Red valve G series User manual

IMPORTANT

Please take a moment to review this manual. Before performing any maintenance on the

valve be sure the pipeline has been de-pressurized. The improper installation or use of this

productmayresultinpersonalinjury,productfailure,orreducedproductlife. RedValveCo.,Inc.

can accept NO liability resulting from the improper use or installation of this product. If you have

any questions or problems, please call the customer service department at (412) 279-0044. We

appreciate your comments. And thank you for choosing Red Valve.

The Red Valve Series G Knife Gate Valve

is a 100% full bore, all-metal knife gate

valve designed for the toughest applications.

The Series G features heavy-duty cast-iron

body, stainless-steel wetted parts, and either a

metal or resilient seat.

The Series G is designed to meet MSS-SP81

face-to-face dimensions, so that it can be readily

placed in service replacing inferior knife gates.

Series G Knife Gate

Metal and Resilient Seated

Installation,Operation,andMaintenanceManual

The Series G Knife Gate Valve has A.N.S.I. B16.5 Class 125/150 flange

bolting dimensions, and a 150 psi cold working pressure rating. During

installation, great care must be taken to install the gate valve in the

proper direction. The gate must be installed so that the gate is pushed

against the seat by the flow pressure.

1. Remove the flange covers from the valve.

2. Check the flange faces of the pipe and valve for rough spots and

dents. Remove any damaged areas with fine sandpaper or file.

3. Check the valve for proper operation and any damage to the gate or

seat. Repair any damaged areas.

4. Clean the gasket surfaces of both the valve and the mating pipe

flanges.

5. IMPORTANT: Install the valve so that the gate is pushed against

the seat by the flow pressure. The seat must be placed on the

downstream or low pressure side of the gate. The word "SEAT" or "S"

is cast into the body, showing the position of the seat.

NOTE: Great care must be taken to properly install the valve, if the

valve is installed backwards the line pressure will push the gate away

from the seat, causing the valve to leak.

6. When installing the valve, be sure that the faces of the pipe flanges

are parallel to the raised faces of the valve. If the flanges are not parallel

the face gaskets may leak. 7. Install the face gaskets between the

flanges. Be sure that the inside diameter of the face gasket has the same

or slightly larger inside diameter than the raised face for the valve.

8. Install the flange bolts. Stud bolts should be installed in the chest area

of the valve. Be sure that the bolts are the proper length.

NOTE: Be sure that the bolts do not bottom out on the liner. If the

bolts bottom out on the liner, they may damage the pressure containing

part of the valve.

9. Tighten the flange bolts. Tighten the bolts to the recommended

torque and tighten all of the bolts evenly. NOTE: If the flange bolting is

not tightened evenly the valve may be damaged.

10. Apply grease to both the stem and grease nipple. Operate the valve

open and close, repeat the application of grease. Repeat this every three

months or as necessary.

11. IMPORTANT Tighten the packing bolts before applying pressure

to the valve. Packing bolts are loosened to increase the life of the

packing during storage.

ACTUATORS All actuators are furnished completely assembled and

fully operational. All valves with positioners and limit switches or

other instruments are properly set at the Red Valve factory.

HANDWHEEL The standard Series GSR has a left hand stem thread.

This allows the valve to close when the handwheel is turned in the

clockwise direction. The handwheel is labeled O-S (open and shut). The

handwheel is turned in either direction until the gate stops moving or is

fully seated.

BEVEL GEAR Bevel gears operate the same as the standard handwheel.

The handwheel is turned clockwise to close and counter clockwise to

open.

CHAINWHEEL Chainwheels can be furnished on both standard valves

and valves with bevel gears. The chain must be fed through the guides

and over the spokes around the outside diameter of the rim. The ends of

the chain are then connected with a connecting link.

CYLINDER ACTUATORS Cylinder actuated valves require a 50 psi

air supply to operate the standard cylinder. Actuators may be sized for

higher or lower plant air supply. A four-way valve must be used to

operate a standard cylinder. The open air supply is connected to the

lower cylinder head and close air source is attached to the upper

cylinder head. The valve must be assembled so that one side of the

piston is exposed to plant air, the other side of the piston must be

vented. If the valve has a fail safe system, air only needs to be supplied

to the open connection for fail close systems and the close connection

for fail open valves. The spring side of the piston should be vented.

If a pneumatic positioner is used, a 3 to 15 psi instrument signal is used

to control the positioner. Other pressure ranges of instrument signals

are available. Unless otherwise specified, the positioner will close the

valve upon increase of signal pressure.

Electronic positioners require a 4 to 20 mA control signal to position

the valve. As with pneumatic positioners, other control signals may be

provided and the standard positioner closes on increase of the

instrument signal.

