ITT Engineered Valves CU27 User manual

Installation, Operation, and
Maintenance Manual
CU27 Uni-Directional and CB27 Bi-Directional
Knife Gate Valve

Table of Contents
1 Introduction and Safety ....................................................................................................................................2
1.1 Safety message levels .............................................................................................................................. 2
1.2 User health and safety .............................................................................................................................. 2
2 Transportation and Storage.............................................................................................................................. 4
2.1 Handling and unpacking guidelines........................................................................................................... 4
2.2 Storage, disposal, and return requirements ..............................................................................................4
2.3 Lifting the valve ......................................................................................................................................... 5
3 Product Description ..........................................................................................................................................7
3.1 CU27 uni-directional valve ........................................................................................................................ 7
3.1.1 General description .........................................................................................................................7
3.1.2 General diagram .............................................................................................................................8
3.2 CB27 bi-directional valve........................................................................................................................... 9
3.2.1 General description .........................................................................................................................9
3.2.2 General diagram ...........................................................................................................................10
4 Installation........................................................................................................................................................ 11
4.1 Preinstallation.......................................................................................................................................... 11
4.2 Installing the valve...................................................................................................................................12
4.3 Piping Installation ....................................................................................................................................13
5 Operation..........................................................................................................................................................15
5.1 Range of operators.................................................................................................................................. 15
6 Maintenance.....................................................................................................................................................16
6.1 Precautions ............................................................................................................................................. 16
6.2 Inspection ................................................................................................................................................ 16
6.2.1 Visual inspection ........................................................................................................................... 16
6.3 Lubrication...............................................................................................................................................16
6.3.1 Stem lubrication ............................................................................................................................16
6.3.2 CB27 seat lubrication ....................................................................................................................16
6.4 Repack the stuffing box ..........................................................................................................................17
6.5 Replace the seats.................................................................................................................................... 17
Table of Contents
CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual 1

1 Introduction and Safety
1.1 Safety message levels
Definitions
Safety message level Indication
DANGER:
A hazardous situation which, if not avoided, will result in death or
serious injury
WARNING:
A hazardous situation which, if not avoided, could result in death
or serious injury
CAUTION:
A hazardous situation which, if not avoided, could result in minor
or moderate injury
ELECTRICAL
HAZARD:
The possibility of electrical risks if instructions are not followed in a
proper manner
NOTICE:
• A potential situation which, if not avoided, could result in an
undesirable result or state
•A practice not related to personal injury
1.2 User health and safety
General precautions
This product is designed and manufactured using good workmanship and materials, and meets all appli-
cable industry standards. This product should be used only as recommended by ITT.
WARNING:
•Misapplication of the valve can result in injury or property damage. Select valves and
valve components of the proper materials and make sure that they are consistent with
your specific performance requirements. Incorrect application of this product includes but
is not limited to:
• Exceeding the pressure or temperature rating
• Failing to maintain this product according to the recommendations
• Using this product to contain or control media that is incompatible with the materials
of construction
Qualifications and training
The personnel responsible for the assembly, operation, inspection, and maintenance of the valve must
be appropriately qualified. The operating company must do the following tasks:
• Define the responsibilities and competency of all personnel handling this equipment.
• Provide instruction and training.
1 Introduction and Safety
2 CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual

• Ensure that the contents of the operating instructions have been fully understood by the personnel.
Instruction and training can be carried out by either ITT or the reseller of the valve by order of the operat-
ing company
Non-compliance risks
Failure to comply with all safety precautions can result in the following conditions:
• Death or serious injury due to electrical, mechanical, and chemical influences
• Environmental damage due to the leakage of dangerous materials
• Product damage
• Property damage
• Loss of all claims for damages
Operational safety precautions
Be aware of these safety precautions when operating this product:
• Do not leave hot or cold components of the product unsecured against contact if they are a source
of danger.
• Do not remove the contact guard for moving parts when the product is in operation. Never operate
the product without the contact guard installed.
• Do not hang items from the product. Any accessories must be firmly or permanently attached.
• Do not use the product as a step or hand hold.
• Do not paint over the identification tag, warnings, notices, or other identification marks associated
with the product.
Maintenance safety precautions
Be aware of these safety precautions when performing maintenance on this product:
• You must decontaminate the product if it has been exposed to harmful substances such as caustic
chemicals.
• You must use the appropriate lock-out procedures to isolate the valve from all power sources be-
fore performing maintenance on externally actuated valves.
• Upon completion of work, all safety and protective equipment must immediately be fitted again or
reactivated.
Use of unauthorized parts
Reconstruction or modification of the product is only permissible after consultation with ITT. Genuine
spare parts and accessories authorized by ITT serve to maintain safety. Use of non-genuine ITT parts
can annul liability of the manufacturer for the consequences. ITT parts are not to be used in conjunction
with products not supplied by ITT as this improper use can annul all liability for the consequences.
Unacceptable modes of operation
The operational reliability of this product is only guaranteed when it is used as designated. The operating
limits given on the identification tag and in the data sheet may not be exceeded under any circumstan-
ces. If the identification tag is missing or worn, contact for specific instructions.
1.2 User health and safety
CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual 3

2 Transportation and Storage
2.1 Handling and unpacking guidelines
CAUTION:
Always observe the applicable standards and regulations regarding the prevention of accidents
when handling the product.
Handling guidelines
Follow these guidelines when handling the product to prevent damage:
•Use care when handling the product.
• Leave protective caps and covers on the product until installation.
Unpacking guidelines
Follow these guidelines when unpacking the product:
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, file a claim with the shipping company.
4. Do not lift or pull on the electrical conduit lines. Doing so may cause the POC switches to come
out of calibration.
2.2 Storage, disposal, and return requirements
Storage
The package is designed to protect the valve only during shipping. If you are not installing the valve im-
mediately after delivery, then you must store it according to these requirements.
Table 1: Storage period
This table describes requirements for short-term and long-term valve storage.
Storage period Requirements
Less than 6
months
• Do not expose the valve to direct sunlight.
•Do not expose the valve to weather conditions.
• Do not expose the valve to temperature extremes.
• Do not stack the valves on top of each other.
• Make sure the gate is in the full-open position.
More than 6
months
• Store in accordance with the short-term action items.
•Store in accordance with ITT's Long Term Storage Procedure. Contact ITT to obtain this
procedure.
Storage of rubber components
As rubbers possess varying degrees of resistance to deteriorating influences which may be present dur-
ing storage, they should be stored in a cool, dry, dark place away from sunlight, extreme weather etc.
Rubber components should be supported under undue stress from loading or bending. Seals in assem-
bled valves and actuators should be positioned to minimize compression on the seals.
2 Transportation and Storage
4 CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual

The shelf life for different rubbers as mentioned in below is guideline data and is not substitute for exami-
nation of cured material at the time of intended use.
Aflas: 4 years
Natural Rubber: 2 Years
EPDM / NBR: 4 Years
Disposal
Dispose of this product and associated components in compliance with federal, state, and local regula-
tions.
Return
Ensure these requirements are met before you return a product to :
• Contact for specific instructions on how to return the product.
• Clean the valve of all hazardous material.
• Complete a Material Safety Data Sheet or Process Data Sheet for any process fluid that could re-
main on the valve.
• Obtain a Return Material Authorization from the factory.
2.3 Lifting the valve
WARNING:
•When handling the products it is mandatory to observe the applicable standards and reg-
ulations regarding the prevention of accidents.
• Never tamper with the fasteners on the cylinder. Serious injury could result if the nuts on
the cylinder tie rods are either tightened or loosened.
• DO NOT attach lifting gear to the valve handwheel, gear operator, or gate guards (if pro-
vided).
• DO NOT lift the valve using the seat bore area. This could cause damage to the seating
surfaces and seals.
• DO NOT remove protective caps and covers on the product until installation.
CAUTION:
•Personal injury or valve damage could occur if the valve is lifted by any part of the bevel
gear assembly. The bevel gear assembly is not designed to support the weight of the
valve.
• One person should not attempt to lift cylinder-operated valves larger than 15.24 cm | 6.00
in. or handwheel-operated valves larger than 30.48 cm | 12.00 in.
• Use lifting equipment rated for the weight of the valve assembly.
• Do not lift the valve by the handwheel.
1. To lift larger valves, loop a lifting strap around the body. Raise the valve into a vertical position.
2. Lifting procedure:
When using lifting gear to move the valve, it should be supported by two or more eyebolts screwed
into the tapped holes in the valve body for large sizes.
2.3 Lifting the valve
CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual 5

Loop the lifting scrap under the support plate for handwheel operated and bevel gear operated
valves by ensuring the lifting straps do not tighten against any part of the valve.
For the cylinder operated valves it is advised to lift the valves using the two opposite tie rods located
above the bottom plates by using lifting eyes.
3. Slowly take up the slack in the lifting straps to ensure that the straps are clear and not binding
against the valve or valve top-works.
WARNING:
Do not adjust or remove the cylinder nuts. Cylinder failure may result from improperly tightened
fasteners.
2.3 Lifting the valve
6 CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual

3 Product Description
3.1 CU27 uni-directional valve
3.1.1 General description
The CU27 is a uni-directional knife gate valve whereas the line pressure assists the closing of the valve
by pushing the gate against the integral metal seat in the body. The valve has a range of application in
Pulp and Paper, Water and Wastewater, and General Industry. These valves may be supplied with man-
ual handwheels, bevel gear operators and pneumatic cylinder actuators. The CU27 is designed accord-
ing to the MSS SP-81 standard. it is supplied with PTFE impregnated synthetic fiber packing in the body
chest which can be tightened to stop a packing leak. The valve should be installed with consideration of
the flow direction and seat arrow cast into the valve body.
3 Product Description
CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual 7

3.1.2 General diagram
Body
Seat
Gate
Gland Packing
Gland
Stem
Support Plate
Thrust Washer
Stem Nut
Parallel Key
Thrust Washer
Hand Wheel
Lock Nut
Seat
Retainer Ring
Figure 1: CU27
3.1 CU27 uni-directional valve
8 CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual

3.2 CB27 bi-directional valve
3.2.1 General description
The CB27 is a bi-directional knife gate valve using a perimeter seating design with single-piece design
for sizes 2" to 20" (DN50 to DN500) and two-piece design for sizes above 20" (> DN500). The perimeter
seat design provides bi-directional shut off regardless of line pressure. The body seals are designed to
be field replaceable. These valves may be supplied with manual handwheels, bevel gear operators and
pneumatic cylinder actuators. The CB27 is designed according to the MSS SP-81 standard. The CB27 is
supplied with PTFE impregnated synthetic fiber packing in the body chest which can be tightened to stop
a packing leak.
3.2 CB27 bi-directional valve
CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual 9

3.2.2 General diagram
Seat
Gate
Body
Scrapper
Gland Packing
Gland
Support Plate
Hand Wheel
Stem
Stem Nut
Thrust Washer
Thrust Washer
Parallel Key
Figure 2: CB27
3.2 CB27 bi-directional valve
10 CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual

4 Installation
4.1 Preinstallation
Precautions
WARNING:
•Air cylinders, when provided, are sized for a specified input pressure. Excessive pressure
could result in serious personal injury or may cause damage to the valve and cylinder. Air
regulators and air filters are available from ITT or your authorized ITT distributor.
• All procedures must be performed by qualified personnel.
• Always wear protective clothing and equipment to safeguard the eyes, face, hands, skin,
and lungs from the fluid in the line.
NOTICE:
• Weld any flanges or pipelines before you install the valves. If this is impossible, protect
the valve from excessive heat.
• Remove all weld slag, rods, debris, and tools from the pipeline before valves are installed
or cycled.
• Always use studs in tapped holes to ensure full thread engagement of flange fasteners.
• Do not over-tighten a machine bolt that has bottomed out. Valve damage may result, pre-
venting proper operation.
• Always use appropriate fasteners for the service, in compliance with applicable piping co-
des and standards.
Recommended fasteners
Table 2: Recommended fasteners and torques for CU27
Valve
Size
Face
to
Face
Flange
OD
Bolt
Circle
PCD
No.of
Holes
(each side)
Tapped
Holes in
valve chest
Thru
Tapped
Holes
Fastener
Thread Size
Max Depth
tapped holes
in chest
(Fig 1)
Max allowa-
ble fastener
torque
IN DN A OD P N T1 T2 F1 T (ft.lb.)
2" 50 1.89 5.91 4.74 4 2 2 5/8" - 11 UNC 0.31 43
3" 80 2.00 7.48 6.00 4 2 2 5/8" - 11 UNC 0.34 43
4" 100 2.00 9.06 7.50 8 2 6 5/8" - 11 UNC 0.34 43
6" 150 2.25 11.02 9.51 8 2 6 3/4" - 10 UNC 0.41 51
8" 200 2.75 13.58 11.75 8 2 6 3/4" - 10 UNC 0.47 51
10" 250 2.75 15.94 14.25 12 4 8 7/8" - 09 UNC 0.47 80
12" 300 3.00 19.09 17.01 12 4 8 7/8" - 09 UNC 0.47 80
14" 350 3.00 21.06 18.74 12 4 8 1" - 8 UNC 0.59 108
16" 400 3.50 23.62 21.26 16 6 10 1" - 8 UNC 0.59 108
18" 450 3.50 25.00 22.76 16 6 10 1.1/8" - 8 UN 0.59 137
20" 500 4.50 27.56 25.00 20 8 12 1.1/8" - 8 UN 0.87 137
24" 600 4.50 32.09 29.51 20 8 12 1.1/4" - 8 UN 0.87 166
4 Installation
CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual 11

Table 3: Recommended fasteners and torques for CB27
Valve
Size
Face
to
Face
Flange
OD
Bolt
Circle
PCD
No.of
Holes
(each side)
Tapped
Holes
in
valve
chest
Thru Tapped
Holes
Fastener
Thread Size
Max Depth
tapped holes
in chest
(Fig 1)
Max allowa-
ble fastener
torque
IN DN A OD P N T1 T2 F1 T (ft.lb.)
2" 50 1.89 5.91 4.74 4 2 2 5/8" - 11 UNC 0.20 43
3" 80 2.00 7.48 6.00 4 2 2 5/8" - 11 UNC 0.20 43
4" 100 2.00 9.06 7.50 8 2 6 5/8" - 11 UNC 0.27 43
6" 150 2.25 11.02 9.51 8 2 6 3/4" - 10 UNC 0.39 51
8" 200 2.75 13.58 11.75 8 4 4 3/4" - 10 UNC 0.47 51
10" 250 2.75 15.94 14.25 12 4 8 7/8" - 09 UNC 0.47 80
12" 300 3.00 19.09 17.01 12 4 8 7/8" - 09 UNC 0.47 80
14" 350 3.00 21.06 18.74 12 4 8 1" - 8 UNC 0.59 108
16" 400 3.50 23.62 21.26 16 6 10 1" - 8 UNC 0.59 108
18" 450 3.50 25.00 22.76 16 6 10 1.1/8" - 8 UN 0.59 137
20" 500 4.50 27.56 25.00 20 8 12 1.1/8" - 8 UN 0.78 137
24" 600 4.50 32.09 29.51 20 8 12 1.1/4" - 8 UN 0.78 166
Figure 3: Max depth tapped holes in chest
4.2 Installing the valve
General Guidelines
•Handling and maintenance in charge of the valve must be qualified and trained in valve operations.
• Use appropriate personal protection equipment (Gloves, safety shoes, etc.).
• Shut off all operating lines to the valve and place a warning sign. Isolate the valve completely from
the process.
• Release process pressure.
• Drain the process fluid from the valve and insert the open-closed lockout (if the valve has it).
• Before installation, inspect the valve body and components for any damage that may have occurred
during shipping or storage.
• Make sure the internal cavities within the valve body are clean.
• Inspect the pipeline and mating flanges, making sure the pipe is free of foreign material and that the
flanges are clean.
CU27 Installation
As the CU27 valve is uni-directional (shuts off in one direction only), the shut off direction of the process
must be considered during the installation. The arrow indicated on the valve body represents the
4.2 Installing the valve
12 CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual

direction of shutoff of the process fluid. Installation and correct orientation with respect to the shut off di-
rection is the responsibility of the user.
PRESSUREPRESSURE
SEAT SIDE
SEAT SIDE
Figure 4:
Refer to Table 2: Recommended fasteners and torques for CU27 on page 11.
CB27 Installation
As the CB27 valve is bi-directional (shuts off in both directions), it permits installation without considering
the flow direction. Install the valve in the fully open position only. Special care should be taken to main-
tain the correct distance between the flanges and to ensure that they are parallel to the valve body. Incor-
rect alignment of the valve can cause body deformation, which can lead to difficulties in operation. Refer
to Table 3: Recommended fasteners and torques for CB27 on page 12.
4.3 Piping Installation
The valve can be mounted in any position with regard to the pipe. However, it is advisable to place it
vertically in a horizontal pipeline if the installation allows it. With larger diameter valves (> 12" mm),
valves with heavy actuators (pneumatic, electric, etc.), or with the valve installed horizontally or at an an-
gle on a horizontal pipeline, the installation will require the construction of suitable supports. See Figure
below and consult the technical department at ITT. * For these positions please consult ITT Engineered
Valves.
4.3 Piping Installation
CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual 13

1
2
2
33
1*
3*
3*
Installation Check
Once the valve is installed, verify that the flanges have been fastened correctly and that all electrical
and / or pneumatic connections have been properly made. Where electric accessories are mounted on
the valve (i.e. solenoid valves, limit switches, positioners, etc.) the corresponding grounding connections
must be made before it is put into operation. The operation of automated valves is limited only with fitted
gate covers.
Valves should be initially operated without any flow in the pipeline. Then, operation of the valve and seal
can be tested with the flow in pipeline. It should be noted that the packing material might be loosened
during shipping and storage, which can cause minor packing leakage. This can be corrected by tighten-
ing the gland. The gland nuts shall be tightened gradually in a crosswise direction until the leakage
stops. See below table for fastener torques.
Valve Size Torque (ft.-lb.)
2" - 4" 15
6" - 8" 22
10" - 24" 26
Figure 5: Fastener torques
Check that there is no metal contact between the gland follower and the gate. If the gland follower nuts
are tightened too hard the force needed to operate the valve will increase, the valve function will be af-
fected and the packing life could be shortened. Once performance has been tested, the valve can be put
into operation.
4.3 Piping Installation
14 CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual

5 Operation
5.1 Range of operators
Hand Wheel
To open the valve, turn the hand wheel counterclockwise. To close the valve, turn the hand wheel clock-
wise. See general assembly drawing for more details.
Bevel Gear
The bevel gear is designed for full force below 30Kg. To open the valve, turn the hand wheel counter-
clockwise. To close the valve, turn the hand wheel clockwise. See general assembly drawing for more
details.
Pneumatic Cylinder
Cylinder operated valves are generally supplied with a double acting pneumatic actuator. The inlet air
pressure should be between 60 - 90 psi. It is essential for a good maintenance of the cylinder that air
should be well dried, filtered and lubricated. It is recommended to actuate the cylinder 3-4 times before
the start up, once it is installed in the pipeline.
5 Operation
CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual 15

