Beruflich Dokumente
Kultur Dokumente
Secondary seal: the KGA utilizes a multipart 5. All valves should be operated within the FIGURE 1
gate wiper assembly to wipe the gate and design pressure and temperature ranges.
reduce potential for discharge from the top of Under no circumstances should the valves
the valve where the gate enters the housing be operated at conditions outside these
assembly. The KGA+ features a secondary seal parameters. Do not exceed 100% of the
assembly capable of being lubricated without maximum pressure rating of the valve at
disassembly. Similar to what is currently any time during its operation. Pressure
offered on the KGD; this new seal design spikes beyond the valves pressure rating
incorporates an external lubrication fitting to are solely the responsibility of the user.
directly inject lubrication into the seals interior Operators
(patent pending). 2 INITIAL INSPECTION
Simplified housing assembly: housing spacers 1. Examine entire valve and report any
found on the KGA have been eliminated from damage or discrepancies immediately. Retainer flanges
the KGA+ allowing for an easier disassembly / 2. Sleeves: visually examine the sleeves
assembly process. interior, looking for chunking, irregularities
or other damage. It is not recommended you
With these changes, spare parts and remove the retainer flanges (if equipped).
Sleeves
interchangeability with the prior design have 3. Retainer flanges: sizes NPS 8 (DN 200) and
been impacted. These changes are detailed below may or may not have the optional
in Sections Spare parts (KGA+ and KGA). retainer flanges, retainer flanges are
standard on sizes NPS 10 (DN 250) and
1 GENERAL INFORMATION larger. Visually examine the retainer flanges
surfaces, looking for tears, irregularities or
1. The KGA+ is a packingless, slurry knife other damage. Check tightness of retainer
gate valve. All the sealing is accomplished flange bolting.
by the elastomeric sleeves in the valve 4. Operators: standard manual handwheels
housing. The sleeves also form the wear may be shipped loose for field installation,
section for the valve. The gate is removable be sure to fully tighten.
for inspection or replacement while the 5. Valves are normally shipped with gate in
valve is in service. open position, the recommended position
2. The KGA+ is BIDIRECTIONAL for installation. Valves supplied with spring
(two-way shut-off) product and can be to extend (fail close) cylinder actuators are
installed without concern over direction of shipped with the gate in the closed position.
flow. Since they will shut-off equally with The KGA+ should be installed with the gate
in either direction, you will find no arrows in the open position, exercise caution when
or other indicators of a direction of flow or applying air to open this valve and then
seat side. ensure that it is locked in the open position
3. Clarkson slurry knife gate valves are when installing in the line.
suitable for on-off service only. They are 6. Accessories: if provided, including
not to be used in a throttling application. solenoids, limit switches, positioners,
4. The style, size, pressure rating and material etc., are tested for functionality prior to
selection are the responsibility of the piping shipment. Examine carefully for damage
system designer. which may occur during shipment.
2
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
TABLE 1 - MAXIMUM TIGHTENING TORQUE STANDARD FLANGES TABLE 2 - MAXIMUM TIGHTENING TORQUE FRP FLANGES
Valve size Valve size
NPS DN ft·lb N·m NPS DN ft·lb N·m
3 80 37 50 3 80 25 34
4 100 37 50 4 100 25 34
6 150 69 93 6 150 40 54
8 200 69 93 8 200 40 54
10 250 113 153 10 250 65 88
12 300 113 153 12 300 65 88
14 350 169 229 14 350 100 135
16 400 169 229 16 400 100 135
18 450 238 322 18 450 140 190
20 500 238 322 20 500 140 190
24 600 345 467 24 600 200 271
26 650 345 467 26 650 200 271
30 750 345 467 30 750 200 271
36 900 610 827 36 900 320 434
42 1050 610 827 42 1050 320 434
48 1200 610 877 48 1200 320 434
54 1350 1000 1355 54 1350 600 443
60 1500 1000 1355 60 1500 600 813
3
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
NOTES
• Flange dimensions per ASME B16.5/150 for NPS 2 - 24 (DN 50 - 600) and MSS SP44 for NPS 26 - 60 (DN 650 - 1500).
• Type B standard washers are not included in bolt / stud sizing.
• Mating flange thickness assumed to match ASME B16.5/150 for NPS 2 - 24 (DN 50 - 600) and MSS SP44 for NPS 26 - 60 (DN 650 - 1500).
4 OPERATION
1. Clarkson slurry knife gate valves are 4. As the gate strokes, a gap is created
suitable for on-off service only. They are between the facing sleeves, allowing any
not to be used in a throttling application. media that could potentially clog or jam the
2. To close the valve and provide isolation, valve to be purged out from between the
the actuator (handwheel, bevel gear, sleeves, and potentially expelled outside
air/hydraulic cylinder or electric motor the valve housing to atmosphere.
actuator) moves the metal gate in a linear 5. The KGA+ valve incorporates a built-in
motion between the elastomeric sleeves clean-out area at the base of the housing
to shut off the flow. To open, reverse the assembly. The clean-out area may be
operation and the gate moves up and out enclosed by an optional, removable
from between the sleeves, opening the splash guard assembly. This splash guard
valve port. will allow controlled drainage of any
3. Matching elastomer sleeves seal against accumulated solids that may prevent full
each under a high compression load gate closure. Flush water can be used to
when the valve is open, creating the valve improve the drainage efficiency. With the
pressure vessel. When the valve is closed, splash guard in place, any solids, slurry, or
the sleeves seal against the gate face, flush water ejected from the valve can be
isolating upstream from downstream. handled in a controlled manner. See Section
See Figures 2 and 3. Installation instructions for splash guard.
Note: it is normal for the KGA+ to discharge 6. All valves should be operated within the
media during opening and closing cycles. design pressure and temperature ranges.
This helps prevent any solids from building Under no circumstances should the valves
up between the sleeves that would prevent be operated at conditions outside these
a tight seal when the valve is fully open or parameters.
closed. Discharge can be controlled with Note: actuated Clarkson valves have a
the use of an optional splash guard. Do not maximum recommend stroke speed of
install valve over walkways, electrical or 1 (25 mm) per second. Exceeding this
other critical equipment without the use of speed can shorten sleeve life and may
splash guards or similar considerations. void warranty. Speed controls provided by
factory will require adjustment in the field
to obtain proper stroke speed against actual
operating conditions.
