These instructions provide information about safe handling and operation of the valve.
If you require additional assistance, please contact the manufacturer or manufacturer's representative.
Addresses and phone numbers are printed on the back cover.
SAVE THESE INSTRUCTIONS!
Subject to change without notice.
All trademarks are property of their respective owners.
4 KH 70 en3
1PRODUCT DESCRIPTION
Knife gate valves from Metso are designed and
manufactured to meet strict quality and safety standards.
This manual is intended to provide advice and instructions
to the installation engineers and qualified service
personnel so that they can safely undertake the necessary
procedures to correctly install the product and carry out the
future service and maintence work.
Our certified quality management system is an assurance
for you as our customers. You can rely on our products and
service always fulfilling the most demanding quality and
environmental standards in place today. Metso® quality
assurance system fulfils demands and instructions specified
in ISO 9001 and ISO 14001.
IMPORTANT! This installation- and service instruction must
be read carefully and understood prior to the installation,
use and servicing of this product.
1.1Liability for defects
The Supplier warrants that the product will be free from
defects in materials and workmanship when used properly
and in accordance with the directions of the product. The
Supplier´s obligations shall not apply to nor include any
products, which have been subjected to accidents,
alterations, abuse or misuse.
Every country (state) has its own safety regulations. It is the
work management’s and installation engineer’s
responsibility
to know and follow these. If the recommendations in this
manual diverge from those of your country’s, then the local
safety regulations shall prevail.
It is of great importance that the installation engineer is
aware of the product’s functions and characteristics. It is
also the installation engineer’s responsibility to know and
follow general regulations as well as national legal
requirements and provisions. It is the installation engineer’s
responsibility to know and follow the information given on
labels, in instructions and safety regulations for the
product.
Always use approved personal safety equipment.
Installation engineers and other personnel who are in the
working area should use at least the following safety
equipment: Protective clothing, protective gloves,
protective helmets, protective goggles, protective shoes,
hearing protection..
CAUTION:
Beware of extreme temperatures!
The valve body may be very hot or very cold during
use.
Protect people against cold injuries or burns.
1.2Important information
Pictures shown in this manual are illustrative only and do
not necessarily show the design of the products on the
market at any given point in time. For detailed illustrations,
please refer to specific assembly drawings and parts list.
Specifications of the products and equipment presented
herein are subject to change without notice.
1.3General application
Knife gate valves from Metso are recommended for many
industries such as:
Mining
Chemical plants
Fertilizer plants
Sewag Waste Water applications
Pulp & Paper
Power Generation
2SAFETY AND RECYCLING
The product must be used in conformity with applicable
practice and safety regulations and only for the type of
operation that it is intended for. Use only spare parts and
accessories that are recommended by the manufacturer.
Every country (state) has its own safety and recycling
regulations. It is the work management’s and installation
engineer’s responsibility to know and follow these. If the
recommendations in this manual diverge from those of
your country’s, then the local regulations shall prevail.
2.1Safety Precautions
The product must be used in conformity with appl icable
practice and safety regulations and only for the type of
operation that it is intended for. Use only spare parts and
accessories that are recommended by the manufacturer.
CAUTION:
When handling the valve or the valve package, bear in
mind its weight!
Never lift the valve or valve package by the actuator,
positioner, limit switch or their piping. Place the lifting
ropes securely around the valve body. Damage or
personal injury may result from falling parts.
CAUTION:
Do not exceed the valve performance limitations!
The valve may produce noise in the pipeline. The noise
level depends on the application. Observe the relevant
work environment regulations on noise emission.
CAUTION:
Beware of the cutting movement!
Keep hands, other parts of the body, tools and other
objects out of the open flow port. Leave no foreign
objects inside the pipeline. Close and detach the actuator
pressure supply pipeline for valve maintenance.
Failure to do this may result in damage or personal injury.
CAUTION:
Do not exceed the valve performance limitations!
Exceeding the limitations recommended by the supplier
may cause damage and lead to uncontrolled pressure
release.
2.2Recycling and disposal
Most valve parts can be recycled if sorted according to
material. Most parts have material marking. A material list is
supplied with the valve. In addition, separate recycling and
disposal instructions are available from the manufacturer. A
valve can also be returned to the manufacturer for recycling
and disposal against a fee.
