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Operating instruction

MV, XV, HG, HP,RKO, D2G, BV, TV

AB STAFSJ BRUK, SE-618 95 STAVSJ, SWEDEN TEL:+46 (0)11-39 31 00 FAX: +46 (0)11-39 30 67

DECLARATION of CONFORMITYThe Manufacturer AB Stafsj Bruk, SE-618 95 STAVSJ, SWEDEN, hereby certify that the products in thescope

KNIFE GATE VALVES - types MV, XV, HG, HP, RKO, D2G, BV, TV,

have been designed, manufactured, inspected and tested according to the European directive

Pressure Equipment Directive PED (97/23/EC) Category II Module A1

When applicable, the products also fulfil the basic requirements of the European directives:

73/23/EEC Low voltage

89/336/EEC Electromagnetic compatibility

98/37/EC Safety of machinery

The monitoring of the final assessment is performed by the Notified Body F-Kontroll AB, Box 74, SE-601 02NORRKPING, SWEDEN. The Manufacturer is, therefore, authorised to provide the manufactured pressureequipment, within the scope mentioned above, with the Notified Body identification number (following theproducts CE marking as illustrated): CE 0640

Stavsj, March 3, 2003

AB STAFSJ BRUK

Magnus WestherManaging Director

TABLE of CONTENTS

OPERATING INSTRUCTION.....................................2

A. KNIFE GATE VALVES ........................................2B. TECHNICAL INFORMATION ................................2C. STORAGE .......................................................3D. TRANSPORTATION AND HANDLING ....................3

Lifting and moving..................................................... ... 3

Installation in pipe line ................................................. 4E. INSTALLATION .................................................5Pressure and valve direction ....................................... 5Flange...................................... .................................... 6Box packing .................................................. ............... 7Surrounding environment ............................................ 7Support ..................................................... ................... 7End valve...................................................... ............... 8Actuators ..................................................................... 8Accessories .................................................. ............... 8

F. OPERATION ....................................................8G. SERVICE AND MAINTENANCE ............................9

Maintenance ................................................. ............... 9Troubleshooting.................................................... ....... 9

H. SPARE PARTS ...............................................10


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OPERATING INSTRUCTIONThe Operating instruction describes how the knife gate valves of Stafsj shall be installed and operated to

ensure the products function and safety during its lifetime.

The Operating instruction shall be made available to the personnel responsible for the installation, operatingand service of the Stafsj knife gate valves.

More detailed information on the specific knife gate valve, its actuator and accessories, is available in Datasheets and Service instructions on www.stafsjo.com or please contact AB Stafsj Bruk or your localrepresentative.

A metal plate is placed on each valve containing the valve article number and unique serial number. Thesenumbers shall always be stated when corresponding with AB Stafsj Bruk or your local representative.

AB Stafsj Bruk accepts no responsibility for the product if this Operating instruction is not followed when

installing, operating and maintaining the Stafsj knife gate valve. Nor does AB Stafsj Bruk acceptresponsibility for the product if any essential change has been done to the product.

A. Knife gate valvesThe Stafsj knife gate valve is designed of a valvebody, a gate, a gland, a seat ring, a retainer ringand an actuator. The valves are uni- or bi-directional seated and have various pressureratings.

The knife gate valves consists of a one piece or

two-piece valve body in cast iron, ductile iron orstainless steel. The gate is made of stainlesssteel. The closed valve is sealed by a sealingprofile or a seat ring. The seat ring is mechanicallylocked in the valve body by the dismountableretainer ring, making it easy to replace. The seatmaterial is variable depending on valve type andsize.

All valves are delivered with the unique Stafsjbox packing TwinPack, which is held into placeby the gland.

The Stafsj knife gate valve is of modular designenabling it to be easily equipped with differentmanual or automatic actuators and accessoriessuch as limit switches.

B. Technical informationThe Stafsj knife gate valves, actuators and accessories are described in different Data sheets. Thelimitations of the products are given in the Data sheets. All Data sheets are available on www.stafsjo.com.

If you have any questions regarding the products or your application, please contact AB Stafsj Bruk or your

local representative.


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C. StorageThe Stafsj knife gate valve shall be stored in a clean and dry environment. It shall be protected against dirt,

dust and other pollutants and should not be exposed to direct sunlight. Keep the valve in an open positionduring storage to ensure the knife gate valve function.

If the knife gate valve is stored outside it must be wrapped up in plastic or similar to protect against moisture.

D. Transportation and handlingThe knife gate valve has been packed according to the conditions of the transport for the delivery.Unfortunately damage can occur to the product due to mishandling during the transportation. It is importantto make a visual inspection of the valve at arrival. If transport damages are detected a report shall be writtento the transportation company.