4
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
B A
C A
B
C
F D E
7. The operator of any valve should have an 11. Electric motor actuated valves should be
understanding of the effects of opening/ left in their factory set condition, unless
closing the valve with regards to its role the system operating parameters dictate
in the overall piping system. Operators of a change. If changes are necessary, they
valves under pressure should take caution should be performed in small increments
to ensure that the valve is in good operating using the lightest/lowest setting possible
condition prior to operating it under to achieve the desired performance and
pressure. then the valve/actuator function inspected.
8. Certain processes contain hazardous and/or Excess torque and/or thrust in the motor
otherwise unstable media. Care should be settings may damage or lockup the valve.
taken in these circumstances to ensure the 12. Clarkson KGA+ valves are position seated
operator is aware of the specific health and and should never be torque seated. Do not
safety risks associated with that medium. use the motor torque settings to seat the
9. When operating the valve stand clear of any valve.
moving parts such as the stem and/or gate 13. Care should be taken to ensure that
assembly, use of gloves is suggested when electrical motors are wired correctly to the
operating manual valves to minimize the power source. Incorrect phasing of 3-phase
risk of injury. wiring may cause valve/motor damage.
10. All manually 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.
5
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
6
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
7
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
The shelf life listed is guideline data and is not This would put the spring in a compressed,
a substitute for examination of cured material fully energized position. For storage, it is
at the time of intended use. recommended the valve sleeves be removed from
To maintain shelf-life, spare sleeves should be the valve housing and stored separately from the
stored in accordance with the following. valve. Reinsert sleeves prior to installation.
1. Store at ambient temperature up to 80°F
(27°C), with 60 - 90% relative humidity away 2. The preferred storage location is a clean,
from direct sunlight and at a minimum dry protected warehouse. If valves are to
distance of 15 feet (5 meters) away from be stored outside, precautions should be
electric motors is mandatory. taken to keep valves clean and dry. Standard
2. Care must be taken to avoid storage in a packaging materials provided in valve
stressed condition such as piled too high or shipment cannot be considered sufficient
on a plain pallet overhanging a sharp edge. for outdoor storage.
3. First in - first out inventory control should 3. If outdoor storage is required, the
be practiced. equipment should be totally covered with
4. The above elastomer shelf life guidelines a heavy, light colored, plastic covering.
are for components that are not already It is essential that the plastic be opaque
installed in a valve. to eliminate sunlight, and light colored
to minimize heat buildup. The covering
Note: Emerson recommends customers always should be spread in a manner that allows
use genuine Clarkson OEM sleeves, secondary underside ventilation. To insure proper
seals and other replacement parts to maintain ventilation the equipment should be
the expected, superior, performance of their elevated 2 - 4 (50 - 100 mm) above the
KGA+. Genuine Clarkson sleeves and secondary ground.
seals from Emerson are easily recognized by 4. Manual actuated valves may be stored in
the laser etched identifying marks found on the vertical or horizontal position. For air
the outside surface. These marks include or hydraulic actuated valves, the preferred
the size, part number, applicable patent orientation for optimum protection is with
number, elastomer batch compound and date the valve fully opened and the cylinder in
of manufacture; all of which allow complete the vertical position. This position gives
traceability of the part. Clarkson replacement the best support to the cylinder rod and
sleeves, secondary seals and other parts helps reduces the chance of a flat spot
from Emerson are the only ones authorized developing on the cylinder seals. An
for use and offer the best fit and continued acceptable alternate position for valves with
performance that non-OEM parts simply cannot cylinder diameters of less than 6 (150 mm)
give. The use of copycat parts may invalidate is with the cylinder in the horizontal position.
any remaining warranty. If valve requires Motor actuated valves should be oriented
further repair, please contact our office for an in the direction as preferred by the actuator
estimate of feasibility and cost of repair. manufacturer.
5. Valves with cylinder and motor actuators
8 STORAGE should be stored in accordance with
actuator manufacturers recommendations.
The following are the factorys Access ports or panels should be secured
recommendations for storage procedures to to prevent unauthorized entry and prevent
retain maximum product integrity during long contamination.
term storage of 1 to 5 years. 6. Where auxiliary equipment is included,
1. Valves are normally shipped with gate in such as limit switches, solenoid valves, etc.,
open position, the recommended position care must be taken to avoid moisture and
for storage. During storage, the gate should condensation conditions on the equipment.
always be in the open position. Storage 7. Storage inspection: visual inspection shall
should be in an area out of direct sunlight, be performed on a semiannual basis and
away from heat, ozone and extreme weather results recorded. Inspection as a minimum
conditions. Freezing is not considered shall include reviewing the following:
detrimental as long as the valve is kept - Packaging
dry. High voltage rectifiers and other ozone - Flange covers
generating equipment and sources should - Dryness
not be near the storage area. - Cleanliness
8. Maintenance shall consist of correcting
CAUTION deficiencies noted during inspection. All
Valves supplied with spring to extend (fail close) maintenance shall be recorded. Contact
cylinder actuators are shipped with the gate in factory prior to performing any maintenance
the closed position. DO NOT store a KGA+ with a if valve is still covered under warranty.
spring to extend (fail close) in the open position.
