DeZurik KSL-SD Manuel utilisateur

DeZURIK, Inc. Sartell, Minnesota USA | Phone: 320-259-2000 | www.dezurik.com | i[email protected]

DeZURIK

2-24” (50-600mm) KSL-SD

SLURRY KNIFE GATE

VALVES

Instruction D11046

December 2021

DeZURIK

Instructions

These instructions are for use by personnel who are responsible for the installation, operation and

maintenance of DeZURIK valves, actuators or accessories.

Safety Messages

All safety messages in the instructions are identified by a general warning sign and the signal word CAUTION,

WARNING or DANGER. These messages indicate procedures to avoid injury or death.

Safety label(s) on the product indicate hazards that can cause injury or death. If a safety label becomes difficult

to see or read, or if a label has been removed, please contact DeZURIK for replacement label(s).

Personnel involved in the installation or maintenance of valves should be constantly alert to potential

emission of pipeline material and take appropriate safety precautions. Always wear suitable protection

when dealing with hazardous pipeline materials. Handle valves which have been removed from service

with suitable protection for any potential pipeline material in the valve.

Inspection

Your DeZURIK product has been packaged to provide protection during shipment; however, items can be

damaged in transport. Carefully inspect the unit for damage upon arrival and file a claim with the carrier if

damage is apparent.

Parts

Replaceable wear parts are listed on the assembly drawing. These parts can be stocked to minimize

downtime. Order parts from your local DeZURIK sales representative or directly from DeZURIK. When ordering

parts please provide the following information:

If the valve has a data plate: please include the 7-digit part number with either 4-digit revision number

(example: 9999999R000) or 8-digit serial number (example: S1900001) whichever is applicable. The

data plate will be attached to the valve assembly. Also, include the part name, the assembly drawing

number, the balloon number and the quantity stated on the assembly drawing.

If there isn't any data plate visible on the valve: please include valve model number, part name, and

item number from the assembly drawing. You may contact your local DeZURIK Representative to help

you identify your valve.

DeZURIK Service

DeZURIK service personnel are available to maintain and repair all DeZURIK products. DeZURIK also offers

customized training programs and consultation services. For more information, contact your local DeZURIK

sales representative or visit our website at DeZURIK.com.

DeZURIK

2—24” KSL-SD SLURRY KNIFE GATE VALVES

December 2021 Page 3 D11046

Table of Contents

Instructions........................................................................................................................................................2

Safety Messages...............................................................................................................................................2

Inspection..........................................................................................................................................................2

Parts..................................................................................................................................................................2

DeZURIK Service..............................................................................................................................................2

Description ........................................................................................................................................................4

Installation.........................................................................................................................................................4

Installation continued.........................................................................................................................................5

Gravity (Dry) Service Installation....................................................................................................................5

Operation ..........................................................................................................................................................5

Outdoor/Cold Service (below freezing)...........................................................................................................5

Lubrication (for Non-Dry Service Installations)...................................................................................................6

Adjustment ........................................................................................................................................................6

Drawings ...........................................................................................................................................................7

Top Seal Replacement......................................................................................................................................8

Installing the New Top Seal............................................................................................................................8

Sleeve Replacement .........................................................................................................................................9

Removing the Sleeves...................................................................................................................................9

Installing the New Sleeves.............................................................................................................................9

Storage and Shipping......................................................................................................................................10

Troubleshooting...............................................................................................................................................11

DeZURIK

2—24” KSL-SD SLURRY KNIFE GATE VALVES

December 2021 Page 4 D11046

Description

The KSL-SD is available in 2—24” (50-600mm) sizes, with a choice of several actuators and

accessories. The gate is removable for inspection or replacement while the valve is in an open position

during service.

Installation

Install the valve between ASME Class 125 or Class 150 pipeline flanges or other flanges that match the

valve end connection. The resilient sleeves seal against pipe flanges, and thus no flange gaskets are

required. Before installation, remove foreign material such as oil, grease, and dirt from the valve and

pipeline.

Observe the following points to prevent distortion of the

valve body and gate when the flange fasteners are

tightened.

1. Align the mating pipe flanges.

2. If using bolts, select the bolt length so that they

do not extend through the flange so far as to

interfere with the valve body.

3. Tighten the fasteners evenly, in a criss-cross

pattern. Refer to Table 1 for recommended

flange torque ranges.

Normal Installation

The valve is bi-directional, it can be installed in either

direction.

After installation, pressurize the pipeline and ensure the

valve does not leak in the full open and full closed

positions. The valve is fitted with a self-adjusting top seal

and therefore, no tightening is required.

It is the responsibility of the user to determine the final

torque values and the bolt, flange, and gasket selections,

as applicable, to ensure they are stressed within

acceptable limits.

