DeZurik KGC-MC Bedienungsanleitung

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

DeZURIK

KGC-MC METAL CUTTING

KNIFE GATE VALVES

Instruction D11060

November 2020

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 
KGC-MC METAL CUTTING KNIFE GATE VALVES 
 
November 2020 Page 3 D11060 
Table of Contents 
 Description................................................................................................................................................................... 4 
Handling....................................................................................................................................................................... 4 
Installation.................................................................................................................................................................... 6 
Cyclone or Gravity (Dry) Service Installations...........................................................................................6 
Other Installations.....................................................................................................................................6 
General Guidelines...................................................................................................................................6 
Operation..................................................................................................................................................................... 7 
Lubrication................................................................................................................................................................... 7 
Packing......................................................................................................................................................................... 7 
Adjustment................................................................................................................................................................... 7 
Drawings...................................................................................................................................................................... 8 
Packing Replacement................................................................................................................................................ 9 
Removing the Old Packing........................................................................................................................9 
Installing the New Packing......................................................................................................................10 
Reassembling Valve...............................................................................................................................11 
Seat Replacement.................................................................................................................................................... 11 
Reassembling the Valve .........................................................................................................................12 
Replacing the Gate................................................................................................................................................... 12 
Replacing the Clip.................................................................................................................................................... 13 
Purge Port Option..................................................................................................................................................... 14 
Troubleshooting........................................................................................................................................................ 16 
 
 

DeZURIK

KGC-MC METAL CUTTING KNIFE GATE VALVES

D11060 Page 4 November 2020

Description

KGC-MC metal cutting knife gate valves have a stainless steel body and gate, and an all-metal or

metal/resilient seat. The KGC-MC metal cutting knife gate valve is available in 3-24" sizes.

Handling

WARNING!

A potential hazard exists with handling valves. Failure to handle valves properly

may cause a valve to shift, slip or fall causing serious injury or death and/or

equipment damage.

The points below are for reference purposes only, use safe and proper lifting and support

techniques. DO NOT lift valves with any adjoining pipe or other equipment attached. Lift with

properly rated lifting equipment. Follow jurisdictional safety requirements.

Suggested lifting points are as shown below to lift valve assemblies that are in a horizontal orientation.

Eye bolts in flange through holes can be used to lift the valve body or, for 3” through 12” valves, a

sling can be strapped around the top of the valve body.

For valves with pneumatic cylinder actuators, a sling can be wrapped around the cylinder, near the

cylinder head (piston rod end). This would be in conjunction with lifting from the valve body. Utilize

caution to not bump, dent or damage the cylinder tube. DO NOT utilize the cylinder tie-rod ends to lift.

See Figure 1.

Figure 1 - Knife Gate Valve with Pneumatic Cylinder Actuator,

Horizontal Lifting

DeZURIK

KGC-MC METAL CUTTING KNIFE GATE VALVES

November 2020 Page 5 D11060

Handling continued

Suggested lifting option is as shown below to lift valve assemblies that are in a vertical orientation.

For valves with pneumatic cylinder actuators, wrap slings around the top of each leg. Use caution

to not bump, dent or damage the cylinder tube and avoid any side load on the cylinder piston rod.

DO NOT utilize the cylinder tie-rod ends to lift. See Figure 2.

Figure 2 - Knife Gate Valve with Pneumatic Cylinder Actuator,

Vertical Lifting

DeZURIK

KGC-MC METAL CUTTING KNIFE GATE VALVES

D11060 Page 6 November 2020

Installation

Install the valve between ASME Class 125 or Class 150

pipeline flanges, or other flanges that match valve end

connection. Flange gaskets are required. Before installation,

remove foreign material such as weld spatter, oil, grease, and

dirt from the valve and pipeline.

Cyclone or Gravity (Dry) Service Installations

When installing the valve in a vertical pipeline (such as a

cyclone hopper bottom, gravity flow, or other dry service

application), install the “SEAT” side of the valve facing

upstream as shown in Figure 3. Installing the valves with the

seat side upstream prevents process media buildup in the

seat and chest area of the valve. This orientation also allows

the seat to act as an integral deflection cone, protecting the

seat from wear.

Other Installations

Install the valve so that the side marked “SEAT” is on

the lower pressure side of the valve when the valve is

closed; the pipeline pressure will then help seal the

valve in the closed position.

General Guidelines

Observe the following points to prevent distortion of

the valve body and gate when the flange bolts are

tightened:

•

Align the mating pipeline flanges.

•

Select the length of the flange bolts so that the

bolts used in the blind holes near the chest

areaof the valve do not bottom out when

tightened. We recommend using studs with

nuts in the blind holes.

•

Tighten the flange bolts evenly, in a crisscross

pattern. Refer to Table A for recommended

flange bolt/stud torques.

Note: All DeZURIK Recommended Torque values

may vary according to process conditions,

environment and type of lubricant used. Lubricated

torque values are 65% of dry values.