8
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
9
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
10. Turn the valve over so the installed sleeve 3. For ease of reassembly, using a permanent FIGURE 9
is on the flat surface. marker, draw a line on the gate face along Example of a segmented retainer
11. Apply a silicone base lubricant to the the top of the secondary retainer plate. If
sealing-nose radius of the installed sleeve. marking gate is not an option, make note
Also apply it to the second sleeve sealing of the dimension from top of valve housing
nose and O.D. of seal end. to top of gate in full open position (refer to
12. Install the second sleeve, following steps Table 5, Figure 13, dimension A).
1 through 11. It may be necessary to use two 4. Remove the cotter pin from the clevis pin
or more C-clamps to pull down the second and remove the clevis pin from the gate. It
retainer flange. Do not fully tighten retainer may be necessary to actuate the valve down
flange bolts until after checking the sleeve slightly in order to relieve pressure on the
bores for concentricity; using a straight clevis pin to facilitate removal.
edge, check the sleeve position in four (4) 5. Actuator assembly removal:
places, 90 degrees apart in relation to the Smaller valves: remove the frame to
installed sleeve bore I.D. Adjust as required housing bolts of one side except for the
to make the sleeve concentric with the lowest bolt on the opposite side of the frame
other sleeve. (see Figure 10). This bolt will act as a pivot
13. Fully tighten retainer flange bolts per point for the frame / actuator assembly. FIGURE 10
Paragraph 9. While supporting the actuator assembly,
14. Remove C-clamps, if used. pivot the frame / actuator assembly away
15. The valve is now ready for installation. from the valve. Continue to provide support
Keep gate in the open position until valve while actuator is in this position.
is installed. Larger valves: remove the frame to housing
bolts. Lift the frame and actuator assembly
10 SECONDARY SEAL REPLACEMENT off the housing assembly to allow secondary
seal and gate removal.
CAUTION 6. Loosen the secondary seal retainer plate
Since this procedure may be performed with the bolts.
valve in an active pipeline, plant standard safety 7. Remove the gate by lifting it out of the
procedures must be followed. Use of personal secondary seal.
protective equipment, tag out or other plant 8. Remove all fasteners and lockwashers that
standard safety procedures must be followed. retain the secondary seal retainer plate in
Procedure SHOULD NOT be done with valve in position. Pivot frame
closed position. If valve is removed for this service, 9. Remove the secondary seal retainer plate on bolt
assure line is not pressurized before removing by lifting it up.
valve. Valve assembly and parts may be heavy, 10. Remove the secondary seal by inserting a
use proper lifting and support techniques, refer flat blade screwdriver midway along the
to Lifting, Section 15. outside of the seal, between the seal and the
valve housing. Pry the seal up and remove.
Disassembly 11. Inspect the gate for sharp edges or
1. Replacement of the secondary seal can be excessive damage. Refer to Gate
accomplished without having to remove the replacement section if gate requires For gate and or secondary seal replacement,
valve from service, however, this procedure replacement. smaller valves may have the actuator frame
SHOULD NOT be done with valve in closed swung out of the way as illustrated here.
position. If it is suspected that either one or Remove frame bolts on one side only and
both of the elastomer sleeves have failed, loosen the opposite side just enough to allow
the valve should be removed from service movement. Be sure and properly support
before secondary seal removal. If valve is weight of actuator assembly, taking care to
to be removed, refer to Lifting section. avoid injury.
2. Open the valve, so the gate is in the fully
raised position.
10
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
11
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
12
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
Visual inspection of parts prior to reassembly Use a disc grinder or belt sander to remove Tap the edges of the housings to align the
1. Check and ensure all housing interior rough surfaces. Take particular care on the internal sleeve bores to within 1/16 (1.5 mm),
surfaces and drain ports are free and clear leading and beveled edge to remove burrs at the same time maintaining bolt hole
of hardened slurry or other obstructions. and other sharp edges. alignment in the square flanges.
Clean as required. 7. Examine frame for signs of corrosion, 5. Install new sleeves and retainer flanges
2. Inspect the valve housing ensuring that the damage or other potential problems. (if used) per instruction in Section Sleeve
bores at the center of the valve are aligned 8. Check all bolting hardware for thread replacement.
with each other. Check the bore diameter integrity, signs of corrosion, straightness, 6. Lift the valve assembly to vertical position.
for wear per Table 4. Replace if there are etc. Replace as required. Refer to Lifting, Section 15.
signs of excessive or unusual wear. 9. Examine actuator assembly. 7. Using DOW III or approved alternate,
3. Examine exterior housing surfaces for A) Manual valves: check stem for completely fill all internal cavities of the
buildup of hardened slurry or other corrosion, straightness, etc. Look for new secondary seal.
contamination, clean as required. signs of wear on brass stem nut. 8. Insert the new lubricated secondary seal
4. Examine sleeves for signs of wear, cracking, B) Air or hydraulic: check for seal leaks into the valve housing assembly. Make sure
chunking, deep cuts, severe abrasion or around cylinder rod seal, heads and that the lube path openings on the seal line
chemical attack (softening or gumming). caps. Examine cylinder rod for signs of up with corresponding external housing
Replace if in doubt; sleeves must be corrosion, straightness, etc. Service per lubrication fittings.
replaced as a set. manufacturers instructions. 9. Place the secondary seal retainer plate
5. Examine secondary seal for signs of wear C) Electric motor: service per into position.
or cracking, severe abrasion or chemical manufacturers instructions. 10. Replace and hand tighten all the retainer
attack (softening or gumming). Replace if plate fasteners and lockwashers.
in doubt. Reassembly
6. Inspect the gate for sharp edges or 1. Lay the first housing half face down on
excessive damage. Some scoring will a suitable flat surface.
occur in normal use. If the gate has been 2. Carefully lay two new housing gaskets on
bent beyond 1/16 (1.5 mm) permanent face of housings. Gaskets may be held
deflection at the center, straighten or in place with a small amount of silicone
replace. If straightening is performed, lubricant placed between gasket and
use considerable care to minimize housing.
marks on gate surface. Scores or other 3. Take second housing and place into position
distress marks may be cleaned up on the first housing, and properly align bolt
with a belt sander. Machining the gate holes making sure spacer plates remain
surface is not recommended. Light in place.
scale buildup may be removed with a 4. Insert most of the housing bolts,
putty knife or gasket scraper. Inspect leaving out the top bolts that are
the gate for wear and roughness. used to hold the actuator assembly
to the housing and loosely tighten.
FIGURE 12
Gate
Secondary seal
Housing
Housing gasket
Sleeve
Retainer flange
13
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
11. Apply a small amount of recommended 17. Cycle valve to full open position and check FIGURE 13
lubricant to the two tapered faces of the the gate position using the data in the
sharp end of the gate. Table 5, Figure 13. Adjust as required.
