increase scheduled lubrication. Lubricate the actuator.

Opening/closing force too high*

Insufficient lubrication

Lubricate valve and increase scheduled lubrication. Lubricate the actuator.

Flange or tower mounting bolts too tight

Check and loosen bolts

Damaged gate, ring sleeve or secondary seal

Check and change damaged parts

Ring sleeve lifetime is short

Insufficient flushing

Check flushing flow and pressure or install flushing

Insufficient lubrication

Increase scheduled lubrication

Unsuitable ring sleeve material for process

Check with Flowrox

Damaged gate

Check gate for scrapes and bending and change if damaged

Table 12.Troubleshooting.

31

* Manually operated valves are actuated with normal hand force.

Appendix A: Main measurements of SKW and SKF valves

Valve

size

(DN)

B

B* C D E F G J U K N P R S V W

Weight (kg)

T

M

MG A H

E MG M A

MG E H M MG A E H

50

54

58

165

102

566 - 586 - - - -

350

110 - - - 20 - 17 - -

G1/2”

80

57

61

200

112

628 - 683 - 739

80 - 350

110 - 513 - 24 - 22

48 - G1/2”

100

57

61

230

132

648 - 725 - 751

100 - 350

120 - 513 - 30 - 28

51 - G1/2”

150

64

68

285

157

921 - 972 - 879

150 - 350

176 - 513 - 42 - 49

64 - G1/2”

200

76

80

346

188

1006

1148

1115

988

972

200

466

350

220

400

513

150

61

87

75

83

59

G1/2”

250

76

80

410

223

1133 - 1316 - 1150

250 - 350

250 - 537 - 82 - 113

104 - G1/2”

300

83

87

483

262 - 1380

1512 - 1363

300

535 - 340

400

537 - -

134

190

150 - G 1”

350

83

87

533

285 - 1455

1661

1521

1481

350

560 - 340

400

724

200 - 145

215

184

146

G 1”

400

95

99

600

322 - 1574

1799

1700

1600

400

698 - 340

400

724

200 - 186

260

222

187

G 1”

450

95

99

645

352 - 1875

2049

1831

1834

450

771 - 450

400

724

250 - 229

318

262

243

G 1”

500

121

125

705

403 - 1962

2180

1962

2015

500

801 - 450

400

731

250 - 316

400

370

320

G 1”

600

121

125

825

447 - 2250

2323

2291

2234

600

861 - 630

400

795

250 - 461

592

532

484

G 1”

Figure 18.SKW valve dimensions.

32

B* = ring sleeve uncompressed

M = handwheel

MG = manual with gearbox

A = pneumatic

E = electric

H = hydraulic

T = flushing connection

Dimensions and weight are for guidance only – detailed drawings are available on request. All other dimensions are in millimeters, but flushing connections are in inches.

Valve

size

(DN)

B

B* C D E F G J U K N P R S V W

Weight (kg)

T

M

MG A H

E MG M A

MG E H M MG A E H

80

175

179

200

112

628 - 683 - 739

80 - 350

110 - 513 - 32 - 31

57 - G 1/2”

100

175

179

230

132

640 - 725 - 751

100 - 350

120 - 513 - 39 - 41

64 - G 1/2”

150

178

182

285

157

913 - 972 - 879

150 - 350

176 - 513 - 41 - 66

80 - G 1/2”

200

184

188

346

188

1006 - 1115 - 972

200 - 350

220 - 513 - 85 - 100

108 - G 1/2”

250

226

230

410

223 - -

1316 - 1150

250 - -

270 - 537 - - - 143

142 - G 1/2”

300

257

261

483

262 - 1380

1512 - 1363

300

535 - 340

400

537 - -

187

253

203 - G 1”

350

257

261

533

285 - 1455

1661

1521

1481

350

560 - 340

400

724

200 - 215

282

252

216

G 1”

400

279

283

600

322 - 1574

1799

1700

1600

400

698 - 340

400

724

200 - 284

349

320

285

G 1”

450

311

315

645

352 - 1875

2049

1831

1834

450

771 - 450

400

724

250 - 335

420

368

344

G 1”

500

359

363

705

402 - 1961

2180

1962

2015

500

801 - 450

400

731

250 - 447

527

501

451

G 1”

600

372

376

825

447 - 2250 - 2291

2234

600

861 - -

400

795

250 - 629 - 700

652

G 1”

Figure 19. SKF valve dimensions.

33

B* = ring sleeve uncompressed

M = handwheel

MG = manual with gearbox

A = pneumatic

E = electric

H = hydraulic

T = flushing connection

Dimensions and weight are for guidance only – detailed drawings are available on request. All other dimensions are in millimeters, but flushing connections are in inches.

FLOWROX OY

P.O. Box 338

FI-53101 Lappeenranta, Finland

Tel. +358 (0)201 113 311 Fax +358 (0)201 113 300

E-mail: sales@flowrox.com

www.flowrox.com

FLOWROX SKW Series, SKF Series Installation, Operation And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual