CLARKSON URETHANE KNIFE GATE VALVES Installation and maintenance instructions for field replaceable urethane lined knife gate valves GENERAL INFORMATION The Clarkson SU10R knife gate valve offers bi-directional isolation with a field replaceable liner that completely protects the wetted area from abrasion and corrosive slurries, increasing reliability and service life. Note: 1. Face to Face to MSS SP-81 2. Bi-directional valve, no special concerns in relation to direction of flow are required when installing the valve. 3. Mating line flanges must be properly aligned. Never try to make up for misaligned pipe flanges by the line bolting. 4. Slip-on or weld flanges can be used. The flange inside diameter can t be any larger that the outside diameter of schedule 40 pipe, plus 2mm (3/32). Generally, the life and sealing will be better with full face flanges. 5. Flange fasteners should be tightened in a uniform manner using a cross-pattern to pull the flange down uniformly onto the integral flange seal. Additional gaskets are not required but a hard compressed fiber sheet gasket can be used if desired. Do not use soft gaskets. Compression of the liner flange locks it to the valve body 6. Pipe supports and/or expansion joints should be used to minimize pipe loads on valves. SU10R valves are suitable for use in either vertical or horizontal lines. If installation is other than vertical, additional support will be required for cylinder actuated valves. INITIAL INSPECTION 1. Examine entire valve and report any damage or discrepancies immediately. 2. Accessories, if any, including solenoids, limit switches, positioners, etc., are tested for functionality prior to shipment. Examine carefully for damage which may occur during shipment. 3. Operators: Large manual hand wheels may sometimes be shipped loose for field installation. 4. Packing assembly: The packing gland bolts should be checked and adjusted to obtain a first time packing seal. Packing glandnuts may become slightly loose when the valve is shipped. This is normal. Field adjustment is expected and desired. Tighten just enough to stop any leakage. Overtightening may increase valve operating force and shorten packing life. Label contents Item Description Example MAWP Maximum allowable working pressure 1000 kpa Comply Manuf. Ref. Manufacturers reference. N/A CRN Canadian Registation Number N/A Patent Patent N/A Size Valve nominal size DN250 Flange Valve mounting flange standard. ASME 150 Body Body material. ASTM A395-60 Gate Gate material 316 S/S Temp Maximum working temperature, wet or dry 50 C Wet/80 C Dry Emerson.com/FinalControl 2017 Emerson. All Rights Reserved. VCIOM-07212-EN 17/09
J K ØF C3 C4 C1 C2 ØF1 C G ØB ØA H D E Dimensions (mm) Valve Size DN ØA ØB C C1 C2 C3 C4 D E ØF ØF1 G H J K 50 50 96 264 59 81-202 48 186 200-126 73 - Ø89 11-11 - P1 80 80 135 323 86 108-255 51 228 300-134 98 - Ø110 19-20 - P3 100 100 157 364 86 130-330 51 275 300-134 117 - Ø150 24-29 - P4 150 150 243 451 86 181-343 57 331 300-144 147 - Ø210 33-43 - P5 200 200 351 581 48 308 368 431 70 408 600 400 208 175 320 Ø210 75 97 81 B20 P6 250 250 411 687 48 308 458 508 70 483 600 400 220 207 320 330SQ 106 128 180 B20 P8 300 300 488 790 - - 458 622 76 559-400 220 246 320 Ø448 144 166 279 B20 P11 350 333 538 861 - - 508 622 76 596-400 224 271 320 Ø448 170 192 305 B20 P11 400 381 603 980 - - 602 816 89 667-600 290 303 320 Ø505-306 479 B20 P14 450 429 647 1078 - - 602 825 89 719-600 304 326 320 Ø560-371 627 B20 P15 500 478 722 1183 - - 657 830 114 815-600 304 363 380 Ø626-500 834 B30 P16 600 575 832 1434 - - 775 952 114 924-610 336 418 617 Ø718-728 1220 BG44GT P18 Dimensions (inches) Valve Size NPS ØA ØB C C1 C2 C3 C4 D E ØF ØF1 G H J K 2 2.00 3.78 10.39 2.32 3.19-7.95 1.89 7.32 8-4.96 2.87 - Ø3.5 24-24 - P1 3 3.00 5.31 12.72 3.39 4.25-10.04 2.00 8.98 12-5.28 3.86 - Ø4.4 42-44 - P3 4 4.00 6.18 14.33 3.39 5.12-13.00 2.00 10.83 12-5.28 4.61 - Ø5.9 53-64 - P4 6 6.00 9.57 17.76 3.39 7.13-13.50 2.25 13.03 12-5.67 5.79 - Ø8.3 73-95 - P5 8 8.00 13.82 22.87 1.89 12.13 14.50 16.97 2.75 16.06 24 12 8.19 6.89 13.59 Ø8.3 165 213 179 BG3 P6 10 10.00 16.18 27.05 1.89 12.13 18.10 22.50 2.75 19.02 24 12 8.66 8.15 13.59 12.8SQ 