12. Press the gate firmly through the secondary 18. Rattle the gate. It should be mostly
seal into the valve housing assembly until disengaged from the sleeves. The outboard
the mark drawn on the gate reaches the edges of the gate should be free and the
top of the retainer plate or gate reaches center still partially engaged in between the
approximately dimension A, Table 5, sleeves.
Figure 13. 19. Cycle gate full closed and full open.
13. Fully tighten all the retainer fasteners. 20. Inspect gate for pieces of rubber. If
14. Reinstall the actuator / frame assembly significant amount of rubber is present, a
A
with the housing / frame fasteners loosely. sharp edge(s) on the gate may be causing
15. Reconnect the gate to the actuator. (In order seal damage or the gate is extending too
to facilitate installation and future removal, far on the up stroke. The ends of the gate
a coating or anti-seize compound should be should be free and the center still engaged.
applied to the outside of the clevis pin over If the sleeve / gate is misaligned, loosen the B
the yoke contact area.) frame actuator bolts and / or adjust the yoke
16. Stretch the frame / actuator assembly until the proper position, open and closed,
with respect to the housing by pulling (not is obtained.
lifting) the frame / actuator assembly to 21. Reinstall the valve, refer to Lifting section.
its maximum movement away from the
housing assembly (holding housing in place
if valve is removed from pipeline). Tighten
the frame / housing bolts and verify the Dimensional tolerance:
tightness of the actuator to frame bolts. NPS 3 - 10 (DN 80 - 250) +/-1/16 (1.5 mm)
NPS 12 - 16 (DN 300 - 400) +/-3/32 (2.4 mm)
NPS 18 - 26 (DN 450 - 650) +/- (3 mm)
NPS 30 - 60 (DN 750 - 1500) +/-¼ (6 mm)
TABLE 5
Valve size A B
NPS DN inch mm inch mm
3 80 1.59 40.39 5.22 132.59
4 100 1.53 38.86 6.28 159.51
6 150 1.52 38.61 8.77 222.76
8 200 1.59 40.39 10.59 268.99
10 250 1.46 37.08 12.59 319.79
12 300 2.12 53.85 15.30 388.62
14 350 2.18 55.37 17.18 436.37
16 400 2.44 61.98 19.82 503.43
18 450 5.06 128.52 24.31 617.47
20 500 4.26 108.20 26.01 660.65
24 600 5.34 135.64 32.34 821.44
26 650 4.00 101.60 33.00 838.20
30 750 4.75 120.65 37.75 958.85
36 900 4.75 120.65 43.75 1111.25
42 1050 6.62 168.15 52.62 1336.55
48 1200 6.49 164.85 58.00 1473.20
54 1350 5.73 145.54 63.23 1606.04
60 1500 8.00 203.20 70.50 1790.70
14
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
12 FIELD REPLACEMENT OF GATES 2. Inspect the gate for sharp edges or FIGURE 14
excessive damage. Some scoring will
Disassembly occur in normal use. If the gate has been
1. Replacement of the gate can be bent beyond 1/16 (1.5 mm) permanent
accomplished without having to remove deflection at the center, straighten or
the valve from service. However, if it is replace. If straightening is performed,
suspected that either one or both of the use considerable care to minimize marks
elastomer sleeves have failed, the valve on gate surface. Scores or other distress
should be removed from service before marks may be cleaned up with a belt
gate replacement. If valve is to be removed, sander. Machining the gate surface is not
refer to Lifting, Section 15. recommended. Light scale buildup may
be removed with a putty knife or gasket
CAUTION scraper. Inspect the gate for wear and
Since this procedure may be performed with the roughness. Use a disc grinder or belt sander
valve in an active pipeline, plant standard safety to remove rough surfaces. Take particular
procedures must be followed. use of personal care on the leading and beveled edge to
protective equipment, tag out or other plant remove burrs and other sharp edges.
standard safety procedures must be followed.
Procedure CANNOT be done with valve in closed Reassembly
position. If valve is removed for this service, 1. Apply a small amount of recommended For gate and or secondary seal replacement,
assure line is not pressurized before removing lubricant to the two tapered faces of the smaller valves may have the actuator frame
valve. Valve assembly and parts may be heavy, sharp end of the gate. swung out of the way as illustrated here.
use proper lifting and support techniques, refer 2. Press the gate firmly through the secondary Remove frame bolts on one side only and
to Lifting, Section 15. seal into the valve housing assembly until loosen the opposite side just enough to allow
the gate beveled edge reaches the sleeve movement. Be sure and properly support
2. Open the valve, so the gate is in the fully bore I.D. weight of actuator assembly, taking care to
raised position. 3. Fully tighten all the retainer fasteners. avoid injury.
3. Remove the cotter pin and clevis pin from 4. Reinstall the actuator / frame assembly
the gate. It may be necessary to actuate with the housing / frame fasteners loosely.
the valve down slightly in order to relieve 5. Reconnect the gate to the actuator. (In order
pressure on the clevis pin to facilitate to facilitate installation and future removal,
removal. a coating or anti-seize compound should be
4. Actuator assembly removal: applied to the outside of the clevis pin over
Smaller valves: remove the frame to the yoke contact area.)
housing bolts of one side except for the 6. Stretch the frame / actuator assembly
lowest bolt on the opposite side of the with respect to the housing by pulling (not
frame. This bolt will act as a pivot point for lifting) the frame / actuator assembly to
the frame / actuator assembly. Pivot the its maximum movement away from the
frame / actuator assembly away from the housing assembly (holding housing in place
valve and temporarily support. if valve is removed from pipeline). Tighten
Larger valves: remove the frame to housing the frame / housing bolts and verify the
bolts. Lift the frame and actuator assembly tightness of the actuator to frame bolts.
off the housing assembly to allow gate 7. Cycle valve to full open position and check
removal. the gate position using the data in the
5. Loosen the secondary seal retainer plate Table 5, Figure 13. Adjust as required.
bolts. 8. Rattle the gate. It should be mostly
6. Remove the gate by lifting it out of the disengaged from the sleeves. The outboard
secondary seal. edges of the gate should be free and the
center still partially engaged in between
Visual inspection of parts prior to reassembly the sleeves.
