Victaulic 795 Series, 906 Series, I-795, I-906 Installation And Maintenance Instructions Manual

Page 1

WARNING

• Read and understand all instructions before attempting to install, remove, adjust, or maintain any Victaulic piping products.

• Depressurize and drain the piping system before attempting to install, remove, adjust, or maintain any Victaulic piping products.

• Wear safety glasses, hardhat, foot protection, and hearing protection.

Failure to follow instructions and warnings could cause system failure, resulting in death or serious personal injury and property damage.

HANDWHEEL OPERATOR PNEU MATI C OP ERAT OR

HYDRAULIC OPERATOR

I-795/9 06

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I-795/906INSTALLATION AND MAINTENANCE INSTRUCTIONS

Series 795 and 906 Installation-Ready™ Knife Gate Valves

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

TABLE OF CONTENTS

Hazard Identification ......................................3

Knife Gate Valve Components ...............................4

Handwheel Operator Components ............................5

Pneumatic Operator Components ............................5

Hydraulic Operator Components .............................6

Dimensions – With Handwheel Operator .......................7

Dimensions – With Bevel Gear Operator........................8

Dimensions – With Pneumatic Operator ........................9

Dimensions – With Hydraulic Operator ........................10

Dimensions – Seat Cartridge ...............................11

Important Information ....................................12

Recommended Spare Parts and Tools ........................12

Manual Operation .......................................12

Pneumatic Operation.....................................12

Hydraulic Operation......................................12

SECTION I

Installing the 795 Valve Into a Steel Piping System............... 14

Installing the 906 Valve Into an HDPE Piping System .............18

SECTION II

Maintenance ...........................................24

Packing Adjustment....................................24

Lubrication ..........................................24

Removing the Existing Seat Cartridge.........................24

Installing the Replacement Seat Cartridge .....................29

HAZARD IDENTIFICATION

Definitions for identifying the various hazard levels are provided below. When you see this symbol, be alert to the possibility of personal injury. Carefully read and fully u nderstand the message that follows.

DANGER

• The use of the word “DANGER” identifies an immediate hazard with a likelihood of death or serious personal injury if instructions, including recommended precautions, are not followed.

WARNING

• The use of the word “WARNING” identifies the presence of hazards or unsafe practices that could result in death or serious personal injury if instructions, including recommended precautions, are not followed.

CAUTION

• The use of the word “CAUTION” identifies possible hazards or unsafe practices that could result in personal injury and product or property damage if instructions, including recommended precautions, are not followed.

NOTICE

• The use of the word “NOTICE” identifies special instructions that are important but not related to hazards.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

KNIFE GATE VALVE COMPONENTS

NOTICE

• Drawings and/or pictures in this manual may be exaggerated for clarity.

• Dimensions listed are for reference only. Refer to Victaulic submittal 08.25 or submittal 19.06 for complete dimensional information.

• The product, along with these installation and maintenance instructions, contains trademarks, copyrights, and/or patented features that are the exclusive property of Victaulic.

BILL OF MATERIALS

Item Qt y. Description

1 1 Upper Body 2 1 Lower Body 3 2 Pipe Gasket 4 1 Seat Gasket 5 1 Seat 6 1 Knife Seal 7 1 Knife 8 1 Retaining Plate 9 1 Packing Gland

10 4 Full Thread Hex Bolt

†

11 4 Washer

†

12 4 Heavy Hex Nut

†

13 4 Washer 14 4 Helical Spring-Lock Washer 15 4 Hex Cap Screw 16 1 Dowel Pin 17 1 Dowel Pin 18 4 Hex Bolt 19 4 Helical Spring-Lock Washer 20 4 Hex Nut 21 1 O-Ring 22 1 Plug 23 8 Washer 24 2 Square Head Set Screw

‡

25 2 Spacer Bolt 26 2 Retainer * 27 2 Hex Cap Screw **

NOTES:

†

Items 10, 11, and 12 comprise the assembly hardware.

‡

Item 24 is used for 795 valve (carbon steel) only. * Item 26 is used for 906 valve (HDPE) only. ** Item 27 is required when servicing the valve. Vic taulic offers a kit to replace

the entire seat cartridge. Refer to Section II in this manual for complete removal and replacement instructions.