WARNING

The suggested guidance for installation and bolt tensioning is advisory only, its use by

anyone is voluntary and users assume all risks. Care should be taken as any fattener

torque is only an indirect indication of tension and is affected by several variables outside

of DeZURIK’s control. Under/over tightening of fasteners can result in personal injury or

costly equipment failure such as, but not limited to flange leakage/damage, bolt failure,

gasket under/over compression, chest distortion/seat leakage, gate galling, inability to

stroke the gate as designed and other permanent gate and seat damage.

Table 1: Recommended Flange

Bolt/Stud Torque Ranges

Valve Size

Torque Range (ft-lbs)

2” (50 mm)

8 –9

3” (80 mm)

14 –16

4” (100 mm)

11 –12

6” (150 mm)

22 –24

8” (200 mm)

35 –39

10” (250 mm)

40 –44

12” (300 mm)

59 –65

14” (350 mm)

81 –89

16” (400 mm)

79 –87

18” (450 mm)

102 –112

20” (500 mm)

99 –109

24” (600 mm)

155 –171

DeZURIK

2—24” KSL-SD SLURRY KNIFE GATE VALVES

December 2021 Page 5 D11046

Installation continued

Gravity (Dry) Service Installation

As the valve is bi-directional, it can be installed in either direction in a vertical pipeline.

Before installation, ensure that the sleeves and gate are free from any grease or liquid type lubricants that might

contaminate the media.

Operation

The valve gate (A2) is positioned by the valve actuator. The actuator strokes the gate through the sleeves to the

closed position, flushing the valve in the process. In the closed position, the sleeves press up against the gate,

preventing flow and providing a drip-tight seal. In the open position, the sleeves press against each other to seal to

provide a drip-tight seal and allow the process media to flow with minimal disturbance. The top seal is designed to

prevent leakage from the top of the valve body during stroking.

Refer to the Actuator Instructions document for adjustment and maintenance requirements for the actuator.

Outdoor/Cold Service (below freezing)

For applications where the valve will be closed for an

extended period of time in freezing conditions, we

recommend heat tracing or blankets to ensure proper

sleeve operation when the valve is opened.

Table 2: Approved Lubricants

Silicone-Based Lubricant

Manufacturer

Recommended:

MOLYKOTE 111

Dow Corning

Approved Alternatives:

MOLYKOTE 44

Dow Corning

Sil Glyde

AGS Company

Chemplex 825

FUCHS

7 Release Compound

Dow Corning

G661

Novagard

CAUTION

The KSL

SD knife gate valve is designed to discharge media to atmosphere when

stroking to prevent solid build

up that may cause leakage. If installing over walkways,

electrical equipment or other equipment, ensure that proper precautions (such as the

installation and plumbing of the optional drain plate) are taken.

WARNING

Do not plug all ports on the drain plate. This can cause top seal failure.

DeZURIK

2—24” KSL-SD SLURRY KNIFE GATE VALVES

December 2021 Page 6 D11046

Lubrication (for Non-Dry Service Installations)

Lubrication is provided to the top seal and sleeves by four 1/8” grease fittings in the body of the valve. See Table

2 for a list of approved silicone based lubricants. See Table 3 for recommended lubrication intervals.

The top seal and sleeves should be lubricated during

inspection. Apply a thin coat of lubricant to the top seal

and sleeves

before installation. See the Top Seal Replacement and

Sleeve Replacement sections of this manual for

instructions.

•In between inspections, lubricate the valve

using the grease fittings on the body.

•Wipe the gate clean at regular intervals to

prolong the life of the top seal and sleeves.

Adjustment

The valve is fitted with a self-adjusting top seal and therefore, no tightening is required.

Table 3: Recommended Lubrication Intervals

Valve Size

Number of

Strokes

Quantity

Grease/ per

Fitting

2 –10” (50-250 mm)

100

50g

12 –24” (300-600 mm)

80g

DeZURIK

2—24” KSL-SD SLURRY KNIFE GATE VALVES

December 2021 Page 7 D11046

Drawings

(OPTIONAL)

Figure 1—Component Identification

A8) SCREW

(

A7) LOCK WASHER

(

A6) FLAT WASHER

(

A2) GATE

A1) BODY

(

A5) TOP SEAL PLATE

A4) TOP SEAL

(

A11) DRAIN PLATE

(

A10) GASKET

(

)

OPTIONAL

(

A9) GREASE FITTING

A14) SCREW

(

A13) LOCK WASHER

(

A12) FLAT WASHER

(

OPTIONAL

)

A14) SCREW

(

A13) LOCK WASHER

(

A12) FLAT WASHER

A8) SCREW

(

A7) LOCK WASHER

(

A6) FLAT WASHER

(

A3) SLEEVE

DeZURIK

2—24” KSL-SD SLURRY KNIFE GATE VALVES

December 2021 Page 8 D11046

Top Seal Replacement

The resilient molded top seal is designed to apply even sealing force to the top of the valve. The seal must be

replaced if it has been damaged or if it still leaks after it is fully tightened.