DO NOT over torque the flange bolts. This could

result in distortion of the chest, leading to seat

leakage, gate galling and inability to stroke the gate,

further leading to permanent gate and seat damage.

Table A: Recommended Flange Bolt/Stud

Torque Range in ft-lbs (non-lubricated)

Figure 3 - Vertical Line/

Hopper Bottom

Valve Size

ASME Gasket Types

Rubber with

Soft Fabric

Filler, & 1/8”

Thick Hard

Soft Elastomer

Gasket Shore

Durometer <

75A

3” (80mm)

37 - 41

14 - 16

4” (100mm)

26 - 29

11 - 12

5” (125mm)

41 - 45

22 - 24

6” (150mm)

41 - 45

22 - 24

8” (200mm)

55 - 61

35 - 39

10” (250mm)

56 - 62

40 - 44

12” (300mm)

80 - 88

59 - 65

14” (350mm)

107 - 118

81 - 89

16” (400mm)

103 - 114

79 - 87

18” (450mm)

128 - 141

102 - 112

20” (500mm)

123 - 136

99 - 109

24” (600mm)

188 - 207

155 - 171

DeZURIK

KGC-MC METAL CUTTING KNIFE GATE VALVES

November 2020 Page 7 D11060

Installation continued

Note: The packing gland is slightly loosened prior to shipping. This is done to increase the life of the

packing during extended storage.

After installing the valve, pressurize pipeline and ensure the packing is not leaking. If the packing leaks,

adjust the packing as described below.

Operation

The gate in the valve is positioned by the valve actuator. The actuator moves the gate over the valve port

in the closed position, and withdraws the gate from the port in the open position. Refer to the Actuator

Instructions for adjustment and maintenance requirements for the actuator.

Lubrication

The valve does not require lubrication. If applicable, ensure that valve threaded stems are maintained

with proper lubrication. Refer to the Actuator Instructions for lubrication requirements for the actuator.

Packing

The gate packing is contained and compressed by the packing gland. See Figure 4 for component

identification.

Adjustment

If packing leaks, tighten the adjustment nuts on top of the packing gland. Tighten the nuts equally and

gently just enough to stop the leak. Over tightening will cause excessive operating forces, and will

decrease the life of the packing.

DeZURIK

KGC-MC METAL CUTTING KNIFE GATE VALVES

D11060 Page 8 November 2020

Drawings

Figure 4 - Component Identification

DeZURIK

KGC-MC METAL CUTTING KNIFE GATE VALVES

November 2020 Page 9 D11060

Packing Replacement

Removing the Old Packing

WARNING!

Pipeline pressure can cause personal injury or equipment damage. Relieve pipe-

line pressure before removing gate stem and packing gland nuts.

1. Relieve the pressure in the pipeline and close the valve.

WARNING!

Accidental operation of power actuator can cause personal injury or

equipment damage. Disconnect and lock out power to actuator before

servicing.

2. If the actuator is powered, disconnect and lock out power to prevent accidental operation of the

actuator.

3. Remove the two screws and nuts near the top of the gate and disengage the stem from the gate

by stroking the actuator (not the valve) to the open position.

4. Remove the gland nuts (A7), screws (A5) and packing gland (A4).

5. Remove the used scraper rings (A2) and packing (A8) from the packing chamber.

DeZURIK

KGC-MC METAL CUTTING KNIFE GATE VALVES

D11060 Page 10 November 2020

Installing the New Packing

The CW2 packing option scraper ring

(A2) and packing (A8) ring length and

quantity are shown in Table B.

DeZURIK provides extra packing in the

packing kit, but do not try to put more

packing into a layer than shown in

Table B. If packing for low pressure

applications (<40 psi [276 kpa]),

contact DeZURIK.

1. Ensure the gate (A3) is fully closed

and centered in the body before

packing.

2. Assemble and pack the rings one at a

time, with the ends together, but not

overlapped. Ensure the inside and

outside edges of each ring are

packed against the gate and packing

chamber, so that each ring is

compressed flat and evenly.

Note:Stagger the joints, on the long side

of the packing chamber. To pack the

rings, we recommend using a square-

ended wood or plastic tool, driven by a

hammer or mallet. DO NOT use a sharp

tool to pack the rings.

Table B: Packing Rings and Scraper Rings

Length and Quantity

a. Place scraper ring (A2) in the bottom of the packing chamber.

b. Assemble and pack two rows of packing (A8).

c. Assemble and pack the last row of scraper ring (A2). See Figure 5 for packing detail:

Figure 5 - Packing Detail

Valve Size

Square

Size

Length

No. of

Scraper

Rings

No. of

Packing

Rings

in.

mm.

3/8

9.50

75mm

242

11.50

100mm

293

5”

13.50

125mm

343

9.5

15.50

150mm

394

20.00

200mm

508

10"

1/2

25.00

250mm

635

12"

29.00

300mm

737

14"

12.7

32.00

350mm

813

16"

36.75

400mm

934

18"

5/8

41.25

450mm

1048

20"

45.25

500mm

15.9

1150

24"

53.50

600mm

1359

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