Lifting and moving

When lifting and moving the Stafsj knife gate valve, you shall always use two or more metallic lifting eyebolts. These lifting eye bolts shall be screwed into the holes of the flange drilling. The lifting equipment shallbe attached to the lifting eye bolts.


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Before lifting you must always check:o Check that the lifting equipment is safe and is designed to hold the weight of the valve. (See Data sheet

on www.stafsjo.com.)o Check that the lifting eye bolts have a thread corresponding to the flange drilling. (See Data sheet flange

drilling on www.stafsjo.com.)o Check that the lifting eye bolts have been screwed to the bottom of the flange drilling hole and do not risk

loosening.o Do not expose the actuator, accessories or gate guards to blows or thrusts.o Do not exert the weight of the valve to actuator, accessories or gate guards.

Installation in pipe lineWhen installing the Stafsj knife gate valve into a pipe line, all lifting and handling shall be carried out withsoft straps. The soft straps shall be placed and fastened under the valve body beam surface. The beamsurface is the place on the valve body where the gland and/or the beams are attached. It is also possible toplace a soft strap around the yoke for the actuator but never place a strap on the actuator. Carefully displacethe gate in the valve to move the point of balance and obtain contemplated equilibrium before mounting.

Before lifting you must always check:o Check that the lifting equipment is safe and designed to hold the weight of the valve. (See Data sheet on

www.stafsjo.com.)o Check that the soft straps are fastened and do not risk to slide along the valve.o Do not expose the actuator, accessories or gate guards to blows or thrusts.o Do not exert the weight of the valve to actuator, accessories or gate guards.


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Note!Never place lifting equipment In the actuator, accessories or gate guards In the knife gate valve bore which can damage the retainer ring and seat

E. InstallationThe Stafsj knife gate valve is delivered ready for installation between flanges.

Before installation of the Stafsj knife gate valve in the pipe line, the following must be checked:o Check that the pipe line in which the valve is to be installed is empty and free from pressure.o Check that the operation data of the application do not exceed the maximum allowable values for the

valve. (See Data sheet on www.stafsjo.com.)o Check that the valve materials correspond to the operating conditions of the application. (See Data

sheet on www.stafsjo.com.)o Check that the surrounding environment does not imply any risks to the valve, actuator or

accessories.o Check that the flange, the inside of the pipe and the valve is free from deposits and other solid

particles.

Note!No work is allowed in the pipe line when it is pressurized and contains media. The pipe linemust be free from pressure and empty before work begins.

Pressure and valve directionWhen the knife gate valve is open, P1=P2 and may not exceed maximum allowable working pressureaccording to each valve type Data sheet.

When the valve is closed, the differential pressure P, is the difference between P1 and P2 (P = (P1-P2)).The differential pressure P may not exceed maximum allowable differential pressure according to eachvalve type Data sheet.

For Data sheets, see www.stafsjo.com.

P1 P2

SEAT SIDE

The Stafsj knife gate valve MV has different differential pressure P capacities in the two directions. It isimportant that this valve is installed in the correct direction in the pipe line, in relation to the pressuredirection of the media when the valve is closed. When the valve is closed, the pressure ratio shall be P1>P2with reference to the valve body seat side, called preferred direction. Some sizes of the MV valve alsohandles a certain pressure ratio P2>P1, see maximum allowable differential pressure in the reverseddirection in the MV Data sheet.


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The Stafsj knife gate valve TV shall be installed with the seat side to the tank. When the valve is closed, ithas a capacity of differential pressure P2>P1 according to the TV Data sheet. The removable retainer ringshall be mounted against the tank which means that changing seat in the valve can only be done when the

tank is empty.

The Stafsj knife gate valve RKO shall be installed in a vertical pipe line with a circular inlet (seat side) and asquare outlet and is independent of the differential pressure direction when the valve is closed. Seemaximum allowable differential pressure in the RKO Data sheet.

The Stafsj knife gate valve D2G shall be installed in a vertical pipe line and is independent of the differentialpressure direction when the valve is closed. See maximum allowable differential pressure in the D2G Datasheet.

The Stafsj knife gate valves XV, HG, HP and BV are bi-directional seated and can therefore be installedindependent of the pressure ratio in any direction in the pipe line. For closed valve, see maximum allowabledifferential pressure in Data sheets.

FlangeDetailed information on the valve type flange drilling with dimensions, thread, length and number of screws isavailable in Flange drilling data sheets on www.stafsjo.com.