1. Examine secondary seal for signs of wear 9. Cycle gate full closed and full open.
or cracking, severe abrasion or chemical
attack (softening or gumming). Replace if
in doubt.
15
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
10. Inspect gate for pieces of rubber. If 4. Install the pipe cap on one end of the splash
significant amount of rubber is present, a guard.
sharp edge(s) on the gate may be causing 5. Position the guard below the valve and fit
seal damage or the gate is extending too a U-bolt on each end with the fasteners
far on the up stroke. The ends of the gate loosely attached.
should be free and the center still engaged. 6. Verify the position of the gasket material
If the sleeve / gate is misaligned, loosen the and the bottom of the housing and tighten
frame actuator bolts and / or adjust the yoke the installed U-bolts.
until the proper position, open and closed, 7. Tighten all U-bolt fasteners until the gasket
is obtained. is visually compressed.
11. If out of pipeline, reinstall the valve, refer
to Lifting, Section 15. WARNING!
Do not cap or close-off both ends of the
13 INSTALLATION INSTRUCTIONS FOR splash guard. This can result in valve failure.
SPLASH GUARD (B7 OPTION)
Note: it is normal for the KGA+ to discharge
1. Remove the splash guard, mounting media during opening and closing cycles.
hardware, and gasket from the valve crate. This helps prevent any solids from building up
Verify that the proper number of mounting between the sleeves that would prevent a tight
U-bolts, washers, nuts, along with the seal when the valve is fully open or closed.
guard, end cap, and gasket material are Discharge can be controlled with the use of an
present. optional splash guard or drain plate. Do not
2. Cut the gasket material into four pieces install valve over walkways, electrical or other
that will form the rectangular dimensions critical equipment without the use of splash
of the bottom of the valve if adhesive back guards, drain plates or similar considerations.
strip is used. If the gasket is cut from
sheet elastomer stock, ¼" (6.4 mm) thick 14 INSTALLATION INSTRUCTIONS FOR DRAIN
material is recommended. Material should PLATE (B9 OPTION)
be compatible with the slurry chemistry.
The material used for the retainer flanges 1. Using a wire brush / scraper, clean the
or sleeves will be suitable for the B7 gasket. bottom of the housing.
Other choices may be possible. Consult 2. Check the tapped mounting holes on the
the factory for recommendations. bottom of the valve. Remove any debris or
3. Clean the flat machined surface of the obstructions from the holes.
splash guard so that there is no dirt, grit, 3. Position gasket on drain plate and mount
grease, or other debris present. Remove to the valve using provided bolts and
the adhesive backing from the gasket lockwashers.
material and apply to the splash guard on 4. Connect drain piping (if used) to NPT port(s)
the machined flat mating surface (adhesive as required.
back strip). If a cut sheet gasket is used, it
should be attached to the splash guard with WARNING!
an RTV type adhesive compound to hold it Do not plug or close-off all ports on the drain
during installation. Attach gasket material plate. This can result in valve failure.
to the flat surface along the edge of the
machined slot.
FIGURE 15 FIGURE 16
Housing
Bracket
Hex nut
Gasket Lockwasher
Cap
(one only, do Splash guard
not cap both
ends)
U-bolt
16
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
17
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
Travel limit
Cap nut
Set screw
Handwheel
Thrust washer
Woodruff key
Adapter plate
Stem nut
Stem assembly
Frame (yoke)
End nut
Stem cover
Handwheel
Travel limit
Stem nut
Adapter plate
Stem assembly
Frame (yoke)
18
CLARKSON SLURRY KNIFE GATE VALVES
KGA+
Yoke (clevis)
Frame (yoke)
Yoke (clevis)
Frame (yoke)
19
CLARKSON SLURRY KNIFE GATE VALVES
KGA
1. The KGA is a packingless, slurry knife 1. Examine entire valve and report any
gate valve. All the sealing is accomplished damage or discrepancies immediately.
by the elastomeric sleeves in the valve 2. Sleeves: visually examine the sleeves
housing. The sleeves also form the wear interior, looking for chunking, irregularities
section for the valve. The gate is removable or other damage. It is not recommended you
for inspection or replacement while the remove the retainer flanges (if equipped).
valve is in service. 3. Retainer flanges: sizes NPS 8 (DN 200) and
2. The KGA is BIDIRECTIONAL below may or may not have the optional
(two-way shut-off) product and can be retainer flanges, retainer flanges are Operators
installed without concern over direction of standard on sizes NPS 10 (DN 250) and
flow. Since they will shut-off equally with larger. Visually examine the retainer flanges
in either direction, you will find no arrows surfaces, looking for tears, irregularities or
or other indicators of a direction of flow or other damage. Check tightness of retainer Retainer flanges
seat side. flange bolting.
3. Clarkson slurry knife gate valves are 4. Operators: standard manual handwheels
suitable for on-off service only. They are may be shipped loose for field installation,
not to be used in a throttling application. be sure to fully tighten.
Sleeves
4. The style, size, pressure rating and material 5. Valves are normally shipped with gate in
selection are the responsibility of the piping open position, the recommended position
system designer. for installation. Valves supplied with spring
5. All valves should be operated within the to extend (fail close) cylinder actuators are
design pressure and temperature ranges. shipped with the gate in the closed position.
Under no circumstances should the valves As the KGA should be installed with the gate
be operated at conditions outside these in the open position. Exercise caution when
parameters. Do not exceed 100% of the applying air to open this valve and then
maximum pressure rating of the valve at ensure that it is locked in the open position
any time during its operation. Pressure when installing in the line.
spikes beyond the valves pressure rating 6. Accessories: if provided, including
are solely the responsibility of the user. solenoids, limit switches, positioners,
etc., are tested for functionality prior to
shipment. Examine carefully for damage
which may occur during shipment.