44 KH 70 en
3ASSEMBLY
THE KNIFE GATE VALVE COMPLIES WITH THE FOLLOWING:
Machinery Directive: DIR 2006/42/EC (MACHINERY)
Pressure Equipment Directive:
The knife gate Valve complies with the Directive
on Equipment and Protective Systems for
Potentially Explosive Atmospheres. In these
cases the logo will appear on the identification label. This
label shows the exact classification of the zone in which the
valve can be used. The user is responsible for its use in any
other zone.
3.1Handling
When handling the equipment please pay special attention
to the following points:
SAFETY WARNING: Before handling the valve check
that the crane to be used is capable of bearing the
valve installation’s weight.
? Do not lift the valve or hold it by the actuator. Lift-
ing the valve by the actuator can lead to operating
problems as it is not designed to withstand the
valve’s weight.
? Do not lift the valve by holding it in the flow pas-
sage area. The valve’s seal is located in this area. If the
valve is held and lifted by this area it can damage the
surface and the seal and lead to leakage problems
whilst the valve is operating.
? To prevent damage, especially to the anticorrosive
protection, it is recommended to use soft straps to
lift the knife gate valves. These straps must be fitted
around the top of body.
? Packing in wooden boxes: If the equipment is
packed in wooden boxes these must be provided
with clearly marked holding areas where the slings
will be placed when securing them. In the event that
two or more valves are packed together, separation
and securing elements must be provided between
them to prevent possible movements, knocks and
friction during transport. When storing two or more
valves in the same box you must ensure they are correctly supported to prevent deformations. In the
case of dispatches by sea we recommend the use of
vacuum bags inside the boxes to protect the equipment from contact with sea water.
Pay special attention to maintaining the correct lev-
elling of the valves during loading and unloading as
well as during transport to prevent deformations in
the equipment. For this purpose we recommend the
use of mounts or trestles.
3.2Testing the Valve
We recommend that the valve body be pressure tested
after the valve has been assembled.
The pressure test should be carried out in accordance with
an applicable standard using the pressure rating required
by the pressure class or flange drilling of the valve.
CAUTION:
Pressure testing should be carried out using equipent
conforming to the correct pressure class!
3.3Installation
In order to avoid personal harm and other type of damage
(to the facilities, the valve, etc.) please follow these
instructions:
The staff responsible for the installation or operation
of the equipment must be qualified and trained.
Use suitable Personal Protective Equipment (PPE)
(gloves, safety boots, goggles…).
Shut off all lines that affect the valve and put up a
warning sign to inform about the work being performed.
Completely isolate the valve from the whole process.
Depressurise the process.
Drain all the line’s fluid through the valve.
Use hand tools not electric tools during the installa-
tion and maintenance, in accordance with EN13463‐
1(15).
Before installation, inspect the valve to ensure no damage
has occurred during transport or storage. Make sure that
the inside of the valve’s body and, in particular the seal area,
are clean. Inspect the installation’s pipes and the flanges to
make sure they are clean.
3.4Aspects to be considered during
assembly
Always install the valve in the right direction in
regards to the flow in the pipe. If the valve is bi‐directional, the direction of the fluid does not matter, it
works correctly in both directions.
Special care must be taken to respect the correct dis-
tance (gap) between the flanges and ensure they are
correctly aligned and parallel (Fig. 1).
Fig. 1
4 KH 70 en5
The incorrect position or installation of the flanges
can cause deformations on the valve’s body and this
could lead to operating problems.
It is very important to make sure that the valve is correctly aligned and parallel to the flanges to prevent
leakages and avoid deformations. Ensure the valve is
assembled in open position.
The screws in the tapped blind holes will have a
maximum depth (Fig. 2) and will never reach the
bottom of the hole. The following table (Table 1)
shows the maximum thread depth in the holes and
the maximum torque to be applied to the flange
screws:
The equipment must be firmly installed in the pipe.
It will be joined to the pipe with a screw joint.
The screws and nuts to be fitted must also be suita-
ble for the operating conditions and their measurements must in accordance with the approved plans.
The screws and nuts must be fitted diametrically.