ELECTRIC ACTUATORS Electric Actuators come completely

operational, with limit and torque switches set. Please refer to the

individual actuator manuals for additional operation or maintenance

information.

INSTALLATION OPERATION

RESILIENT SEAT REPLACEMENT

1. Make sure there is no pressure on the valve.

2. Remove the valve from the pipeline.

3. Close the valve so that the metal retaining ring is pushed away from

the body.

4. Insert a standard screwdriver between the body and metal retaining

ring. Do not insert the screwdriver too deeply or it may damage the

gasket. Gently twist the screwdriver several times around the

circumference of the seal retainer ring. NOTE: Be sure to remove the

retaining ring evenly.

5. Remove the two alignment pins. Remove the seat and the gasket.

6. Remove any rough spots with a fine file or sand paper. Only remove

enough metal to smooth the surface. Clean the metal retaining ring.

Make sure that the faces of the valve and seal retainer are clean and free

of scratches and dents.

7. Replace the seat ring and gasket it necessary. Use silicon seal to keep

gasket in place.

8. Open the valve.

9. Insert the retainer ring assembly. NOTE: Be sure that the alignment

pins are installed and the retainer ring is installed evenly.

10. Install the valve and new flange gaskets per the Installation Section.

NOTE: Be sure that the valve is installed in the proper direction, with

the seat on the low pressure side of the valve.

CYLINDER MAINTENANCE

The air used to operate the pneumatic cylinders, should be free of water

and other debris; it is not necessary to lubricate the air, but an air filter

is recommended. If water and other debris are in the air supply, cylinder

life may be shortened.

1. Check the piston rod for scratches and damage. Repair any minor

damage with a fine sandpaper or file. Only remove enough metal to

smooth the damaged area.

2. Make sure that there is no pressure in the valve.

3. Close the valve and remove air pressure from the cylinder. For valves

with fail open cylinders, closing pressure must be maintained on the

cylinder. Remove the bolts that connect the piston rod to the gate.

Operate the cylinder to the open position. For valves with fail close

cylinders, remove the cylinder assembly from the yoke.

PISTON ROD SEAL REPLACEMENT

4. Remove the adapter plate on the end of the piston rod.

5. Remove the four (4) bolts that connect the bronze seal retainer to the

lower cylinder head. Remove the bronze seal retainer.

6. Apply approximately 3 to 5 psi to the open side of the cylinder.

This should push the piston rod seal down the piston rod. Remove the

piston rod seal from the piston rod.

7. Replace the piston rod seal. Be careful not to damage the seal during

installation. Inspect the wiper ring in the seal retainer and replace it if

necessary. Reinstall the seal retainer and tighten the four bolts evenly.

PISTON SEAL AND CYLINDER GASKET REPLACEMENT

8. Cylinders with failsafe systems may remain bolted to the valve body.

Remove the four upper cylinder head nuts.

CAUTION: Make sure there is no pressure on the cylinder. If the

system has a spring loaded fail safe system, remove the top

cylinder head nuts evenly. If the nuts are not removed evenly, the

tie rod studs may be bent or broken, possibly causing Injury.

9. Remove the upper cylinder head. Remove the spring if the cylinder

has a fail safe option. Remove the cylinder from over the piston.

10. Clean the inside of the cylinder of any scale or buildup that has

developed. If the cylinder walls are scratched, use a very fine sandpaper

to remove the scratch or debris.

11. Clean both cylinder gasket grooves and replace the gaskets if

necessary.

12. Remove the nut that retains the piston to the piston rod. Remove

the upper piston stop and piston head and small o-rings.

13. Replace the first small o-ring that seals the piston rod and piston

head. Install the piston head and second small o-ring. Install the upper

piston stop and retainer nut. Tighten the retainer nut, use the hole in the

piston rod to keep the piston rod from turning. NOTE: Do not use a

pipe wrench or chain wrench on the piston rod.

14. Remove the o-ring on the piston head with a blunt instrument. Be

very careful not to scratch the outer edge of the o-ring groove or piston

O.D. If the areas are damaged, remove any scratches of damaged areas

with a fine file or sandpaper.

15. Lubricate the piston o-ring. cylinder gaskets and inside of the

cylinder. Use only compatable lubricants. Install the cylinder over

piston head. NOTE: Install the spring if the valve has a fail safe system.

Install the upper cylinder head, tighten the cylinder head nuts evenly.

16. Attach the adapter plate to the end of the piston rod. Slowly close

the piston, be sure that the groove in the adapter plate lines up with the

gate. Install the bolts that connect the gate to the piston rod.

17. Operate the valve open and close several times and check that all

nuts and bolts are tight.