20
CLARKSON SLURRY KNIFE GATE VALVES
KGA
21
CLARKSON SLURRY KNIFE GATE VALVES
KGA
NOTES
• Flange dimensions per ASME B16.5/150 for NPS 2 - 24 (DN 50 - 600) and MSS SP44 for NPS 26 - 60 (DN 650 - 1500).
• Type B standard washers are not included in bolt / stud sizing.
• Flange thickness from ASME B16.5/150 for NPS 2 - 24 (DN 50 - 600) and MSS SP44 for NPS 26 - 60 (DN 650 - 1500).
23 OPERATION
1. Clarkson slurry knife gate valves are 4. As the gate strokes, a gap is created
suitable for on-off service only. They are between the facing sleeves, allowing any
not to be used in a throttling application. media that could potentially clog or jam the
2. To close the valve and provide isolation, valve to be purged out from between the
the actuator (handwheel, bevel gear, sleeves, and potentially expelled outside
air/hydraulic cylinder or electric motor the valve housing to atmosphere.
actuator) moves the metal gate in a linear 5. The KGA valve incorporates a built-in
motion between the elastomeric sleeves clean-out area at the base of the housing
to shut off the flow. To open, reverse the assembly. The clean-out area may be
operation and the gate moves up and out enclosed by an optional, removable
from between the sleeves, opening the splash guard assembly. This splash guard
valve port. will allow controlled drainage of any
3. Matching elastomer sleeves seal against accumulated solids that may prevent full
each under a high compression load gate closure. Flush water can be used to
when the valve is open, creating the valve improve the drainage efficiency. With the
pressure vessel. When the valve is closed, splash guard in place, any solids, slurry, or
the sleeves seal against the gate face, flush water ejected from the valve can be
isolating upstream from downstream. handled in a controlled manner. See Section
See Figures 2 and 3. Installation instructions for splash guard.
Note: it is normal for the KGA to discharge 6. All valves should be operated within the
media during opening and closing cycles. design pressure and temperature ranges.
This helps prevent any solids from building Under no circumstances should the valves
up between the sleeves that would prevent be operated at conditions outside these
a tight seal when the valve is fully open or parameters.
closed. Discharge can be controlled with Note: actuated Clarkson valves have a
the use of an optional splash guard. Do not maximum recommend stroke speed of
install valve over walkways, electrical or 1 (25 mm) per second. Exceeding this
other critical equipment without the use of speed can shorten sleeve life and may
splash guards or similar considerations. void warranty. Speed controls provided by
factory will require adjustment in the field
to obtain proper stroke speed against actual
operating conditions.
22
CLARKSON SLURRY KNIFE GATE VALVES
KGA
B A
C A
B
C
F D E
7. The operator of any valve should have an 11. Electric motor actuated valves should be
understanding of the effects of opening/ left in their factory set condition, unless
closing the valve with regards to its role the system operating parameters dictate
in the overall piping system. Operators of a change. If changes are necessary, they
valves under pressure should take caution should be performed in small increments
to ensure that the valve is in good operating using the lightest/lowest setting possible
condition prior to operating it under to achieve the desired performance and
pressure. then the valve/actuator function inspected.
8. Certain processes contain hazardous and/or Excess torque and/or thrust in the motor
otherwise unstable media. Care should be settings may damage or lockup the valve.
taken in these circumstances to ensure the 12. Clarkson KGA valves are position seated and
operator is aware of the specific health and should never be torque seated. Do not use
safety risks associated with that medium. the motor torque settings to seat the valve.
9. When operating the valve stand clear of any 13. Care should be taken to ensure that
moving parts such as the stem and/or gate electrical motors are wired correctly to the
assembly, use of gloves is suggested when power source. Incorrect phasing of 3-phase
operating manual valves to minimize the wiring may cause valve/motor damage.
risk of injury.
10. All manually 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.
23
CLARKSON SLURRY KNIFE GATE VALVES
KGA
24
CLARKSON SLURRY KNIFE GATE VALVES
KGA
25
CLARKSON SLURRY KNIFE GATE VALVES
KGA
To maintain shelf -life, spare sleeves should be 3. If outdoor storage is required, the
stored in accordance with the following. equipment should be totally covered with
The shelflife listed is guideline data and is not a heavy, light colored, plastic covering. It
a substitute for examination of cured material is essential that the plastic be opaque to
at the time of intended use. eliminate sunlight, and light colored to
1. Store at ambient temperature up to 80°F minimize heat buildup. The covering should
(27°C), with 60 - 90% relative humidity away be spread in a manner that allows underside
from direct sunlight and at a minimum ventilation. To insure proper ventilation
distance of 15 feet (5 meters) away from the equipment should be elevated 2 - 4
electric motors is mandatory. (50 - 100 mm) above the ground.
2. Care must be taken to avoid storage in a 4. Manual actuated valves may be stored in
stressed condition such as piled too high or the vertical or horizontal position. For air
on a plain pallet overhanging a sharp edge. or hydraulic actuated valves, the preferred
3. First in - first out inventory control should orientation for optimum protection is with
be practiced. the valve fully opened and the cylinder in
4. The above elastomer shelf life guidelines the vertical position. This position gives
are for components that are not already the best support to the cylinder rod and
installed in a valve. helps reduces the chance of a flat spot
developing on the cylinder seals. An
Note: Emerson recommends customers always acceptable alternate position for valves with
use genuine Clarkson OEM sleeves, secondary cylinder diameters of less than 6 (150 mm)
seals and other replacement parts to maintain is with the cylinder in the horizontal position.
the expected, superior, performance of their Motor actuated valves should be oriented
KGA. Genuine Clarkson sleeves from Emerson in the direction as preferred by the actuator
are easily recognized by the laser etched manufacturer.
identifying marks found on the outside surface. 5. Valves with cylinder and motor actuators
These marks include the size, part number, should be stored in accordance with
applicable patent number, elastomer batch actuator manufacturers recommendations.
compound and date of manufacture; all of Access ports or panels should be secured
which allow complete traceability of the part. to prevent unauthorized entry and prevent
Clarkson replacement sleeves, wiper sets and contamination.