To torque to apply to the fastening screws and nuts
must be correct according to the applicable standard, we recommend the initial assembly be carried
out with a low tightening torque and after all the
screws are in place, the final torque is applied.
As regards scaffolding, ladders and other auxiliary
elements to be used during the assembly, follow the
safety recommendations indicated in this dossier.
Once the equipment has been assembled make sure
that there are no elements, whether interior or exterior, which can interfere with the gate valve’s movement.
Make the relevant connections (electrical, pneu-
matic, hydraulic) in the equipment’s drive system following the instructions and wiring diagrams
supplied it.
The operation of the equipment must be coordi-
nated with the site’s control and safety staff and no
modifications are permitted in the equipment’s
external indication elements (limit switches, positioners, etc.).
When operating the equipment follow the safety
recommendations indicated in this dossier.
3.5Assembly position
(Horizontal Pipe)
In horizontal pipes it is recommended that the knife gate
valves be assembled in vertical position, although other
assembly positions are also possible.
Fig. 3
Position 1: This is the most advisable position.
Position 8: The valve can be installed in this position but
you are advised to contact the supplier if this is necessary.
Positions 2, 3, 6 and 7: For large valves (more than DN300),
the maximum angle with the installation vertical is 30º. For
smaller sizes the angle can be increased up to 90º (positions
4 and 5).
When it is necessary to install large valves in any of these
positions, it is recommended to consult the supplier, as in
these cases, due to the weight of the actuator, a suitable
support must be made to prevent deformations and
operating problems in the valves.
Positions 4 and 5: For smaller sized valves, the valves can
be installed in these positions. To install larger valves (more
than DN300) in any of these positions, please contact the
supplier. In these cases, due to the weight of the actuator, a
suitable support must be made to prevent deformations
and operating problems in the valves.
64 KH 70 en
3.6Assembly positions
(Vertical/Inclined Pipe)
The knife gate valves can be assembled in all positions;
however, certain aspects must be taken into account:
In the event of a leakage, tighten the nuts on the packing
gland crosswise until the leakage stops, ensuring that there
is no contact between the packing gland and the gate.
A very high tightening torque on the packing gland’s nuts
can lead to problems, such as an increase in the valve’s
torque, reduction in the packing’s working life, or the
breaking of the packing gland. The tightening torques are
indicated in Table 2:
Tabla 2
Tightening torques for packing gland screws
DN50 to DN12525 Nm
DN150 to DN30030 Nm
DN350 to DN140035 Nm
Once the valve is installed in its place, check that the
flanges and electrical and pneumatic connections are
secure. If the valve has electrical accessories or you are in an
ATEX zone, earth connections must be made before
operating it.
If you are in an ATEX zone, check the continuity
between the valve and the pipeline (EN 12266‐2,
annex B, points B.2.2.2. and B.2.3.1.). Check the
pipeline’s earth connection and the conductivity between
the outlet and inlet pipelines.
Fig. 4
Positions 1.2 and 3: In these positions, it is recommended
to make a suitable support, because, due to the weight of
the actuator, deformations may arise and this can lead to
operating problems in the valves.
Once the valve has been installed, check that all the screws
and nuts have been correctly tightened and that the whole
valve action system has been correctly adjusted (electrical
connections,pneumaticconnections, instruments…).
All our valves are tested at its facilities, however, during the
handling and transport the screws on the packing gland
can come loose and must be re‐ tightened.
Once the valve is installed in the pipeline and it has been
pressurised, it is very important to check for any leakages
from the packing gland to the atmosphere.
4 KH 70 en7
4 ACTUATOR
4.1Handwheel
(Rising or Non‐Rising Stem and Stem
with Gear Box)
To operate the valve: Turn the handwheel clockwise to
close or anticlockwise to open.
4.2Chainwheel
To operate the valve pull one of the chain’s vertical drops,
taking into account that locking is carried out when the
chainwheel turns clockwise.
4.3Lever
First loosen the position locking clamp located on the yoke.
Once it is unlocked raise the lever to open or lower it to
close. To complete the operation lock the lever again.
4.4Pneumatic
(Double and Single Acting)
The pneumatic actuators are designed to be connected to a
6 kg/cm² pneumatic network, although these cylinders
support up to 10 kg/cm
2
.