INSPECTION Valves should occasionally be inspected for damage and

wear. The inspection period should be determined by the severity of

the service and environment. If valves are periodically inspected and

preventative maintenance done, the valve will last longer and operate

better.

CAUTION: Do not remove any valve parts or bolting with pressure in

the valve. It is very easy to inspect the valve for obvious problems.

Several items should be checked, they are as follows: Check the stem

for wear and any damaged threads. If threads are damaged, use a small

file to remove the damaged portion of the thread. Check the stem and

stem bushing for small pieces of bronze which may have worn away. If

excess material is noticed the stem bushing should be removed and

inspected closer. If the stem or stem bushing is severely worn or

damaged, replace the damaged part. After the stem and stem bushing are

inspected, lubricate the entire stem and apply grease to the grease

nipple until clean grease begins to appear.

The next item to be inspected should be the exposed portion of the gate

when it is in the full open position. Check for scoring and excessive

wear. If the gate is excessively worn or scored, the valve should be

removed from the line and both the seat and entire gate inspected. If the

gate and seat show only slight damage, they may be repaired by using a

fine grinding wheel or fine sandpaper. If the gate is severely damaged it

should be replaced. If the metal seat is severely damaged the valve body

must be replaced. Severely damaged elastomer seats or seat rings may

be replaced.

Leakage through and gland packing can be easily checked. If the packing

is leaking, tighten the packing bolts. All packing bolts must be tightened

evenly. If this does not eliminate or reduce the leakage to a satisfactory

level, another ring of packing may be added, or the packing may be

replaced. If the outside of the valve is exposed to a corrosive

atmosphere or fluids, the flange bolting and cast iron body should be

checked for severe corrosion. CAUTION: Do not remove any valve

parts with pressure in the valve.

ADDITIONAL PACKING INSTALLATION

If the gate packing leaks and the leak can not be stopped by tightening

the packing bolts, check to see if the packing gland is bottomed out on

the body or the base of the yoke. If additional packing needs to be

added, follow the instructions below.

1. Be sure that there is no pressure in the valve.

2. Open the valve. For large cylinder sizes, open pressure may have to

be maintained. For valves with a fail close cylinder, open pressure must

be maintained on the cylinder.

3. Remove the bolts from the packing stuffer. Lift the packing stuffer,

exposing the upper layer of packing.

4. Insert one ring of packing around the gate. Packing should be scarf cut

(on a 450 angle). If packing is cut straight across, be sure that the ends

of the packing butt together and do not overlap.

5. Tamp the packing down with a wood, plastic or brass rod, be sure

that the packing contacts the gate and wall of the gland all the way

around.

6. Lower the packing stuffer and partially tighten the bolts. Tighten the

bolts evenly.

7. Operate the valve open and close several times to break in the

packing. Fully tighten the packing bolts.

PACKING REPLACEMENT

1. Be sure that there is no pressure in the valve.

2. Close the valve. Disconnect the stem from the gate by removing the

pin or bolts from the gate.

3. Raise the stem or piston rod. Open pressure must be maintained on

fail close cylinders.

4. Remove the bolts from the packing stuffer. Remove the packing

stuffer. Remove the old packing. NOTE: Be very careful not to damage

the gate or lining.

5. Insert one ring of packing around the gate. Packing should be scarf cut

(on a 45 degree angle), to make the packing seal better. Great care must

be taken to make sure that the gate is flush against the seat. NOTE: If

the packing is cut straight across, be sure that the ends of the packing

butt together and do not overlap. Alternate the cut ends of the packing.

6. Tamp the packing to the bottom of the gland. Use a wood, plastic or

brass rod and be sure not to scratch the gate or wall of the gland.

NOTE: Be sure that the gate is against the seat, and that packing

contacts wall of the gland and the gate all the way around.

7. Repeat steps 5 and 6 with another strip of packing. The end joints of

the packing should be alternated to reduce the possibility of leakage.

8. Install the rubber secondary seal and push it to the bottom of the

gland.

9. Repeat steps 5 and 6 with the third and final layer of packing.

10. Install the packing stuffer and tighten the bolts evenly. The bolts

should not be completely tightened. Reconnect the gate to the actuator.

11. Operate the valve several times to break in the packing. Be sure that

the gate is against the seat. Fully tighten the packing bolts.

MAINTENANCE

PARTS – Pneumatic Cylinder

1. Cylinder Top Head

2. Tie Rods

3. Cylinder

4. Cylinder Bottom

Head

5. Seal Assembly

6.*Spring

7.*Piston Stop

8. Piston with O-ring

9. Piston Rod

7.*

6.*

* Spring Return Cylinders Only

1.REQUIREMENTS

A four-way valve must be used to operate a standard

cylinder. The open air supply is connected to the lower

cylinder head and close air source is attached to the

upper cylinder head. The valve must be assembled so

that one side of the piston is exposed to plant air, the

other side of the piston must be vented. If the valve has

a fail open or fail closed spring system, air only needs to

be supplied to the open connection for fail close systems

and the close connection for fail open valves. The spring

side of the piston must be vented.