NIPPLES SHOWN FOR CLARITY ONLY

20 19

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

BILL OF MATERIALS

Item Qt y. Description

1 1 Yoke 2 1 Drive Nut 3 1 Spacer 4 1 Parallel Key 5 1 Handwheel 6 1 Washer 7 1 Stem 8 1 Hex Jam Nut

9 1 Gate Connector 10 1 Slotted Spring Pin 11 1 Stroke Limiter Assembly 12 1 Washer

HANDWHEEL OPERATOR COMPONENTS (3 TO 8 INCH)

BEVEL GEAR COMPONENTS (10 TO 12 INCH)

BILL OF MATERIALS

Item Qt y. Description

21 1 Yoke 22 1 Gear Actuator 23 4 Washer 24 4 Helical Spring-Lock Washer 25 4 Hex Cap Screw 26 1 Stem 27 1 Gate Connector 28 1 Slotted Spring Pin 29 1 Stroke Limiter Assembly 30 1 Washer

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BILL OF MATERIALS

Item Qt y. Description

21 1 Yoke 22 1 Hydraulic Cylinder 23 4 Washer 24 4 Helical Spring-Lock Washer 25 1 Bushing 26 1 Gate Connector 27 4 Hex Cap Screw 28 4 Hex Nut 29 1 Stroke Limiter Assembly 30 1 Washer

HYDRAULIC OPERATOR COMPONENTS

BILL OF MATERIALS

Item Qt y. Description

1 1 Yoke 2 1 Pneumatic Cylinder with Nuts 3 4 Washer 4 4 Helical Spring-Lock Washer 5 1 Bushing 6 1 Gate Connector 7 1 Stroke Limiter Assembly 8 1 Washer

PNEUMATIC OPERATOR COMPONENTS

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

DIMENSIONS – WITH HANDWHEEL OPERATOR

VALVE CLOSED

NOT INSTALLED

VALVE OPEN

INSTALLED

VALVE OPEN

INSTALLED

Nominal Size

Dimensions – inches/millimeters

Weight

lbs

C E F H

3 0.88 10.25 6.75 32.25 113 .0 0

DN80 22.4 260.4 171. 5 819. 2 51.3

4 0.88 11. 25 6.75 34.75 122 .00

DN10 0 22.4 285.8 171. 5 882.7 55. 3

6 1.13 13.75 7. 00 43.75 166 .00

DN150 28.7 349.3 17 7.8 1111. 3 75.3

8 1.63 15. 50 7.00 53.25 23 7.0 0

DN200 41.4 393.7 17 7.8 1352. 6 107. 5

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DIMENSIONS – WITH BEVEL GEAR OPERATOR

VALVE CLOSED

NOT INSTALLED

VALVE OPEN

INSTALLED

VALVE OPEN

INSTALLED

Nominal Size

Dimensions – inches/millimeters

Weight

lbs

B C E F H J

10 11. 22 1.75 19.0 0 7. 50 68.50 16.00 465.00

DN250 284.9 44.5 482.6 19 0.5 173 9. 9 406.4 210.9

12 11.22 2.00 21.00 7. 50 73.00 16.0 0 497.00

DN300 284.9 50.8 533.4 190 .5 1854. 2 406.4 225.4

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DIMENSIONS – WITH PNEUMATIC OPERATOR

VALVE CLOSED

NOT INSTALLED

VALVE OPEN

INSTALLED

VALVE OPEN

INSTALLED

Nominal Size

Dimensions – inches/millimeters

Weight

lbs

C E F H

3 0.88 10.25 6.75 42.0 0 126 .00

DN80 22.4 260.4 171. 5 106 6. 8 5 7.2

4 0.88 11. 25 6.75 44.50 133 .00

DN10 0 22.4 285.8 171. 5 1130.3 60.3

6 1.13 13 .75 7.0 0 53.75 215. 00

DN150 28.7 349.3 17 7.8 13 65.3 97. 5

8 1.63 15.50 7.0 0 55.75 348.00

DN200 41.4 393.7 177. 8 1416 .1 15 7.9

10 1.75 19.0 0 7.50 79.50 550.00

DN250 44.5 482.6 19 0. 5 2 019.3 249.5

12 2.00 21. 00 7. 50 86.50 586.00

DN300 50.8 533.4 19 0. 5 2 19 7.1 265.8

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DIMENSIONS – WITH HYDRAULIC OPERATOR

