Orbinox DT Installation, Operation & Maintenance Manual

ORBINOX SPAIN Pol.Ind. s/n-20270 ANOETA. Tel:[phone] Fax:[phone] e-mail:[e-mail]

ORBINOX CANADA, ORBINOX USA, ORBINOX COMERCIAL, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY,
ORBINOX INDIA, ORBINOX CHINA.

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INSTALLATION, OPERATION &

MAINTENANCE MANUAL

MODEL DT

.

2009 EDITION

DT-2/7

www.orbinox.com

MODEL

DT

INDEX Page

0.- Description .........................………................................ 2

1.- Handling ..................................……….......................... 2

2.- Installation .................................………......................... 3

3.- Actuators .....................................………....................... 5

4.- Maintenance .....................................……….................. 5

4.1.- Gland packing replacement …….………............ 5

4.2.- Seal replacement......………....…....……............ 6

5.- Storage …………................................…..………........... 6

6.- Parts list & drawing ..................................………........... 7

0.- DESCRIPTION

The DT model knife gate is a bi-directional valve used in the Pulp and Paper industry (recycling or
secondary fibre processing) and designed to handle highly concentrated or contaminated media.
When open, both gates retract into the body to allow full flow. When closing, the gates force any
material trapped in the gate guides back into the body of the flow. All components subject to wear
are replaceable.

The DT valve complies with the following European directives:

- DIR 98/37/EC (machines)

- DIR 97/23/EC (PED)

Fluid: Group 1 (b), 2 (Cat. I, mod.A)

It may also comply with the directive:

- DIR 94/9/EC (Explosive Atmospheres)
The EX valve may comply with the directive regarding equipment and protective systems for their
use in explosive atmospheres. In these cases, the logotype shall appear on the identification
label of the valve. This label shows the exact classification of the zone where the valve can be
used. The user will be liable for its use in any other zone.
This directive only applies in the following atmospheric conditions:

0,8 bar ≤ P ≤ 1,2 bar

-20ºC < T < 60ºC
Any increase in temperature due to frictional warmth is negligible, since the relative speed of
the moving parts is extremely low.
The risk analysis associated to this directive does not take into account the fluid that goes
through the valve, even when such fluid produces an explosive atmosphere. The user must take
into account the risks that the fluid generates, such as:

- heating of the valve surface.

- generation of electrostatic charges caused by displacement of the fluid.

- shock waves caused by the installation (water hammer), internal crashes generated by the pellets
or the risks due to foreign bodies susceptible of being present in the installation.

1.- HANDLING

When handling an Orbinox valve please pay attention to the following points:

• Do NOT attach lifting gear to the valve actuators or gate guards. They are not designed to

bear the weight, and could easily be damaged.

• Do NOT lift the valve by the valve bore.

This can cause damage to the seating surfaces and seals.

.

2009 EDITION

DT-3/7

www.orbinox.com

MODEL

DT

Ideally when using lifting gear to move an Orbinox valve, it should be supported by two or more
eyebolts screwed into the tapped fixing holes in the valve body.

SAFETY WARNING:

• Check that the lifting gear is rated to carry the weight of the valve.

• Make sure the eyebolts have the same thread as the boltholes and that they are well secured.

During installation it is recommended to lift the valve via soft straps. These can be to the upper part of
the valve body.

2.- INSTALLATION

To avoid personal injury or damage to property from the release of process fluid:

- Those in charge of handling and maintenance of the valve must be qualified and trained in

valve operations.

- Use appropriate personal protection equipment (gloves, safety shoes, etc).

- Shut off all operating lines to the valve and place a warning sign.

- Isolate the valve completely from the process.

- Release process pressure.

- Drain the process fluid from the valve.