If a pneumatic positioner is used, a 3 to 15 psi instru-

ment signal is used to control the positioner. Other

pressure ranges of instrument signals are available.

Unless otherwise specified, the positioner will close the

valve upon increase of signal pressure.

Electronic positioners require a 4 to 20 mA control signal

to position the valve. As with pneumatic positioners,

other control signals my be provided and the standard

positioner closes on increase of the instrument signal.

2.ACTUATOR REMOVAL AND REFURBISHMENT

WARNING

: SPRING LOADED ACTUATORS MUST BE SERVICED WITH

EXTREME CAUTION TO PREVENT INJURY. THE SPRINGS ARE

COMPRESSED AND HIGHLY STRESSED. THE TOP CYLINDER HEAD

OR OTHER PARTS CAN FLY OFF AND CAUSE SERIOUS INJURY IF

THE SPRING COMPRESSION IS NOT RELIEVED PROPERLY.

ACTUATORS

NUMBER & SIZE OF BOLTS PER VALVE

VALVE THREAD # OF STUD # OF

SIZE BOLTS

SIZE LENGTH STUDS

LENGTH SIZE BOLTS LENGTH

2" 83/8"-l 1 UNC 1.375" 25.50" 5/8-11UNC 41.375"

3”83/8"-l 1 UNC 1.500" 26.00" 5/8"-11 UNC

41.500"

4" 16 3/8"-l 1 UNC 1.500" 66.00" 5/8"-11UNC 41.500"

5"16 3/8"-10UNC 1.625" 66.50" 3/4"-10UNC 41.625"

6”16 3/4"-10UNC 1.750" 66.50" 3/4"-10UNC 41.750"

8”16 ¾"-10UNC 1.875" 87.25" 3/4"-10UNC

41.875"

10”24 7/8"-9UNC 2.000" 87.75" 7/8"-9UNC 82.000"

12" 24 7/8"-9UNC 2.125" 88.00" 7/8"-9UNC 82.125"

14" 24 1 "-8UNC 2.250" 88.50" 1 "-8UNC 82.250"

16”32 1 "-8UNC 2,000" 10 9.25" 1 "-8UNC 12 2.375"

18"32 11/8"-7UNC 2.500" 10 9.75" 11/8"-7UNC 12 2.500"

20" 40 11/8"-7UNC 2.750" 14 11.00" 11/8"-7UNC 12 2.750"

24" 40 11/4"-7UNC 3.000" 14 11.50" 11/4"-7UNC 12 3.000"

*Thru bolted Flanges are drilled and tapped in the chest area. Bolt lengths assume standard ANSI 150.

Flange and 1/8 to 1/16 thick gasket.

RED VALVE WARRANTY

WARRANTIES - REMEDIES - DISCLAIMERS - LIMITATION OF LIABILITY

Unless otherwise agreed to in writing signed by Red Valve, all Products supplied by Red Valve will be described in the specifications set forth on the

face hereof.

THE WARRANTIES SET FORTH IN THIS PROVISIONARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER STATUTORY,

EXPRESS OR IMPLIED (INCLUDING ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSEAND ALL

WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OR TRADE).

Red Valve Products are guaranteed for a period of one year from date of shipment, against defective workmanship and material only, when properly

installed, operated and serviced in accordance with Red Valve’s recommendations. Replacement for items of Red Valve’s manufacture will be made

free of charge if proved to be defective within such year; but not claim for transportation, labor or consequential damages shall be allowed. We shall

have the option of requiring the return of the defective product to our factory, with transportation charges prepaid, to establish the claim and our

liability shall be limited to the repair or replacement of the defective product, F.O.B. our factory. Red Valve will not assume costs incurred to remove

or install defective products nor shall we incur backcharges or liquidated damages as a result of warranty work. Red Valve does not guarantee

resistance to corrosion erosion, abrasion or other sources of failure, nor does Red Valve guarantee a minimum length of service, or that the product

shall be fit for any particular service. Failure of purchaser to give prompt written notice of any alleged defect under this guarantee forthwith upon its

discovery, or use, and possession thereof after an attempt has been made and completed to remedy defects therein, or failure to return product or

part for replacement as herein provided, or failure to install and operate said products and parts according to instructions furnished by Red Valve,

or failure to pay entire contract price when due, shall be a waiver by purchaser of all rights under these representations. All orders accepted shall be