233 282 415 BG3 P8 12 12.00 19.21 31.10 - - 18.10 26.00 3.00 22.01-12 8.66 9.69 13.59 14.8SQ - 365 614 BG3 P11 14 13.11 21.18 34.00 - - 20.00 26.00 3.00 23.46-24 8.82 10.67 16.72 14.8SQ - 422 671 BG3 P11 16 15.00 23.74 38.58 - - 23.70 33.80 3.50 26.26-24 11.42 11.93 19.36 17.0SQ - 680 1054 BG4 P14 18 16.89 25.47 42.44 - - 23.70 34.00 3.50 28.31-24 11.97 12.83 19.46 19.0SQ - 823 1316 BG42 P15 20 18.82 28.43 46.57 - - 25.90 34.30 4.50 32.09-24 11.97 14.29 19.46 21.0SQ - 1070 1713 BG42 P16 24 22.64 32.76 56.46 - - 30.50 37.48 4.50 36.38-24 13.23 16.46 24.30 Ø28.3-1602 2684 BG44GT P18 H/W mass (kg) H/W mass (lbs) B/gear Pneu mass act mass (kg) (kg) B/gear Pneu mass act mass (lbs) (lbs) Bevel gear model Bevel gear model Pneu Act model Pneu Act model NOTES: D = The face to face dimension. E = The maximum valve or upstand clearance dimension for installation. G = The maximum valve width clearance dimension for installation. P = Pneumatic actuator based on air supply pressure of 550 kpa (80 psi) and clean water service. 2
Bolting and Installation Instructions The SU10R flange configuration is tapped holes in the chest and through bolting through the valve flange. Flange mounting holes in the chest area have limited depth and care must be taken to ensure the flange bolt does not bottom out in the hole, causing damage to the valve body. Studs can be used instead of bolts to avoid this damage. The flange bolts are a structural component of the valve and must have a minimum yield strength. For Metric bolts, the minimum yield strength is 640MPa, which is equivalent to ISO898 Class 8.8 or better. ISO 3506-1 A2-80 and A4-80 stainless steel bolts are also suitable. For ASME flanges, ASME B16.5 Table 1B High Strength bolts are suitable. Flange bolts must have the required torque as shown in Table 1. Additional gaskets are not required as the Polyurethane liner flanges perform this function. If additional gaskets are desired use thin compressed fiber sheet gaskets. Do not use thick soft gaskets as the liner flange may not lock into place on the body. TABLE 1 - MINIMUM AND MAXIMUM TORQUE ON FLANGE BOLTS OR STUDS Valve size Bolt Min torque Max torque DN (NPS) size Nm (ft-lb) Nm (ft-lb) 50 (2) M12 17 13 27 20 M16 & ⅝ UNC 41 30 67 49 80-200 (3-8) All 41 30 67 49 250 (10) M16 & ⅝ UNC 41 30 67 49 M20 and larger 80 59 131 97 300 (12) All 80 59 131 96.63 350-500 (14-20) M20-M22 80 59 131 96.63 M24 (+1"UNC) and larger 139 103 225 166 600 (24) M24 139 103 225 166 M27 (+1 1 /4 "UNC) and larger 203 150 330 243 NOTES: Maximum torque should not be exceeded to insure threaded flange holes in valve body are not damaged. Warning: Valves are normally shipped with the gate in the Open position. However, valves fitted with spring to extend actuator (Fail Close) are shipped with the gate in the Closed position. All SU10R valves are to be installed with the Gate in Open Position, exercise caution when applying air/hydraulic pressure to open valve and ensure that it is locked in Open Position when installing in-line. WARNING: Flange Bolts are structural components in valve and must comply with stated ISO or ASME grades. Care must be taken when installing studs or bolts in tapped flange holes in chest area to prevent damage to internal wall profile. 3
Pipe Flanges 1. SU10R polyurethane liner flange provides sealing between valve and pipe flange. 2. The liner flange is locked to valve body by a locking tab. This locking tab is compressed into the liner flange by the pipe flange, providing the locking to prevent the liner flange from moving. 3. Slip on flanges can be used on the pipe flange. However, the pipe flange must compress the polyurethane over the locking tab to locate the liner flange and provide sealing. The following conditions must be met: Inside diameter of pipe flange cannot be any larger than Schedule 40 pipe OD plus 2mm ( 5 /32) Flange ID must be concentric with valve bore during installation 4. Flat flanges, with an inside diameter of the flange matching valve bore, provides best sealing and liner life when valve is being used at its maximum allowable working pressure. Slip on flanges will still provide acceptable life. Slip On Flange Locking Tab Slip On Flange ID must cover locking tab all the way around Pipe Gate Locking Tab Body Liner Flange Valve bore 4