other parts from Emerson are the only ones 6. Where auxiliary equipment is included,
authorized for use and offer the best fit and such as limit switches, solenoid valves, etc.,
continued performance that non-OEM parts care must be taken to avoid moisture and
simply cannot give. The use of copycat parts condensation conditions on the equipment.
may invalidate any remaining warranty. If valve 7. Storage inspection: visual inspection shall
requires further repair, please contact our be performed on a semiannual basis and
office for an estimate of feasibility and cost results recorded. Inspection as a minimum
of repair. shall include reviewing the following:
- Packaging
27 STORAGE - Flange covers
- Dryness
The following are the factorys - Cleanliness
recommendations for storage procedures to 8. Maintenance shall consist of correcting
retain maximum product integrity during long deficiencies noted during inspection. All
term storage of 1 to 5 years. maintenance shall be recorded. Contact
1. Valves are normally shipped with gate in factory prior to performing any maintenance
open position, the recommended position if valve is still covered under warranty.
for storage. During storage, the gate should
always be in the open position. Storage CAUTION
should be in an area out of direct sunlight, Valves supplied with spring to extend (fail close)
away from heat, ozone and extreme weather cylinder actuators are shipped with the gate in
conditions. Freezing is not considered the closed position. DO NOT store a KGA with a
detrimental as long as the valve is kept spring to extend (fail close) in the open position.
dry. High voltage rectifiers and other ozone This would put the spring in a compressed,
generating equipment and sources should fully energized position. For storage, it is
not be near the storage area. recommended the valve sleeves be removed from
2. The preferred storage location is a clean, the valve housing and stored separately from the
dry protected warehouse. If valves are to valve. Reinsert sleeves prior to installation.
be stored outside, precautions should be
taken to keep valves clean and dry. Standard
packaging materials provided in valve
shipment cannot be considered sufficient
for outdoor storage.
26
CLARKSON SLURRY KNIFE GATE VALVES
KGA
27
CLARKSON SLURRY KNIFE GATE VALVES
KGA
CAUTION
Since this procedure may be performed with the
valve in an active pipeline, plant standard safety
procedures must be followed. Use of personal
protective equipment, tag out or other plant
standard safety procedures must be followed.
Procedure SHOULD NOT be done with valve in
closed position. If valve is removed for this service,
assure line is not pressurized before removing
valve. Valve assembly and parts may be heavy,
use proper lifting and support techniques, refer
to Lifting, Section 33.
28
CLARKSON SLURRY KNIFE GATE VALVES
KGA
29
CLARKSON SLURRY KNIFE GATE VALVES
KGA
6. Inspect the gate for sharp edges or Reassembly 7. Install new sleeves and retainer flanges
excessive damage. Some scoring will 1. Lay the first housing half face down on (if used) per Section 5 (one-piece retainers)
occur in normal use. If the gate has been a suitable flat surface. or 9 (segmented retainers), as applicable.
bent beyond 1/16 (1.5 mm) permanent 2. Fill lube cavities with approved lubricant. 8. Lift the valve assembly to vertical position,
deflection at the center, straighten or 3. Place spacers plates into position using refer to Lifting, Section 33.
replace. If straightening is performed, use match marks to properly align the spacer 9. Liberally coat the knife edge along the
a hydraulic press. Use considerable care to plates. entire knife area with approved lubricant.
minimize marks if a steel hammer is used. 4. Take second housing and fill lube cavities Position the gate between the frame resting
Use a belt sander to clean up score or other with approved lubricant. Place into position on the joint between the sleeves. Additional
distress marks. If the gate is straight but on the first housing, and properly align bolt support of gate may be required on larger
has scale buildup, a putty knife or gasket holes making sure spacer plates remain valves.
scraper should be used to remove scale. in place.
Inspect the gate for wear and roughness. 5. Insert most of the housing bolts, leaving
Use a disc grinder or belt sander to remove out the top bolts that are used to hold
rough surfaces. Take particular care on the the actuator assembly to the housing
leading and beveled edge to remove burrs and loosely tighten. Tap the edges of the
and other sharp edges. housings to align the internal sleeve bores
7. Examine frame for signs of corrosion, to within 1/16 (1.5 mm), at the same time
damage or other potential problems. maintaining bolt hole alignment in the
8. Examine actuator assembly. square flanges.
A) Manual valves: check stem for 6. Adjust spacer bars:
corrosion, straightness, etc. Look for For smaller valves where gate can be
signs of wear on brass stem nut. handled with relative ease:
B) Air or hydraulic: check for seal leaks 1. Slide the gate into position between
around cylinder rod seal, heads and the housing spacer bars.
caps. Examine cylinder rod for signs of 2. Tap the edge of the spacer bars to
corrosion, straightness, etc. Service per provide " (3 mm) total running
manufacturers instructions. clearance between the bars and the
C) Electric motor: service per edges of the gate. Remove gate when
manufacturers instructions. complete.
9. Check spacer plates for corrosion and For larger valves:
flatness. 1. Measure the width of the gate.
10. Check all bolting hardware for thread 2. Adjust the distance between the spacer
integrity, signs of corrosion, straightness, " (3 mm) greater than the gate width,
etc. Replace as required. parallel to housing square flanges and
an equal distance from the flange edges.
FIGURE 12
Gate
Wiper
Housing
Spacer bar
Sleeve
Retainer flange
Housing bolts
30
CLARKSON SLURRY KNIFE GATE VALVES
KGA
10. Press the gate into the valve housing 15. Rattle the gate. It should be mostly FIGURE 13
assembly until the mark drawn on the gate disengaged from the sleeves. The outboard
reaches the top of the retainer plate or edges of the gate should be free and the
gate reaches approximately dimension A, center still partially engaged in between
Table 5, Figure 13. the sleeves.