2. If the actuator is powered, disconnect the power source or ensure that it is properly locked out.

3. Remove the fasteners connecting the actuator clip to the gate. Remove the fasteners connecting the leg

to the body. Set aside.

4. Lift the gate straight up and set aside. Make sure there is no damage to the gate.

5. Remove the top fasteners (A6, A7, A8). Remove top seal plate (A5) and set aside for re-use. Remove the

top seal (A4).

Installing the New Top Seal

1. Visually inspect the top seal for any wear or cracking. Apply a liberal amount of approved lubricant (see

Table 2: Approved Lubricants) to the inside ribbed surfaces of the top seal (A4). For dry service

application, no lubricant can be used.

2. Place the top seal (A4) so that the bottom surface (rounded edges) is in contact with the top of the valve

body (A1) and the TOP marking is visible when assembled. For dry service application, a top seal is not

required.

3. Inspect the gate for sharp edges and check the surface of the gate for any damage. If damage is present,

go to “Replacing the Gate” section.

4. Apply silicone lubricant to the leading edge faces of the gate (A2). For dry service application, no lubricant

can be used.

5. Place the gate (A2) into the top seal (A4) and carefully slide it down into the body. Avoid cutting the

rubber.

6. Place the top seal plate (A5) on the top seal (A4) and then tighten the top seal fasteners (A6, A7, A8). Do

not over tighten.

7. Reattach the actuator clip to the gate (A2) and the leg to the body with body fasteners.

8. Tighten the fasteners.

Removing the Top Seal

Ensure the gate (A2) is fully open.

WARNING!

Pipeline pressure can cause personal injury or equipment damage. The top seal

can be replace with the pipeline pressurized with the gate removed.

WARNING!

Accidental operation of power actuator can cause personal injury or equipment

damage. Disconnect and lock out power to actuator before servicing.

WARNING!

Regardless of valve orientation, EXTREME caution should be practiced to handle

and service the gate when replacing the top seal.

DeZURIK

2—24” KSL-SD SLURRY KNIFE GATE VALVES

December 2021 Page 9 D11046

Sleeve Replacement

The sleeves provide a drip-tight seal when the valve is closed. If either sleeve is to be replaced,

the valve must be removed from service.

Removing the Sleeves

WARNING!

Accidental operation of power actuator can cause personal injury or equipment

damage. Disconnect and lock out power to actuator before servicing.

2. Ensure the gate (A2) is fully open.

3. If the actuator is powered, ensure the actuator is properly locked out.

4. Remove the valve from the pipeline.

5. Pull the sleeves (A3) out of the body (A1).

Inspect the sleeves (A3) for damage or excessive wear. If either is present, replace the sleeves.

Installing the New Sleeves

1. Check the gate and body to ensure there is no damage or sharp edges.

2. Apply approved lubricant to the surfaces of each sleeve (A3) that will contact each other after they

are installed into the body. Also apply a thin coating of the same lubricant to the outside diameters

that will contact the valve body (A1) bores. For dry service application, no lubricant can be used.

3. With the gate in the open position (fully retracted), place the sleeves (A3) into the valve body bore

and press into place from each side. It is recommended the valve be placed in a stand so that the

two sleeves are equally inserted into the body (A1).

4. Reinstall the valve into the pipeline following the specifications in the Installation section.

5. If the actuator is powered, remove lock out or reconnect the power.

Relieve the pressure in the pipeline.

WARNING!

Pipeline pressure can cause personal injury or equipment damage. Relieve

pipeline pressure before servicing.

DeZURIK

2—24” KSL- SD SLURRY KNIFE GATE VALVES

December 2021 Page 10 D11046

Storage and Shipping

All KSL-SD valves are shipped in the open position. This is also the recommended position for

installation and storage.

•The valve should be stored away from direct sunlight, excessive heat, and extreme weather conditions

to prevent premature deterioration of the resilient components.

•If possible, store the valve in the vertical position. Manually actuated valves may be stored horizontally

if necessary.

•Always inspect the valve after being removed from storage for damage to the flanged surfaces, sealing

sleeves, gate, sleeve retainer (if equipped), top seal, or actuator. Inspect the valve on a regular basis

while in storage to ensure the valve components have not deteriorated.

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