Table 2 Valve size DN (NPS) Valve Chest full Flange bolting AS 2129 Table C, D Flange bolting AS 2129 Table E Flange bolting ASME 150 face to thread Thread Chest bolt Thru bolt Chest stud Thread Chest bolt Thru bolt Chest stud Thread Chest bolt Thru bolt Chest stud face depth length length length length length length length length length mm mm mm UNC in 50 (2) 48 11 M16 20 90 45 M16 25 100 45 ⅝ 1 ⅜ 4 ½ 1 ½ 80 (3) 51 12 M16 25 100 45 M16 25 100 45 ⅝ 1 ½ 5 1 ¾ 100 (4) 51 12 M16 25 100 45 M16 30 110 50 ⅝ 1 ½ 5 1 ¾ 150 (6) 57 13 M16 30 110 50 M20 35 130 60 ¾ 1 ¾ 5 ½ 2 200 (8) 70 18 M16 35 130 60 M20 40 140 60 ¾ 2 6 ½ 2 ¼ 250 (10) 70 16 M20 35 140 60 M20 40 150 65 ⅞ 2 7 2 ¼ 300 (12) 76 16 M20 40 150 60 M24 45 170 80 ⅞ 2 7 2 ¼ 350 (14) 76 15 M24 45 160 80 M24 50 180 80 1 2 ¼ 8 2 ½ 400 (16) 89 19 M24 45 180 80 M24 55 200 80 1 2 ½ 8 ½ 2 ¾ 450 (18) 89 18 M24 50 180 80 M24 60 200 90 1 ⅛ 2 ½ 9 2 ¾ 500 (20) 114 26 M24 60 220 90 M24 70 230 100 1 ⅛ 3 10 3 ¼ 600 (24) 114 21 M27 60 230 100 M30 75 260 110 1 ¼ 3 11 3 ¼ DETERMINING VALVE BOLT AND STUD LENGTHS WARNING: Flange and washer thickness can vary. Check flange bolting is correct length for chest bolts. Bolts that are too long will damage valve chest and/or prevent flange sealing beads from being compressed. Chest bolts that are too short could result in the chest threads stripping. Consider chest studs to avoid this issue. Note: The valve face to face is after compression of the flange seals. Face to face will be slightly bigger before valve installation. Blind Chest Thread Stud Length: Stud length = Chest full thread depth + Pipe flange thickness + Washer thickness + Nut thickness Round up or add at least 5mm to ensure there are threads outside the nut. This is an option instead of chest bolts. Through Bolt Length: Bolt length = Washer thickness + 2 x Pipe flange thickness + Valve face to face + Nut thickness Round up or add at least 5mm to ensure there are threads outside the nut. Blind Chest Thread Bolt Length: Bolt length = Washer thickness + Pipe flange thickness + Chest full thread depth. Always round down to avoid damage at bottom of tapped hole. If rounding down length by more than 3mm consider adding another flat washer and using the next bolt length up to ensure maximum thread engagement. 5
Clarkson URETHANE KNIFE GATE VALVEs Lock nut and cap screw DN80-600 Lock out pin goes thru gate to lock the in the open position. Lockout pin goes over the gate to lock in the close position. Lock nut all sizes Gland box adjustment Lockout pin illustration LOCKOUTS Options Optional pin style lockouts for open and closed are available for hand wheel, pneumatic and hydraulic valves. Handwheel style lockouts are available on bevel gear operated valves due to the mechanical advantage of the bevel gear. Use energy lockouts for electric, pneumatic and hydraulic cylinder actuators to lock out the actuator from the valve. Safety Pin-style lockouts assume the potential energy of the actuator has been removed through other means and are designed to prevent gate movement caused by line pressure. Lockout Pins are not designed to overcome or resist an energized pneumatic or hydraulic cylinder actuator. Pin-style lockouts are designed as a deterrent to resist unauthorized manual operation of the valve and prevent gate movement caused by line pressure. Pin style lockouts are not available on bevel gear actuated valves. A lockout that locks the bevel gear hand wheel to the gearbox is available. OPERATIONAL CONSIDERATIONS 1. All valves should be operated within their design pressure and temperature ranges. Under no circumstances should a valve be operated at conditions outside these parameters. 2. The operator should have an understanding of the effects of opening/closing a valve with regards to its role in the overall piping system. Take caution to ensure that each valve is in good operating condition prior to operating it under pressure. 3. Care should be taken when processes contain hazardous and/or otherwise unstable media to ensure the operator is aware of specific health and safety risks associated with that medium. Note that a worn out or split liner can result in leakage between valve body halves. 