- According to EN 13463-1 (15), during installation and maintenance operations, use hand

tools (non electric) with Working Allowance

Before installation, inspect the valve body and components for any damage that may have
occurred during shipping or storage. Make sure the internal cavities within the valve body are
clean. Inspect the pipeline and mating flanges, making sure the pipe is free of foreign material and
that the flanges are clean.
The DT valve is bi-directional and can be installed without taking into consideration the direction of
flow.
Special care should be taken to maintain the correct distance between the flanges and to ensure that
they are parallel to the valve body. Incorrect alignment of the valve can cause deformations, which can
lead to difficulties in operation.

Place the valve between flanges. First tighten the side bolts (1) and
then the upper and lower bolts (2).

The following table gives the maximum torque values for the valve fixing bolts. Also shown is the
maximum depth (T) allowed for the tapped blind boltholes drilled into the valve body.

DN 100 125 150 200 250 300 350 400 450 500 600

T (mm) 8 8 10 10 11 11 18 20 20 20 20

Kg.m 6 7 7 7 11 11 15 15 19 19 23

The valve can be mounted in any position with regard to the pipe. However, it is advisable to place it
horizontally in vertical pipeline if the installation allows it. (Please consult the technical department at
Orbinox).

.

2009 EDITION

DT-4/7

www.orbinox.com

MODEL

DT

Horizontal installations of the valve and/or larger
diameters (≥ 300) require the construction of suitable
supports. (See the following diagram and consult the
technical department at Orbinox).

Once the valve is installed, test that the flanges have been fastened correctly and that all electrical
and/or pneumatic connections have been properly made.

Where electric accessories are mounted on the valve (i.e. solenoid valves, electro-pneumatic
positioners, etc.), or is in an ATEX zone, the corresponding earth connections must be made before
it is put into operation.

The operation of automated valves is limited only with fitted gate covers.

First, operate the valve with no flow in the pipeline. Then test operation and valve seal with flow. It
should be noted that the packing material might settle in shipping/storage, which can cause minor
leakage. This can be remedied by tightening the gland (5) during installation.
The nuts shall be tightened gradually and crosswise until the leakage stops (see the next figure).
Check that there is no metal contact between the glandfollower (5) and the gate (2).

4

2

1

3

If the glandfollower nuts are pulled to hard, the force needed to operate the valve will increase, the
valve function will be affected and the box packing lifetime will be shortened.
The table below shows the maximun torque value for tightening the glandfollower nuts.

DN Torque (N.m)

50 - 100 20

125 - 200 30

250 - 1000 35

Once performance has been tested, the valve can be put into operation.

In an ATEX zone, the continuity between the body of the valve and the pipe must be checked (test
in accordance with EN 12266-2 Standard, annex B, points B.2.2.2. and B.2.3.1).
It must also be verified that the pipe is connected to earth and that there is electrical conductivity
between the two pipes (outlet/inlet).

Approximate weight of the double acting pneumatic cylinder valve:

DN 100 125 150 200 250 300 350 400 450 500 600

Weight (Kg) 48 56 67 80 90 160 255 340 405 490 580

.

2009 EDITION

DT-5/7

www.orbinox.com

MODEL

DT

3.- ACTUATORS

3.1.- Pneumatic
Valves are usually supplied with a double acting pneumatic actuator although, upon request,
we can supply single-acting actuators. In either case the feed pressure can vary between 3,5
and 10 Kg/cm

2

.However, the size of the actuator for each valve has been designed for a feed

pressure of 6 Kg/cm

2

.
It is essential for a good maintenance of the cylinder that air should be well dried, filtered and
lubricated.
It is recommended to actuate the cylinder 3-4 times before the start up, once it is installed in the
pipeline.

4.- MAINTENANCE

The valve must not undergo any modifications without a previous agreement with ORBINOX.
ORBINOX shall not be liable for any damages that may arise due to the use of non original parts or
components

To avoid personal injury or damage to property from the release of process fluid:

- Those in charge of handling and maintenance of the valve must be qualified and trained in

valve operations.

- Use appropriate personal protection equipment (gloves, safety shoes, etc).

- Shut off all operating lines to the valve and place a warning sign.

- Isolate the valve completely from the process.

- Release process pressure.

- Drain the process fluid from the valve.