VALVE CLOSED

NOT INSTALLED

VALVE OPEN

INSTALLED

VALVE OPEN

INSTALLED

Nominal Size

Dimensions – inches/millimeters

Weight

lbs

C E F H

3 0.88 10.25 6.75 43.88 115 .0 0

DN80 22.4 260.4 171. 5 111 4 . 6 52.2

4 0.88 11. 2 5 6.75 46.50 125. 00

DN10 0 22.4 285.8 171. 5 1181 .1 56.7

6 1.13 13 .75 7.0 0 55.00 17 2.0 0

DN150 28.7 349.3 17 7.8 13 97.0 78.0

8 1.63 15.50 7.0 0 66.50 259.00

DN200 41.4 393.7 177. 8 16 89.1 117. 5

10 1. 75 19 .0 0 7. 50 80.25 462.00

DN250 44.5 482.6 190. 5 2038.4 209.6

12 2.00 21. 00 7. 50 89.50 525.00

DN300 50.8 533.4 19 0. 5 2273.3 23 8.1

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

DIMENSIONS – SEAT CARTRIDGE

Nominal Size

Dimensions – inches/millimeters

Weight

lbs

E F H

3 9.88 3.88 10.8 8 16.30

DN80 2 51.0 98.6 276 .4 7.4

4 10.75 3.88 12 .13 19.7 0

DN10 0 273.1 98.6 308.1 8.9

6 13.0 0 3.88 15 .00 28.90

DN150 330.2 98.6 381.0 13.1

8 15.5 0 3.88 18. 25 40.70

DN200 39 7.3 98.6 463.6 18. 5

10 19. 00 5.00 23.00 82.0 0

DN250 482.6 127. 0 584.2 37. 2

12 20.63 5.00 25.50 10 0.60

DN300 524.0 127. 0 6 47. 7 45.6

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

IMPORTANT INFORMATION

• Series 795 Installation-Ready™ Knife Gate Valves are designed for installation with grooved- end carbon steel or stainless steel NPS pipe. For other pipe sizes and materials, contact Victaulic. Welding of pipe ends to the valve is not permitted. Refer to the Victaulic I-100 Field Installation Handbook for pipe preparation requirements. The I-100 can be downloaded at victaulic.com.

• Series 906 Installation-Ready™ Knife Gate Valves are designed for installation with plain-end HDPE pipe. Refer to the Victaulic I-900 Field Installation Handbook for pipe preparation requirements. The I-900 can be downloaded at victaulic.com.

• Installation-Ready

™

Knife Gate Valves are rated for a maximum

working pressure of 150 psi/10 Bar.

• Installation-Ready

™

Knife Gate Valves are not intended for throttling

service. These valves are designed for shutoff applications only.

• Installation-Ready™ Knife Gate Valves are not intended for use in air services.

• Installation-Ready™ Knife Gate Valves can be installed in any orientation. NOTE: Additional supports shall be considered when a 795 valve is installed horizontally, especially when a pneumatic, electric, or hydraulic actuator is used. The 906 valve must be fully supported in all installations.

• Installation-Ready

™

Knife Gate Valves and connecting piping must be supported properly to prevent the joints from being subjected to bending loads, shear loads, or any other external loads.

• DO NOT use Installation-Ready

™

Knife Gate Valves as a jack for

pipe alignment or support.

• DO NOT climb on or stand on Installation-Ready™ Knife Gate Valves or other piping system components.

RECOMMENDED SPARE PARTS AND TOOLS

CAUTION

• Ensure that all spare seals and gaskets are compatible with the line temperature and media.

Failure to follow this instruction will cause gasket degradation, resulting in joint leakage and property damage.

• Spare Seat Cartridge

• Ratchet Wrenches

• Crescent Wrenches

• Pipe Wrenches

• Victaulic Lubricant or Silicone Lubricant

• Water-Stabilized Calcium Grease Containing Graphite and Molybdenum Disulfide

• Anti-Seize Compound

MANUAL OPERATION

For Installation-Ready™ Knife Gate Valves installed with a handwheel operator, the following table contains the approximate number of complete rotations required during standard operation (i.e. going from fully closed to fully open) or during maintenance to remove the seat cartridge.

Valve Size

inches

Thrust Load

lbs

Approximate

Number of

Handwheel

Rotations

for Standard

Operation

Approximate

Number of

Handwheel Rotations for Maintenance

Maximum

Torq ue

Required

ft-lbs

N•m

Rim Pull

Effort

lb N

3 150 0

20 45

11 16

80 6672 14 70

4 2100

25 55

15 22

100 9341 20 99

6 3000

35 70

22 33

150 13,344 29 145

8 4600

45 90

33 49

200 20,461 44 217

10* 7000

44 88

72 43

250 31,136 98 189

12* 7200

52 100

73 43

300 32,026 99 192

* These sizes come standard with a bevel gear operator.

PNEUMATIC OPERATION

Pneumatic cylinders are designed to be operated within 80–150 psi/6 –10 Bar air pressure. Contact Victaulic if your system air pressure is less than 80 psi/6 Bar. Additional information will be required to determine appropriate specifications for your system.

HYDRAULIC OPERATION

Hydraulic cylinders are designed to be operated within 1500–3000 psi/103–207 Bar hydraulic pressure. Contact Victaulic if your system hydraulic pressure is less than 1500 psi/103 Bar. Additional information will be required to determine appropriate specifications for your system.