The Stafsj knife gate valve shall always be installed between two full flanges (fixed or loose) to ensure thatthe valve is secure and that the flange keeps tight.

When installing the knife gate valve in the pipe line, the valve centre line must be on the same centre line asthe flanged pipes. The valve must also be placed parallel between the flanges. If the flanges and the valveare not centred, the valve may be damaged by erosion and a dirt pocket may occur which can lead toclogging and corrosion of the valve.

1. Place the gasket between the valve body and the flange and check that the packing is well centred.2. Choose screws with the correct thread and length according to the Flange drilling data sheet. (See

www.stafsjo.com.)3. Lubricate the screws. The grease has two effects; it gives better prestressing of the flange and

makes it easier to dismantle when needed.4. Tighten the screws evenly and crosswise to obtain an evenly divided load on the flange.5. Check that the valve, gasket and flanges are parallel and on the same centre line. Adjust when

needed.6. Finish the valve installation by tightening the screws evenly and crosswise to full moment.


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Note!When the pipe system is pressurized and the temperature increases, leakage can occur in theflange. It is important to check and tighten the flange screws again a short while after start-up of

the system.

Box packingThe box packing seals the valve from the surrounding environment at the gate.

While the knife gate valve is transported between manufacturer and customer, the box packing settles whichcould mean that it will leak after installation. When the valve is mounted, the gland shall be tightened to avoidleakage.

If the box packing leaks, tighten the nuts on top of the gland bit by bit and crosswise until the leakage stops.

Tighten the nuts evenly; it is important that thereis no contact between the gland and the gate. Donot tighten the nuts too hard; it will affect thevalves ability to operate and shortens the life timeof the box packing.

More information on changing and tightening thebox packing is available in the Service instructionson www.stafsjo.com.

Note!When the pipe system is pressurized and the temperature increases, leakage can occur in thebox packing. It is important to check and tighten the gland nuts again a short while after start-upof the system.

Surrounding environmentThe environment around the knife gate valve should be dust free and dry. Too high or low temperatures or

fast temperature swings may affect the valve function and its actuator and accessories.

The knife gate valve must be protected against radiant heat if the valve is placed near a heat source whosetemperature may exceed maximum allowable temperature for the valve or its actuator.

The knife gate valve must be protected against leakage of gas and fluid from the surrounding environment.The gas or fluid can affect the materials in the valve and the function of actuator and accessories.

SupportThe Stafsj knife gate valves MV, XV, HG, HP, BV and TV should be installed in a horizontal pipe line withthe actuator in a vertical upright position. If a knife gate valve is installed in any other direction, the deadweight of a long gate or a large actuator may cause tensions in the valve which might affect the valvetightness and ability to manoeuvre.


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Also valves that are exposed to vibrations or other mechanical stresses can be subject to forces that willaffect the valve tightness and ability to manoeuvre.

In these cases, the knife gate valves and actuators should be supported to avoid function failure. Supportingcan preferably be done by mounting a loop and suspension in a wire or supporting by using a fastened rod.The wire or rod should be placed on the yoke for the actuator.

End valveIf a knife gate valve is installed as an end valve in a pipe line, always use a counter flange to secure thevalve and keep the flange free from leakage.

If you install a knife gate valve as an end valve in a pipe line, always install protective equipment to preventpeople being exposed to the media transported in the system when opening the valve.

If you install a knife gate valve as an end valve in a pipe line and there is a risk for people to come in contactwith the valve bore and the moving gate, always install protective equipment to prevent people getting closeto the valve bore.

ActuatorsManual actuators are not mounted on the knifegate valve at delivery. The actuators shall bemounted on the valve with a locking nut.

Before mounting the actuator on the knife gatevalve, check that there is not any play betweenthe actuator, bearing and actuator yoke. The playappears between the stem and stem nut when thestem changes direction of rotation. Eliminate the

play before mounting the actuator by rotating thestem 360 degrees counter clockwise.

Automatic actuators shall be installed, operated and serviced by qualified personnel according to theinstructions of the manufacturer which comes with the actuator. The instructions must be followed carefullyfor safe operation of the knife gate valve.

AB Stafsj Bruk accepts no responsibility for the product if actuators not tested and approved by AB StafsjBruk are mounted on the knife gate valve.

AccessoriesAccessories shall be installed, operated and serviced by qualified personnel. Instructions for accessories canbe received from AB Stafsj Bruk by stating the article and serial number with which the knife gate valve ismarked.

AB Stafsj Bruk accepts no responsibility for the product if accessories are mounted on the knife gate valvein such a way that it essentially affects the knife gate valve design or function.