4. Stand clear of any moving parts such as the stem and/or gate assembly when operating, use of gloves is suggested when operating manual valves to minimize risk of injury. 5. All manual handwheel operated valves are designed for hand input. Do not apply excessive input torque via pipe wrenches, 'cheater bars', or other devices. If a manual handwheel actuated valve is difficult to operate due to torque requirements, it is recommended that the valve be supplied with or converted to a bevel gear, air/ hydraulic cylinder or electric motor actuator. 6. Electric motor actuated valves should be left in their factory set condition unless the system operating parameters dictate a change. If changes are necessary, they should be performed in small increments using the lightest/lowest setting possible to achieve the desired performance and then the valve/actuator function inspected. Excess torque and/or thrust in the motor settings may damage the valve or liner. 7. For electric motor actuation the travel switches must be set, otherwise liner damage may occur. The limit should be set such that the gate tip bottoms out in seat groove to a maximum of 1mm compression. 8. Care should be taken to ensure that electrical motors are wired correctly. Incorrect phasing of 3-phase wiring may cause valve/motor damage. 6
GENERAL MAINTENANCE It is recommended that all Clarkson SU10R series valves be inspected every 60 days. The following points should be examined and corrected as required: 1. Cylinder rods: Wipe to remove build up if required. Look for wear. Check for cylinder rod seal blow-by. 2. Packing gland: Check for leaks or worn packing. If leakage is occurring around the packing gland, tighten the packing gland bolts evenly at all points, being careful not to over tighten. If the valve requires repacking, see additional instructions. 3. Polyurethane liner: Examine the body for leakage between body halves. Leakage could indicate the liner is split or worn through. To replace a liner, disassembly of the valve is required. See additional instructions. 4. If possible, stroke valve through the full open and closed position to make sure it is functioning properly. 5. Check the liner flanges are sealing. Check flange bolt torques if leakage is evident. Note: If the valve is not in line the gate should be open. This is the best storage position for liner sealing. GLAND PACKING INSTRUCTIONS 1. Prepare the line and valve to be off line and dismantled. 2. Retract the gate to make it easier to withdraw from the liner. Warning, if the liner and gate are worn, the gate may close under its own weight. If this is the case, leave the gate in the closed position as it will be easy to withdraw from the liner. 3. Disconnect the clevis pins or bolts from the gate. 4. Remove the actuator and bridge. 5. Remove the gate and gland box. For large valves, the gate will be heavy and it may be desirable to leave the gate in the body. The options then are to repack the gland box and then fit it over the gate or to place the gland box over the gate and then repack the gland box. Both methods will require some care. 6. See the table below for packing details. 7. Packing should be cut with 45 degree mitres on the ends of each piece of packing. These mitres sit on top of each other and the join should be placed in the middle of the long side of the gland box. 8. Packing is slightly longer that the gland box length, to ensure there is compression on the join. 9. Joins for different layers of packing should be staggered to the opposite side so that there are not 2 joins in contact with each other. 10. Work the layer of packing around the gate being sure not to have any twist. 11. Once the first layer of packing is installed, neatly continue with the second layer. The DN600 (NPS 24) only has a third layer. 12. Use a blunt tool, such as that shown in the photos, to work the packing. This will avoid damaging the packing or gland box paint. It is also safer for the installer. 13. Refit the bridge and actuator. Reconnect the clevis pin/bolts 14. Adjust packing nuts firmly, without over tightening. 