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SECTION I

• Installing the 795 Valve Into a Steel Piping System

• Installing the 906 Valve Into an HDPE Piping System

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INSTALLING THE 795 VALVE INTO A STEEL PIPING SYSTEM

WARNING

• This valve is intended for use on grooved-end carbon steel or stainless steel NPS pipe and is NOT to be used on HDPE pipe.

Failure to follow this instruction could result in personal injury, joint leakage, and property damage, and could void the product warranty.

1. DO NOT REMOVE OR ADJUST THE ASSEMBLY HARDWARE:

Series 795 Installation-Ready™ Knife Gate Valves are designed so that the installer does not need to remove the assembly hardware for installation. This design facilitates installation by allowing the installer to directly insert a grooved pipe end into each opening of the valve.

2. INSPECT PIPE ENDS: The outside surface of the pipe, between the groove and the pipe end, must be smooth and free from indentations, projections, weld seams, and roll marks to ensure a leak-tight seal. All oil, grease, loose paint, dirt, and cut ting particles must be removed. The pipe OD, groove dimensions, and maximum allowable flare diameter must be within the tolerances published in current Victaulic grooving specifications. NOTE: Maximum allowable pipe ovality shall comply with the requirements of ASTM A-999 and API 5L. Greater variations between the major and minor pipe diameters will result in difficult assembly and potential joint leakage.

3. INSPECT PIPE GASKETS: Check the pipe gaskets to ensure that they are suitable for the intended service. The color code identifies the gasket grade. Refer to Victaulic publication 05.01 in the G-100 General Catalog for the color code chart.

CAUTION

• A compatible lubricant must be used to prevent the pipe gaskets from pinching /tearing during installation.

• Pipe gaskets are designed for one-time use only. DO NOT attempt to reuse pipe gaskets that have been placed in service.

Failure to follow these instructions will cause gasket degradation, resulting in joint leakage and property damage.

Lubricate

4. LUBRICATE PIPE GASKETS: Apply a thin coat of Victaulic Lubricant or silicone lubricant only to the sealing lips of the pipe gaskets’ interior.

NOTE: The exterior surface of the pipe gaskets is supplied with a factory-applied lubricant.

NOTICE

• It is not necessary to remove the pipe gaskets from the valve to apply additional lubricant to the exterior surface.

TABLE 1: LUBRICANT COMPATIBILITY

Lubricant

Compatibility with Grade “T” Nitrile Gaskets

Compatibility with Grade “E” EPDM Gaskets

Victaulic Lubricant,

Soap-Based Solutions, Glycerin,

Silicone Oil, or Silicone Release Agent

Good Good

Corn Oil, Soybean Oil,

Hydrocarbon-Based Oils,

or Petroleum- Based Greases

Good

Not

Recommended

WARNING

• Keep hands away from the pipe ends and the openings of the valve when attempting to insert grooved pipe ends into the valve.

Failure to follow this instruction could result in serious personal injury.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

5a. ASSEMBLE JOINT: Assemble the joint by inserting a grooved pipe end into each opening of the valve.

Inspect

5b. INSPECT KEYS: Each grooved pipe end must be inserted into the valve until contact with the seat occurs, as shown above. This will ensure that the valve body’s keys align with the grooves in the pipe ends.

5c. REMOVE ONLY THE SPACER BOLTS: There is one spacer bolt on each bolt pad to maintain spacing between the bolt pads during shipping and assembly. After inserting pipe, remove only the spacer bolts and the attached warning tags before tightening the four nuts in step 6.

CAUTION

• Spacer bolts are designed to keep the valve’s housings at the proper spacing during installation of the pipe ends.

• These spacer bolts must be removed prior to tightening the hex nuts to bring the bolt pads into metal-to-metal contact. The bolts will prevent proper tightening of the valve housings.

Failure to follow these instructions will cause damage to the valve components. This may result in joint leakage or property damage, and could void the product warranty.

NOTE: Do NOT discard the spacer bolts. Reinstall the spacer bolts

to finger-tight after valve installation is complete. If the valve must be removed from the system, the spacer bolts will be necessary to separate housings and maintain spacing (dimension "C", as defined in the dimension tables found on pages 7–10) between the bolt pads during storage, shipping, and reinstallation.

6. TIGHTEN NUTS: Tighten the hex nuts evenly by alternating sides in a crossing pattern (as shown in the sequence above) until metal-tometal contact occurs at the bolt pads. Ensure that the valve body’s keys engage the grooves completely during tightening.

NOTE: It is important to tighten the hex nuts evenly by alternating sides to prevent pinching of the pipe gaskets. An impact wrench or standard socket wrench with a deep-well socket can be used to bring the bolt pads into metal-to-metal contact. Refer to the “Series 795 Helpful Information” and “Impact Wrench Usage Guidelines” sections.