6 Maintenance
6.1 Precautions
WARNING:
•All procedures must be performed by qualified personnel.
• When the process fluid is hazardous, thermal (hot or cold), or corrosive, take extra pre-
cautions. Employ the appropriate safety devices and be prepared to control a process
media leak.
• Always wear protective clothing and equipment to safeguard the eyes, face, hands, skin,
and lungs from the fluid in the line.
6.2 Inspection
6.2.1 Visual inspection
Periodic inspections should be made as valves may wear over time due to the erosive or corrosive na-
ture of the service conditions. Regular inspection of the gate, stem and stem components must be per-
formed periodically to identify any signs of corrosion, wear, and / or damage caused by the process me-
dia. Replace parts with excessive erosion or corrosion.
6.3 Lubrication
6.3.1 Stem lubrication
Look for corrosion, galling or lack of lubrication on the stem, stem nut and extension stem (if any). Lubri-
cant for the stem or stem threads can be applied directly to them. Recommended stem lubricants in-
clude:
• Industrial Grease-Medium (Chevron)
• C5-A Compound (Fel-Pro)
• XL 47-F-2-75 (Moly)
• Molytex Grease #2 (Texaco)
6.3.2 CB27 seat lubrication
The CB27 bi-directional elastomer seal should be lubricated every 100 operations for 2" - 10" (DN 50-
DN250) and every 50 strokes for 12" - 24" (DN 300 - DN 600) sizes. Special application cases may re-
quire more or less frequent lubrication based on the pipe line process fluid. Where the valves are operat-
ed less frequent then once per month, the valve should be lubricated prior to the next stroke.
The gate may be lubricated directly on the gate edges where it contacts the elastomer seat (see
3.2.2 General diagram on page 10. Prior to lubrication completely wipe out the edges of the gate to re-
move sediments / dust that may be present.
Seat life can be improved if the valve gate is wiped clean occasionally. Failure to use ITT recommended
type of lubricant will considerably reduce the life of the valve. Under no circumstances should a hydro-
carbon based lubricant be used. Improper use of lubrication will void the valve warranty. Recommended
seat lubricants include:
6 Maintenance
16 CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual

• Dow 111 (Dow corning)
• Dow 44 (Dow corning)
• Compound G661 (GE)
• Rhodorsil 111 (Rhone-Polenc)
• Sil Glyde (AGS Company)
• Dow 7 (Dow corning)
• Complex 821 (NFO)
6.4 Repack the stuffing box
1. De-pressurize the system and place the valve in the closed position.
2. Unbolt the spindle or stem from the gate.
3. Loosen the screws of the support plate and remove it (without loosening the operator from the
plates).
4. Loosen the nuts of the gland follower and remove the gland.
5. Remove the old gland packing rings and clean out the gland area. For CB27 valves up to 20",
check the scrapper at the bottom of the gland area for damage and replace as needed.
6. Insert the new gland packing rings, making sure that the ring joints alternate (the first on one side of
the gate, the next one on the other side to stagger the packing joints).
7. Once the necessary gland packing rings are inserted, replace the gland follower and fasteners and
proceed with a steady initial tightening of the fasteners. See Figure 5: Fastener torques on page 14
for recommended packing torque.
8. Replace the support plate (with the actuator) and tighten the fasterners.
9. Reattached the spindle or stem to the gate.
10. Stroke the valve several times under pressure to break in the gland packing.
11. Once the valve is installed and the system is pressurized, check the gland packing for leakage. If
leakage occurs, re-tighten the gland follower to the proper torque.
6.5 Replace the seats
Consult factory for procedure to replace the CB27 seat.
6.4 Repack the stuffing box
CU27 Uni-Directional and CB27 Bi-Directional Knife Gate Valve Installation, Operation, and Maintenance Manual 17

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