The pressurised air used for the pneumatic actuator must
be correctly filtered and lubricated.
This type of actuator does not require any adjustment, due
to the fact that the pneumatic cylinder is designed for the
exact stroke required by the valve.
4.5Hydraulic
(Double and Single Acting)
The hydraulic actuators are designed to work at a standard
pressure of 135 kg/cm
This type of actuator does not require any adjustment, due
to the fact that the hydraulic cylinder is designed for the
exact stroke required by the valve.
2
.
4.6Motorised
(Rising or Non‐Rising Stem)
If the valve incorporates a motorised actuator it will be
accompanied with the electric actuator supplier’s
instructions.
Fig. 5
84 KH 70 en
5MAINTENANCE
If the valves suffer any damage due to improper handling or
without the proper authorisation, Metso will not be
responsible. The valves must not be modified except under
express authorisation from Metso.
In order to avoid personal or material damage when
performing the maintenance tasks, it is recommended to
follow these instructions:
The staff responsible for the maintenance or opera-
tion of the equipment must be qualified and trained.
Use suitable Personal Protective Equipment (PPE)
(gloves, safety boots, goggles…).
Shut off all lines that affect the valve and put up a
warning sign to inform about the work being performed.
Completely isolate the valve from the whole process.
Depressurise the process.
Drain all the line’s fluid through the valve.
Use hand tools not electric tools during the mainte-
nance, in accordance with EN13463‐1(15).
The only maintenance required in this type of valve is to
change the packing’s rubber joint and the rubber seals. It is
recommended to carry out regular checks on the sleeves.
The duration of these seals will depend on the valve’s
working conditions, such as: Pressure, temperature,
number of operations, type of fluid and others.
In an ATEX zone, electrostatic charges may be
present inside the valve, which can cause a risk
of explosion. The user will be responsible for
carrying out the appropriate actions in order to minimise
the risks.
The maintenance staff must be informed about the risks of
explosion and ATEX training is recommended.
If the fluid transported constitutes an internal
explosive atmosphere, the user must regularly
check the installation’s correct watertight
integrity.
Regular cleaning of the valve to prevent accumulation of
dust. Assemblies not permitted at the end of the line.
Avoid re‐painting the products supplied.
Due to its great importance, you must check that the
valve’s axle has no load before disassembling the
actuator system.
Taking into account the recommendations indicated, below
we indicate the maintenance operations carried out in this
type of equipment:
5.2Replacing the sealing joint
1. Make sure there is absolutely no pressure and fluid in the
installation.
2. Remove the valve from the pipeline.
3. Place the gate (2) in open position.
4. The sleeves (7) are replaced from outside the valve’s
body, it is a seat with two symmetrical parts, below we
show a diagram of the seat (fig.6).
5. Once the sleeves have been removed, clean their housing thoroughly.
6. Once they have been lubricated with Vaseline, insert
the new sleeves (7) of the same dimensions as those
old ones.
7. Replace the valve between the flanges, taking special
care not to damage the sleeves.
8. Before starting up the installation, perform various
operations to open and close the valve.
*Note: The numbers in brackets refer to the components
list in Table 5.
*Note: During the assembly of the new sleeves it is
recommended to apply “Vaseline” to the seal to facilitate
the assembly process and the valve’s correct operation (do
not use oil or grease), below in Table 3 we show details of
the Vaseline used.
5.1Important safety aspects
In order to work under ideal safety conditions, the
magnetic and electrical elements must be in idle
mode and the air tanks depressurised. The electrical
control cabinets must also be out of service. The
maintenance staff must be up to date with the safety
regulations and work can only start under orders
from the site’s safety staff.
The safety areas must be clearly marked and you
must avoid placing auxiliary equipment (ladders,
scaffolding, etc.) on levers or mobile parts which will
lead to the movement of the gate valve.
In equipment with spring return actuators, the gate
must be mechanically locked and only unlocked
when the actuator is pressurised.
In equipment with electrical actuator, it is recom-
mended to disconnect it from the mains in order to
access the mobile parts without any risk.