WARNING

• Visual inspection of each joint is critical.

• Improperly assembled joints must be corrected before the system is placed into service.

Failure to follow these instructions could cause joint failure, resulting in serious personal injury and/or property damage.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

GOOD

BAD

7. INSPECT PADS: Visually inspect the bolt pads at each joint to ensure that metal-to-metal contact is achieved across the entire bolt pad section.

8. TIGHTEN 360° POSITIONING BOLTS: Tighten the two 360° positioning bolts evenly by alternating sides until they reach a nominal torque of 40 ft-lbs/54.23 N•m.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

NOTICE

A locking pin is provided to assist with Lockout/Tagout procedures during installation and maintenance. Ensure that the pin is removed before attempting to place the valve into service.

IMPACT WRENCH USAGE GUIDELINES

WARNING

• It is important to tighten the nuts evenly by alternating sides until metal-to-metal c ontact occurs at the bolt pads.

• DO NOT continue to tighten the nuts after the visual installation guidelines for the product are achieved.

Failure to follow these instructions could cause gasket pinching and product damage, resulting in joint failure, serious personal injury, and property damage.

Due to the speed of assembly when using an impact wrench, the installer should take extra care to ensure that nuts are tightened evenly by alternating sides until proper assembly is complete. Always refer to the specific product installation instructions for complete installation requirements.

Impact wrenches do not provide the installer with direct “wrench feel” or torque to judge nut tightness. Since some impact wrenches are capable of high output, it is important to develop a familiarity with the impact wrench to avoid damaging or fracturing the bolts or the bolt pads during installation. DO NOT continue to tighten the nuts after the visual

installation guidelines are achieved.

If the battery is drained or if the impact wrench is under-powered, a new impact wrench or a new battery pack must be used to ensure that the visual installation guidelines for the product are achieved.

Perform trial assemblies with the impact wrench and check the assemblies with socket or torque wrenches to help determine the capability of the impact wrench. Using the same method, periodically check additional nuts throughout the system installation.

For safe and proper use of impact wrenches, always refer to the impact wrench manufacturer’s operating instructions. In addition, verify that proper impact grade sockets are being used for product installation.

WARNING

Failure to follow instructions for tightening product hardware could result in:

• Bolt fractures

• Damaged or broken bolt pads or product fractures

• Joint leakage

Series 795 Helpful Information

Valve

Size

Spacer

Bolt Size

Spacer Bolt

Socket

inches/mm

Coupling

Nut

Size

Coupling Nut

Deep-Well Socket

inches/mm

⁄" - 16 UNC x 2"

⁄

½" - 13 Heavy Hex

⁄

14 19

⁄" - 16 UNC x 2"

⁄

½" - 13 Heavy Hex

⁄

14 19

⁄" - 16 UNC x 3"

⁄

⁄" - 11 Heavy Hex

1 ⁄

14 27

⁄" - 16 UNC x 3"

⁄

⁄" - 11 Heavy Hex

1 ⁄

14 27

½" - 13 UNC x 3.5"

⁄" - 9 Heavy Hex

1 ⁄ 

19 36

½" - 13 UNC x 3.5"

⁄" - 9 Heavy Hex

1 ⁄ 

19 36

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

INSTALLING THE 906 VALVE INTO AN HDPE PIPING SYSTEM

WARNING

• Wear gloves while handling valve. Retainer teeth are sharp and may cause injury.

• This valve is intended for use on plain-end HDPE pipe and is NOT to be used on steel pipe.

Failure to follow these instructions could result in personal injury, joint leakage, and property damage, and could void the product warranty.

1a. DO NOT REMOVE OR ADJUST THE ASSEMBLY HARDWARE:

Series 906 Installation-Ready™ Knife Gate Valves are designed so that the installer does not need to remove the assembly hardware for installation. This design facilitates installation by allowing the installer to directly insert a pipe end into each opening of the valve.

1b. REMOVE SLEEVE: Remove the cardboard sleeve from the valve interior. NOTE: This cardboard sleeve will be used as a guide for marking the pipe ends in step 4.

2. INSPECT PIPE ENDS: Ensure that the pipe ends are clean and free from damage and scratches within 2 ½ inches/64 mm from the ends. All oil, grease, dirt, and cutting particles must be removed. Failure to do so will result in difficult assembly and potential joint leakage.

CAUTION

• A compatible lubricant must be used to prevent the pipe gaskets from pinching /tearing during installation.

• Pipe gaskets are designed for one-time use only. DO NOT attempt to reuse pipe gaskets.

Failure to follow these instructions will cause gasket degradation, resulting in joint leakage and property damage.