F. OperationBefore the knife gate valve is put into operation, you must check:


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o Check that the maximum allowable values of the knife gate valve correspond to the operation data ofthe system. (See Data sheet on www.stafsjo.com.)

o Check that the materials in the valve are chosen with regards to the media in the system. (See Data

sheet on www.stafsjo.com.)o Check that the knife gate valve is installed in the correct direction in relation to the direction of

pressure when the valve is closed. (See E above.)o Check that the knife gate valve is centred and parallel in the pipe line flange. (See E above.)o Check that the knife gate valve when necessary is supported to avoid tensions. (See E above.)o Check that the actuator is installed according to the instructions of the manufacturer and carried out

by qualified personnel.o Check that the accessories are installed correctly by qualified personnel.

Note!The gate guards must always be installed on the knife gate valve with an automatic actuator toprevent personal injuries before the valve is put into operation.

The surrounding environment and the system in which the valve is installed shall have normal operatingconditions to obtain the optimal function and lifetime of the knife gate valve. The following must be checkedregularly when operating the valve:

o Check that the environment around the knife gate valve does not imply any risks to the valve, itsactuator or accessories.

o Avoid powerful pressure and temperature swings in the systemo Avoid vibrations in the system.o Be observant to leakage from the knife gate valve and take measures immediately.o Do not expose the knife gate valve, its actuator or accessories to external loads or other strains, for

example by climbing on it.

G. Service and maintenance

MaintenanceThe seat and box packing are wear parts that have to be replaced regularly to keep the knife gate valve tightand free from leakage. The interval for replacement depends on the application and operating data such aspressure, temperature, erosion and chemical and mechanical effect of the media on the materials in the knifegate valve.

The knife gate valve must be inspected every day for leakage and other external effects that might involverisks for operating personnel, the valve, its actuator or accessories.

A full scale manoeuvre test shall be performed at least two times a year to verify that the knife gate valvefunctions correctly.

If a fault or problem is detected at an inspection or manoeuvre test, the knife gate valve should go throughservice and maintenance as soon as possible. Information on spare parts and instructions for service andmaintenance are available on www.stafsjo.com.

TroubleshootingFaults or problems that are detected on the knife gate valve may have several reasons. The most commonproblems and their reasons are listed in the table below. To remove the problem, the knife gate valve shouldundergo service and maintenance. How to perform the service, maintenance and available spare parts isdescribed in Service instructions and Spare part data sheets on www.stafsjo.com.

If you can not find the information you are seeking, please contact AB Stafsj Bruk or your localrepresentative.


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Problem Reason Measure

Leakage in box packing Loose box packing

Worn-out box packingIncorrectly installed box packing

See Service instructions on

www.stafsjo.com

Leakage in flange Wrong length of screws in flangeLoose flangeValve not centred in flangeValve not parallel in flangeGasket not centredWrong material in gasket

See Operating instructionSee Data sheet and Serviceinstructions on www.stafsjo.com

Leakage through knife gatevalve

Worn-out seatGate do not closeDamaged seat/gate

See Service instructions onwww.stafsjo.com

Gate does not open/closecompletely

Fault in actuatorFault in limit switches

Valve cloggedDamaged seat/gate

See instruction for actuator/accessories

See Service instructions onwww.stafsjo.com

Gate does not open/close ina soft movement

Fault in actuatorValve cloggedDamaged seat/gate

See instruction for actuatorSee Service instructions onwww.stafsjo.com

Abnormal large force toopen/close gate

Valve exposed to stress/tensionValve cloggedDamaged seat/gate

See Operating instructionSee Service instructions onwww.stafsjo.com

Note!No work is allowed on the Stafsj knife gate valve when the pipe line is pressurized or theautomatic actuator is connected. The system must be empty and free from pressure beforework begins. The actuator and accessories must be disconnected before work begins.

The gate guards must always be installed on the knife gate valve before the valve is put intooperation after completed work.

AB Stafsj Bruk accepts no responsibility for the product if wear parts not tested and approved by AB StafsjBruk are installed in the knife gate valve. Nor does AB Stafsj Bruk accept responsibility for the product if theService instructions are not followed when maintaining the knife gate valve.

AB Stafsj Bruk offers the customer service and maintenance of Stafsj knife gate valves, either in thecustomers plant or at the Stafsj workshop. Please contact AB Stafsj Bruk or your local representative formore information.

H. Spare partsSpare parts and instructions for service and maintenance are available on www.stafsjo.com or pleasecontact AB Stafsj Bruk or your local representative.

All specifications subject to change without notice. www.stafsjo.com

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