- According to EN 13463-1 (15), during installation and maintenance operations, use hand

tools (non electric) with Working Allowance.

In an ATEX zone, there may be electrostatic charges in the internal parts of the valve. These
electrostatic charges, caused by the evacuation of the fluid, may entail a risk of explosion. It is the
responsibility of the user to take extreme precautions to minimize this risk.

Safety in an ATEX zone:

- The maintenance personnel must be made fully aware of the risks of explosion, and it is

advisable that they receive specific training regarding ATEX.

- Should the fluid transported create an internal explosive atmosphere, the user must check

periodically the correct water-tightness of the installation

- Clean the valve periodically to prevent dust accumulation.

- Assembly at the end of the line is not allowed.

- Avoid repainting the products supplied.

The only maintenance required is to change the gland packing (4) and the seal (9).
The life of these elements will depend on the working conditions of the valve such as: pressure,
temperature, abrasion, chemical action, number of operations, etc.

4.1. - Replacement of the gland packing (4):

1) Depressurise the circuit and place the valve in close position.

2) Remove the gate guards (for automatically actuated valves only).

3) Release the stems (10) from the gate (3). (Photo 1)

4) Loosen the screws of the yoke (6) and remove it (without loosing the actuator).

5) Loosen the nuts of the gland followers (5) and remove them. (Photo 2)

6) Remove the old packing rings (4) and clean the stuffing boxes.

.

2009 EDITION

DT-6/7

www.orbinox.com

MODEL

DT

7) Insert the new packing rings (4), making sure that the ring joints alternate (the first on one

side of the gate, the next on the other and so on).

8) Once the necessary packing rings (4) have been inserted, proceed with a steady initial

tightening of the gland followers (5).

9) Place the yoke (6) (with the actuator) and screw it.

10) Fix the stems (10) to the gate (3). (Photo 1)

11) Remount the gate guards.

12) Carry out some operations with a loaded circuit and then re-tighten the gland followers (5)

to prevent leakage. (Photo 2)

Photo 1 Photo 2

4.2.- Replacement of the seal (9):

1) Remove the valve from the pipeline.

2) Remove the stainless steel ring (7) that supports the seal (9).

3) Take off the worn seal (9) and clean the housing.

4) At this point, it is advisable to clean the internal parts and at the same time, check the

sliders for wear. If the sliders are damaged, please contact Orbinox to arrange for them to
be replaced.

5) Once the new seal (9) is cut according to size, insert it into the seat housing (making sure

that seal join is in line with the actuator stem).

6) Insert the seal retainer ring (7) by hammering gently around the edge.

7) Once the seals (9) have been substituted on the two half bodies, reinstall the valve in

pipeline.

Seal lengths

DN 50 65 80 100 125 150 200 250 300 350 400 450 500 600

Lengths (mm

)

205 255 295 365 440 510 680 860 1020 1190 1350 1510 1630 2010

After maintenance, and in an ATEX zone, it is obligatory to verify the electrical continuity between
the pipe and the different valve components, such as the body, the gate, the supports,... (test in
accordance with EN 12266-2 Standard, annex B, points B.2.2.2. and B.2.3.1).

5.- STORAGE

For long periods it is recommended to store the valves in a well-ventilated room. Valves should not
be exposed to temperatures higher than 30ºC, as some soft seal materials can be damaged when
exposed to higher temperatures.

If outdoor storage cannot be avoided, cover the valve and protect it from sources of heat or direct
sunlight. Provide good ventilation to avoid moisture.

.

2009 EDITION

DT-7/7

www.orbinox.com

MODEL

DT

6.- PARTS LIST & DRAWINGS

1

7

3

4

11

10

6

2

9

8
5

1. – BODY 7. – SEAL RETAINER RING

2. – COUNTERBODY 8. – BODY LINER

3. – GATE 9. – SEAL

4. – PACKING 10. – STEM

5. – GLAND FOLLOWER 11. – PNEUMATIC ACTUATOR

6. – SUPPORT PLATES