4. MARK PIPE: Using the cardboard sleeve and a paint stick, mark

each HDPE pipe end around the full circumference:

• 1 7/8 inches/48 mm for 2–3-inch pipe sizes

• 2 ¼ inches/57 mm for 4–8-inch pipe sizes

This mark will be used for visual inspection to ensure that the HDPE pipe is inserted properly in the valve. If a full circumferential mark cannot be achieved, make at least four marks equally-spaced around the circumference of each HDPE pipe end.

5. LUBRICATE PIPE END: Apply a thin coat of lubricant to the pipe end from the end of the pipe to the paint mark made in step 4.

Lubricate each pipe end in accordance with the “Lubricant Compatibility” table. Always consult with the pipe manufacturer for lubricant compatibility requirements.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

TABLE 1: LUBRICANT COMPATIBILITY

Lubricant

Compatibility with Grade “T” Nitrile Gaskets

Compatibility with Grade “E” EPDM Gaskets

Victaulic Lubricant,

Soap-Based Solutions, Glycerin,

Silicone Oil, or Silicone Release Agent

Good Good

Corn Oil, Soybean Oil,

Hydrocarbon-Based Oils,

or Petroleum- Based Greases

Good

Not

Recommended

WARNING

• Keep hands away from the pipe ends and the openings of the valve when attempting to insert pipe ends into the valve.

Failure to follow this instruction could result in personal injury.

5a. ASSEMBLE JOINT: Assemble the joint by inserting the marked

HDPE pipe end into each opening of the valve. The HDPE pipe ends must be inserted into the valve until (1) contact with the seat occurs AND (2) the marks on the HDPE pipe ends meets the edge of the valve body, as shown above.

Inspect

5b. INSPECT SEAT: Each pipe end must be inserted into the valve until contact with the seat occurs, as shown above. A visual check is required to ensure that the seat meets the pipe ends.

CAUTION

• Spacer bolts are designed to keep the valve’s housings at the proper spacing during installation of the pipe ends.

• These spacer bolts must be removed prior to tightening the hex nuts to bring the bolt pads into metal-to-metal contact. The bolts will prevent proper tightening of the valve housings.

Failure to follow these instructions will cause damage to the valve components. This may result in joint leakage or property damage, and could void the product warranty.

NOTE: Do NOT discard the spacer bolts. Reinstall the spacer bolts

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

6. TIGHTEN NUTS: Tighten the hex nuts evenly by alternating sides in a crossing pattern (as shown in the sequence above) until metal-to-metal contact occurs at the bolt pads.

NOTE: It is important to tighten the hex nuts evenly by alternating sides to prevent pinching of the pipe gaskets. An impact wrench or standard socket wrench with a deep-well socket can be used to bring the bolt pads into metal-to-metal contact. Refer to the “Series 906 Helpful Information” and “Impact Wrench Usage Guidelines” sections.

WARNING

• Visual inspection of each joint is critical.

• Improperly assembled joints must be corrected before the system is placed into service.

Failure to follow these instructions could cause joint failure, resulting in serious personal injury and/or property damage.

GOOD

BAD

7. INSPECT PADS: Visually inspect the bolt pads at each joint to ensure that metal-to-metal contact is achieved across the entire bolt pad section.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

NOTICE

A locking pin is provided to assist with Lockout/Tagout procedures during installation and maintenance. Ensure that the pin is removed before attempting to place the valve into service.

IMPACT WRENCH USAGE GUIDELINES

WARNING

• It is important to tighten the nuts evenly by alternating sides until metal-to-metal c ontact occurs at the bolt pads.

• DO NOT continue to tighten the nuts after the visual installation guidelines for the product are achieved.

Failure to follow these instructions could cause gasket pinching and product damage, resulting in joint failure, serious personal injury, and property damage.

installation guidelines are achieved.

WARNING

Failure to follow instructions for tightening product hardware could result in:

• Bolt fractures

• Damaged or broken bolt pads or product fractures

• Joint leakage

Series 906 Helpful Information

Valve

Size

Spacer

Bolt Size

Spacer Bolt

Socket

inches/mm

Coupling

Nut

Size

Coupling Nut

Deep-Well Socket

inches/mm

⁄" - 16 UNC x 2"

⁄

½" - 13 Heavy Hex

⁄

14 19

⁄" - 16 UNC x 2"

⁄

½" - 13 Heavy Hex

⁄

14 19

⁄" - 16 UNC x 3"

⁄

⁄" - 11 Heavy Hex

1 ⁄

14 27

⁄" - 16 UNC x 3"

⁄

⁄" - 11 Heavy Hex

1 ⁄

14 27

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Page 23

SECTION II

• Maintenance

• Removing the Seat Cartridge

• Installing the Seat Cartridge

Page 24

I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

MAINTENANCE

Maintenance should be performed on the Installation-Ready™ Knife Gate Valve on a regularly scheduled basis, as established by job site requirements, or when leakage occurs.