15. Cycle the gate several times. This will distribute the packing evenly and normally reduce the packing compression. Adjust gland box nuts again. 16. Commission valve in the pipeline and adjust packing until it seals. PACKING Details Valve Size Length Section Layers DN (NPS) mm (in) mm (in) 50 (2) 196 (7.72) 10 (⅜) 2 80 (3) 260 (10.24) 10 (⅜) 2 100 (4) 310 (12.20) 10 (⅜) 2 150 (6) 430 (16.93) 12.7 (½) 2 200 (8) 537 (21.14) 12.7 (½) 2 250 (10) 650 (25.59) 12.7 (½) 2 300 (12) 745 (29.33) 12.7 (½) 2 350 (14) 850 (33.46) 12.7 (½) 2 400 (16) 940 (37.01) 12.7 (½) 2 450 (18) 1040 (40.94) 12.7 (½) 2 500 (20) 1140 (44.88) 14 (9/16) 2 600 (24) 1370 (53.94) 15 (9/16) 3 1). Start the packing in the middle of the long side. 2). Work the packing around with a blunt tool. 3). The packed gland box. 7
CYLINDER SUPPORT METHODS FOR HORIZONTALLY OR OFF-VERTICAL MOUNTING Cylinders may require additional support when mounted in the other than vertical position. Failure to do so could lead to premature failure of cylinder and/or valve. The following illustrations are suggestions; specific details will have to be determined by customer so support best suits surrounding area. It is important that the cylinder/gate alignment be maintained during valve operation. Supports should be designed to maintain alignment and support bulk of cylinder weight. Installation A Appropriate tie-in capable of supporting load Turnbuckle for adjustment saddle style hanger Installation b Recommended long term storage The following are recommendations for storage procedures to retain maximum product integrity during long term storage of 1 to 5 years. Storage facility The preferred storage location is a clean, dry protected warehouse. If valves are to be stored outside, precautions should be taken to keep valves clean and dry. Standard packaging materials cannot be considered sufficient for outdoor storage. Handwheel or bevel gear operated valves Equipment orientation Valves may be stored in the vertical or horizontal position Preparation for storage Valves may be stored as shipped, provided the storage facility and equipment orientation instructions above are followed. If valve packaging is altered or removed for receiving inspection, repackage valve as originally received. Standard packaging materials cannot be considered sufficient for outdoor storage. Cylinder storage These cylinder storage instructions are not intended to replace the instructions of the specific cylinder manufacturer and are to be used as a guide only. If specific instructions are required, please contact our office. For storage of up to 3 years; operate cylinder 6-12 times on a yearly basis. For storage 3-5 years; Securely plug cylinder ports with pipe plugs, if cylinder is not prepiped to control accessories. If cylinder is prepiped to accessories, plug all input and output ports of accessories. Storage inspection Visual inspection shall be performed on a semiannual basis and results recorded. Inspection as a minimum shall include reviewing the following: Packaging Flange covers Dryness Cleanliness Maintenance Maintenance shall consist of correcting deficiencies noted during inspection. All maintenance shall be recorded. Contact factory prior to performing any maintenance if valve is still covered under warranty. CYLINDER OPERATED VALVES Saddle style support Appropriate tie-in capable of supporting load Installation C Appropriate tie-in capable of supporting load Turnbuckle for adjustment Appropriate head-support, saddle style perferred Equipment orientation Valves may be stored in the vertical or horizontal position. For large pneumatic actuators P7 and above, or for all spring return cylinders, the actuator must be supported in storage. This is to ensure the actuator load is taken off the valve top works and the valve gate/ liner. Preparation for storage Valves may be stored as shipped, provided the storage facility and equipment orientation instructions above are followed. If valve packaging is altered or removed for receiving inspection, repackage valve as originally received. Standard packaging materials cannot be considered sufficient for outdoor storage. 8