11. Reinstall the actuator / frame assembly 16. Cycle gate full closed and full open.
with the housing / frame fasteners loosely. 17. Install wipers and wiper retainers on each
12. Reconnect the gate to the actuator. (In order side of the gate.
to facilitate installation and future removal, 18. Inspect gate for pieces of rubber. If
a coating or anti-seize compound should be significant amount of rubber is present, a
applied to the outside of the clevis pin over sharp edge(s) on the gate may be causing
A
the yoke contact area). seal damage or the gate is extending too
13. 'Stretch' the frame / actuator assembly far on the up stroke. The ends of the gate
with respect to the housing by pulling (not should be free and the center still engaged.
lifting) the frame /actuator assembly to If the sleeve / gate is misaligned, loosen the
its maximum movement away from the frame actuator bolts and / or adjust the yoke B
housing assembly (holding housing in place until the proper position, open and closed, is
if valve is removed from pipeline). Tighten obtained.
the frame / housing bolts and verify the 19. If out of pipeline, reinstall the valve, refer to
tightness of the actuator to frame bolts. Lifting section.
14. Cycle valve to full open position and check
the gate position using the data in the
Table 5, Figure 13. Adjust as required.
Dimensional tolerance:
NPS 3 - 10 (DN 80 - 250) +/-1/16 (1.5 mm)
NPS 12 - 16 (DN 300 - 400) +/-3/32 (2.4 mm)
NPS 18 - 26 (DN 450 - 650) +/- (3 mm)
NPS 30 - 60 (DN 750 - 1500) +/-¼ (6 mm)
TABLE 5
Valve size A B
NPS DN inch mm inch mm
3 80 1.59 40.39 5.22 132.59
4 100 1.53 38.86 6.28 159.51
6 150 1.52 38.61 8.77 222.76
8 200 1.59 40.39 10.59 268.99
10 250 1.46 37.08 12.59 319.79
12 300 2.12 53.85 15.30 388.62
14 350 2.18 55.37 17.18 436.37
16 400 2.44 61.98 19.82 503.43
18 450 5.06 128.52 24.31 617.47
20 500 4.26 108.20 26.01 660.65
24 600 5.34 135.64 32.34 821.44
26 650 4.00 101.60 33.00 838.20
30 750 4.75 120.65 37.75 958.85
36 900 4.75 120.65 43.75 1111.25
42 1050 6.62 168.15 52.62 1336.55
48 1200 6.49 164.85 58.00 1473.20
54 1350 5.73 145.54 63.23 1606.04
60 1500 8.00 203.20 70.50 1790.70
31
CLARKSON SLURRY KNIFE GATE VALVES
KGA
32
CLARKSON SLURRY KNIFE GATE VALVES
KGA
13. Stretch the frame / actuator assembly 2. Cut the gasket material into four pieces Note: it is normal for the KGA to discharge
with respect to the housing by pulling (not that will form the rectangular dimensions media during opening and closing cycles.
lifting) the frame /actuator assembly to of the bottom of the valve if adhesive back This helps prevent any solids from building up
its maximum movement away from the strip is used. If the gasket is cut from between the sleeves that would prevent a tight
housing assembly (holding housing in place sheet elastomer stock, ¼" (6.4 mm) thick seal when the valve is fully open or closed.
if valve is removed from pipeline). Tighten material is recommended. Material should Discharge can be controlled with the use of an
the frame / housing bolts and verify the be compatible with the slurry chemistry. optional splash guard or drain plate. Do not
tightness of the actuator to frame bolts. The material used for the retainer flanges install valve over walkways, electrical or other
14. Cycle valve to full open position and check or sleeves will be suitable for the B7 gasket. critical equipment without the use of splash
the gate position using the data in the Other choices may be possible. Consult the guards, drain plates or similar considerations.
Table 5, Figure 13. Adjust as required. factory for recommendations.
15. Rattle the gate. It should be mostly 3. Clean the flat machined surface of the
disengaged from the sleeves. The outboard splash guard so that there is no dirt, grit,
edges of the gate should be free and the grease, or other debris present. Remove
center still partially engaged in between the adhesive backing from the gasket
the sleeves. material and apply to the splash guard on
16. Cycle gate full closed and full open. the machined flat mating surface (adhesive
17. Inspect wipers and wiper retainers, replace back strip). If a cut sheet gasket is used, it
as required (see Section 29). should be attached to the splash guard with
18. Inspect gate for pieces of rubber. If an RTV type adhesive compound to hold it
significant amount of rubber is present, a during installation. Attach gasket material
sharp edge(s) on the gate may be causing to the flat surface along the edge of the
seal damage or the gate is extending too machined slot.
far on the up stroke. The ends of the gate 4. Install the pipe cap on one end of the splash
should be free and the center still engaged. guard.
If the sleeve / gate is misaligned, loosen the 5. Position the guard below the valve and fit
frame actuator bolts and / or adjust the yoke a U-bolt on each end with the fasteners
until the proper position, open and closed, loosely attached.
is obtained. 6. Verify the position of the gasket material
19. If out of pipeline, reinstall the valve, refer and the bottom of the housing and tighten
to Lifting section. the installed U-bolts.
7. Tighten all U-bolt fasteners until the gasket
32 INSTALLATION INSTRUCTIONS FOR is visually compressed.
SPLASH GUARD (B7 OPTION)
WARNING!
1. Remove the splash guard, mounting Do not cap or close-off both ends of the splash
hardware, and gasket from the valve crate. guard. This can result in valve failure.
Verify that the proper number of mounting
U-bolts, washers, nuts, along with the
guard, end cap, and gasket material are
present.
FIGURE 15
Housing
Bracket
Hex nut
Gasket Lockwasher
Cap
(one only, do Splash guard
not cap both
ends)
U-bolt
33
CLARKSON SLURRY KNIFE GATE VALVES
KGA
34
CLARKSON SLURRY KNIFE GATE VALVES
KGA
Travel limit
Cap nut
Set screw
Handwheel
Thrust washer
Woodruff key
Adapter plate
Stem nut
Stem assembly
Frame (yoke)
End nut
Stem cover
Handwheel
Travel limit
Stem nut
Adapter plate
Stem assembly
Frame (yoke)
35
CLARKSON SLURRY KNIFE GATE VALVES
KGA
Yoke (clevis)
Frame (yoke)
Yoke (clevis)
Frame (yoke)
36
© 2017 Emerson. All rights reserved. 37