PACKING ADJUSTMENT

If leakage occurs at the packing, tighten the hex cap screws evenly in ¼ turns by alternating sides (as shown in the sequence above) until leakage stops. If leakage persists, perform the instructions that follow to remove and replace the seat cartridge.

LUB RICATION

For handwheel, bevel gear, or electrically operated valves, Victaulic recommends greasing the threaded stem and drive nut on a quarterly basis, depending on the number of cycles. If the valve is cycled on a daily basis, increase the frequency of lubricating the threaded stem to ensure proper handwheel operation.

Apply a water-stabilized calcium grease containing graphite and molybdenum disulfide (Mobil Mobilux™ EP 1 or equivalent) to the entire threaded stem and

drive nut. Operate the handwheel to raise and lower the threaded stem to ensure that grease is distributed evenly. NOTE: If the valve is in a critical shutoff service and cannot be cycled, insert the locking pin (referenced on page 17) through the yoke (page 5, item 1) into the gate connector (page 5, item 9). Disconnect the threaded stem (page 5, item

7) from the gate connector by removing the slotted spring pin (page 5, item 10). Cycle the threaded stem independent of the gate connector, then replace the slotted spring pin and remove the lockout bolt.

For pneumatically or hydraulically operated valves, refer to the actuator manufacturer’s maintenance instructions.

REMOVING THE EXISTING SEAT CARTRIDGE

DANGER

• Depressurize and drain the piping system completely before attempting to remove the seat cartridge.

Failure to follow this instruction could result in death or serious personal injury and property damage.

WARNING

• Read and understand all instructions before attempting to install, remove, adjust, or maintain any Victaulic piping products.

• Wear safety glasses, hardhat, foot protection, and hearing protection.

Failure to follow instructions and warnings could cause system failure, resulting in death or serious personal injury and property damage.

1. DEPRESSURIZE AND DRAIN SYSTEM: Depressurize, drain, and

flush the piping system completely and return the knife to the fully closed position before attempting to remove the seat cartridge.

Stroke Limiter

2. REMOVE STROKE LIMITER: Remove the stroke limiter in order to raise the stem completely.

Apply grease here

™ Mobilux is a trade mark of Ex xon Mobil Corp oration.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

2a. Using a ⁄inch/11 mm deep-well socket wrench, remove the nut on the T-bolt clamp and pull the clamp apart.

2b. Remove the T-bolt clamp and split the two halves of the stroke limiter to remove.

Remove

3. REMOVE PLUG: Using a 1 ¼-inch/32 mm wrench (for the 3 to 8" valves) or a 1 ½-inch/38 mm wrench (for the 10 to 12" valves), remove the plug from the bottom of the valve body.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

4. REMOVE AND RELOCATE GATE CONNECTOR SCREWS: Remove the two hex cap screws from the gate connector. Relocate them through the tab on each side of the seat and into the side of the knife, then finger-tighten. This is necessary to attach the seat to the knife during removal in later steps.

Valve

Size

Retaining Plate

Bolt Size

Retaining Plate

Socket Size

inches/mm

3–8"

⁄"

⁄-

inch/M16 Bo lt

¾-inch/M19 Nut

10 –12 "

¾"

1 ⁄-inch/M29 Bolt 1

⁄-inch/M29 Nut

5. REMOVE RETAINING BOLTS: Remove the four hex cap bolts and nuts from the retaining plate, as shown above.

NOTE: Do NOT remove the packing screws. Doing so will damage the seat.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

6a. OPEN VALVE: For handwheel operated valves, operate the handwheel in the “open” direction (counterclockwise) to draw the seat out from the valve body.

CAUTION

• Support the seat cartridge during actuation to prevent lateral movement. Though the valve is operable in any configuration, angled placement may allow an unsupported seat cartridge to slide out of the gate connector prematurely.

Failure to follow this instruction could result in personal injury or property damage.

6b. For pneumatically or hydraulically operated valves, actuate the valve

open to draw the seat out from the valve body.

CAUTION

• Support the seat cartridge during actuation to prevent lateral movement. Though the valve is operable in any orientation, angled placement may allow an unsupported seat cartridge to slide out of the gate connector prematurely.

Failure to follow this instruction could result in personal injury or property damage.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

WARNING

• Keep hands away from the edges of the knife seat while lifting it from the valve body.

Failure to follow this instruction could result in personal injury.