Fig. 6
Tabla 3
WHITE PETROLEUM JELLY
Saybolt ColourASTM D‐15615
Melting point (ºC)ASTM D‐12760
Viscosity at 100ºCASTM D‐4455
Penetration 25ºC mm/10ASTM D‐937165
Silicone contentNone
Pharmacopeia BPOK
4 KH 70 en9
5.3Replacing the packing seal
1.Make sure there is absolutely no pressure and fluid in the
installation.
2. Place the valve in closed position.
3. Loosen the screws that connect the stem or rod to the
gate.
4. Release the connection between the support plates (8)
and the body (1).
5. Release and remove the packing gland (3) and the
safety guards where present.
6. Remove the old packing seal (4) and greased packing
using a pointed tool, taking care not to damage the surface of the gate (2).
7. Carefully clean the packing and make sure that there
are no residues anywhere so that the new greased
packing (5) and the pacing seal (4) fit correctly.
8. Insert the new greased packing (5) and the new packing seal (4) correctly lubricated, impregnating their
inner cavities with plenty of Vaseline.
9. Place the packing gland in its original position (step 5),
making sure it does not touch the gate, carefully
tighten all the nuts crosswise and make sure the same
distance is left between the gate and the packing gland
on both sides.
10. Screw down the support plates and the stem, in the
reverse order to what is described in steps 3 and 4.
11. Perform several manoeuvres with no load, checking the
correct operation of the valve and ensuring the packing
gland is correctly centred.
12. Pressurise the valve in the line and tighten the packing
gland crosswise, enough to prevent leakages to the
atmosphere.
Note: The numbers in brackets refer to the components list
in Table 5.
5.4Maintenance of the pneumatic
actuator
The maintenance of these cylinders is simple, if your need
to replace any elements and you have any questions please
consult Metso. Below is an exploded diagram of the
pneumatic actuator and a list of the cylinder’s components.
The top cover and the support cover are usually made of
aluminium, but from pneumatic cylinders greater than
Ø 200 mm, they are made of cast iron GJS‐400.
The maintenance kit normally includes: The socket and its
joints and the scraper, and if the customer wishes the
piston is also supplied. Below we show the steps to follow
to replace these parts.
1. Position the valve in closed position and shut off the
pneumatic circuit pressure.
2. Loosen the cylinder air input connections.
3. Release and remove the cylinder cap (5), the cylinder
tube (4) and the tie rods (16).
4. Loosen the nut (14) which connects the piston (3) and
the rod (1), remove the parts. Disassemble the cir‐clip
(10) and remove socket (7) with its joints (8,9) .
5. Release and remove the cylinder head (2), in order to
remove the scraper (6).
6. Replace the damaged parts with new ones and assem-
ble the actuator in the opposite order to that described
for the disassembly.
It is recommended to lubricate the stem twice a year by
removing the protection cap and filling it with grease up to
half its volume.
After the maintenance and in an ATEX zone, you
must check the electrical continuity between
the pipe and the rest of the valve’s components,
such as the body, gate, stem… EN 12266‐2 Standard, annex
B, points B.2.2.2. and B.2.3.1.)
6 STORAGE
To ensure the valve is in optimum conditions of use after
long periods of storage, it should be stored in a well‐
ventilated place at temperatures below 30ºC.
It is not advisable, but if it is stored outside, the valve must
be covered to protect it from heat and direct sunlight, with
good ventilation to prevent humidity. The following
aspects must be considered for storage purposes:
The storage place must be dry and under cover.
It is not recommended to store the equipment out-
doors with direct exposure to adverse weather con-
ditions, such as rain, wind, etc. Even less so if the
equipment is not protected with packaging.
This recommendation is even more important in
areas with high humidity and saline environments.
Wind can carry dust and particles which can come
into contact with the valve’s mobile parts and this
can lead to operating difficulties. The actuator system can also be damage due to the introduction of
particles in the different elements.
The equipment must be stored on a flat surface to
avoid deformations.
If the equipment is stored without suitable packag-
ing it is important to keep the valve’s mobile parts
lubricated, for this reason, it is recommended to
carry out regular checks and lubrication.
Likewise, if there are any machined surfaces without
surface protection it is important for some form of
protection to be applied to prevent the appearance
of corrosion.
Store the valves in open position to ensure that the