7. REMOVE CARTRIDGE: When the seat has cleared the opening of

the valve body, slide the seat cartridge out from the slot in the gate connector, as shown above. For clearance measurements, reference the E dimension in the table on page 11.

NOTE: When removing the seat cartridge, be prepared to suppor t its weight with both hands. Refer to the table on page 11 for specific weights before attempting to remove the seat cartridge. Larger sizes may require the use of mechanical lifting equipment.

Sealing Faces

8. CLEAN VALVE: Ensure that the seat cavit y and drain plug are free from debris by flushing the cavity with water. Wipe clean the sealing faces with a rag or brush.

Inspect the cavity to ensure that par ticles have been removed. All foreign matter should be cleared away before replacing the seat cartridge.

NOTICE

• Victaulic recommends having a spare replacement seat cartridge available to prevent maintenance delays.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

INSTALLING THE REPLACEMENT SEAT CARTRIDGE

Tab

Slot

1a. PREPARE CARTRIDGE SURFACES: Apply a thin coat of Victaulic Lubricant or silicone lubricant to all exterior surfaces of the new seat cartridge. NOTE: The seat contains a tab that must be installed facing the slot in the valve body, as shown above.

1b. Add a thin coat of anti-seize compound to the top of the knife, as shown to the right, to aid with installation and with future removal of the cartridge.

Apply anti-seize compound

2. INSERT CARTRIDGE: Slide the replacement seat cartridge into the slot in the gate connector, as shown above.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

3a. CLOSE VALVE: For handwheel operated valves, operate the handwheel slowly in the “closed” direction (clockwise) to bring the seat toward the valve body. Ensure that the tab of the seat is facing the slot in the valve body, as shown in step 1. To prevent damage to the surfaces of the seat, do not attempt to operate the handwheel at an increased rate, or by using a drill or impact gun.

3b. For pneumatically and hydraulically operated valves, actuate the valve closed to bring the seat toward the valve body.

WARNING

• Keep hands away from the edges of the knife seat while replacing it into the valve body.

• Keep hands away from the seat cartridge and yoke while actuating the valve.

Failure to follow this instruction could result in personal injury.

4. REPLACE RETAINING BOLTS: When the retaining plate is

1 inch/25 mm or less from the valve body, insert the four hex cap bolts and flat washers through the retaining plate and into the valve body, as shown ab ove.

5. TIGHTEN RETAINING BOLTS: Tighten the four hex cap bolts evenly by alternating sides (as shown in the sequence above) until the lock washers are fully compressed. There should be metal-to-metal contact between the plate and the housing.

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I-795 / 906 / Installation-Ready™ Knife Gate Valve / Installation and Maintenance Instructions

6. REMOVE AND RELOCATE GATE CONNECTOR SCREWS: Remove the two hex cap screws from the knife and relocate them to the gate connector, as shown above. Ensure that the hex cap screw is threaded down so that the head is below the washer (page 5, item 12).

7. REPLACE PLUG: Replace the plug in the bottom of the valve body, tightening the plug as directed in the chart below.

Valve Size

Plug Installation Torque

Lower Nut +/- 20%

3–8"

60 ft-lbs

81.3 N• m

10 –12"

100 ft-lbs

135.6 N•m

Stroke Limiter

8. REPLACE STROKE LIMITER: Replace the stroke limiter on the stem by reversing the procedure for removal. Do not tighten the T-bolt clamp past 75 in-lbs.

CAUTION

• DO NOT attempt to place the valve back in service without replacing the stroke limiter.

Failure to follow these instructions will cause damage to the valve components. This may result in joint leakage or property damage, and could void the product warranty.

9. INSPECT GAP: Operate the handwheel (or the pneumatic or hydraulic

operator) to raise the knife out of the valve body. Ensure that the gap on both sides of the knife is equal, as shown above. The hex cap screws of the packing gland can be adjusted, if necessary, to achieve an equal gap on both sides of the knife. Refer to the "Packing Adjustment" section on page 24 to review adjusting the hex cap screws.

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I-795/906INSTALLATION AND MAINTENANCE INSTRUCTIONS

Series 795 and 906 Installation-Ready™ Knife Gate Valves

For complete contact information, visit victaulic.com

I-795/906 8413 REV D UPDATED 6/2017 Z000795000

VICTAULIC AND INSTALLATION-READY ARE REGISTERED TRADEMARKS OR TRADEMARKS OF VICTAULIC COMPANY AND/OR ITS AFFILIATED ENTITIES IN THE UNITED STATES AND/OR OTHER COUNTRIES. © 2017 VICTAULIC COMPANY. ALL RIGHTS RESERVED.

Victaulic 795 Series, 906 Series, I-795, I-906 Installation And Maintenance Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual