MODEL BC

INSTALLATION, OPERATION & MAINTENANCE MANUAL

BC Knife Gate Valve

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 MODEL BC

INSTALLATION, OPERATION & MAINTENANCE MANUAL

BC Knife Gate Valve

0. INTRODUCTION

1. HANDLING

2. INSTALLATION

3. ACTUATORS
3.1. Handwheel
3.2. Lever
3.3. Pneumatic
3.4. Electric

4. MAINTENANCE
4.1. Gland packing replacement
4.2. Seal replacement
4.3. Lubrication

5. STORAGE

6. ENVIRONMENTAL CONSIDERATIONS

7. PARTS LIST & DRAWING

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0. INTRODUCTION

The BC model knife gate is a square-port low-pressure valve for solid loaded fluids, mainly
used in bulk handling and silo outlet applications.

The BC valve complies with the following European directives:

• Machinery Directive.

When applicable it can also comply with the following additional directives:

• Pressure Equipment Directive

• Potentially Explosive Atmospheres (ATEX)

It is the user’s liability to clearly inform the maximum working conditions (PS, TS), medium (gas
or liquid) and dangerousness group (1 or 2) and if the fluid is unstable to properly classify the
valve according the PED directive.

ORBINOX offers, supplies and certifies valves according to the information received from the
customer. The customer is liable to make sure this information is accurate and according to
specific working conditions requirements where the valve will be installed.

For EU Directives and other Certificates, please see the document:

Directives & Certificates Compliance - Knife Gate Valves - IOM

1. HANDLING

The valves are packed according to the appropriate transport standards. If you receive the
packing damaged, please inform the transport company in writing and contact you ORBINOX
representative.

When handling an ORBINOX valve please pay attention to the following points:

• DO NOT ATTACH LIFTING GEAR TO THE VALVE ACTUATORS OR GATE GUARDS. They
are not designed to bear the weight, and could easily be damaged.

• DO NOT LIFT THE VALVE BY THE VALVE BORE.

This can cause damage to the seating surfaces and seals.

• Check that selected lifting gear is rated to carry the weight of the valve. The valve can be
handled using eyebolts, soft straps or slings.

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• EYEBOLTS: make sure the eyebolts have the same thread as the bolt holes and they are all
well secured. Ideally when using lifting gear to move an ORBINOX valve, it should be
supported by two or more eyebolts screwed into the tapped fixing holes in the valve body.

• SOFT STRAPS: with the valve in the closed position, the straps should be placed between
the gland area and the bore such that the valve is balanced.

Fig. 1 Handling with eyebolts Fig. 2 Handling with soft straps

PNEUMATIC ACTUATED VALVES (Non-standard valves shall be checked case by case)

ORBINOX pneumatic valves (with Ø125 cylinder and above) are supplied with 2 lifting lugs for
a safe handling of the valve for vertical movements

Handling WARNING:

Lifting lugs are not machined so they could have sharp corners; soft straps or slings are
forbidden to be used with these lifting lugs

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Below table shows the maximum weight of valve + pneumatic cylinder that 2 lifting lugs can hold
depending on lifting chain angle (X):

With 2 lifting lugs: max. weight valve + cylinder (kg.)

L: minimum lifting chain length
CYLINDER
X: 60° X: 75°
Kg. Lmin (mm) Kg. Lmin (mm)
125 170 130 310 220
160 270 170 500 280
200 390 220 710 380
250 740 300 1335 500
300 1140 360 2030 600
350 1615 440 2835 720
400 2105 500 3660 830

• For horizontal movement, the valve shall be lifted mainly from the body and the yoke. See
above instructions for further instructions
• Cylinder’s lifting lugs can only be used during horizontal movement of the valve to help
balance the valve given the weight is hold at the body lifting point (center of gravity is approx.
centered on the body)
• The valve can be lowered from vertical to horizontal position when it is hanging from the
cylinder’s lifting lugs

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Below table shows approximate weight of standard BC pneumatic valves (kg):

DN (mm) CYL. Kg.

150 x 150 25
200 x 200 30
CYL 100
250 x 250 35
300 x 300 42
350 x 350 63
400 x 400 CYL 125 72
450 x 450 80
500 x 500 98
CYL 160
600 x 600 125

2. INSTALLATION

For EU Directives and other Certificates, please see the document:

Directives & Certificates Compliance - Knife Gate Valves - IOM

In order to avoid personal injury or damage to property when handling and installing the valve, it
is important to observe the following warnings:

• It is the User’s responsibility to verify compatibility of valve parts materials with the internal fluid
• Qualified and trained personnel must carry out the handling and maintenance of the valve
• Use suitable Individual Protection Equipment (IPE) (gloves, safety footwear...)
• Disconnect all lines affecting the valve and put up a notice notifying that work is being carried
out on the valve
• Isolate the valve completely from the process
• Release process pressure
• Drain the fluid from the valve

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.

The valve is unidirectional. The valve should be set up so that the greatest pressure acts towards
the seat. Except on those cases where the valve is mounted under silo (see next pictures).

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 MODEL BC

a) Pressure towards the seat

b) Valve under silo

It is worth making a special mention of assemblies at the outlet of a hopper or silo where
pressures are low and the valve is used as an isolation valve for solids. In these cases the
cleanliness of the sliding guides takes priority, and the valve should be placed as shown in
the following diagram.

It should be noted that the direction of flow and differential pressure, do not always coincide.

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Special care should be taken to maintain the correct distance between the flanges and to ensure
that they are parallel to the valve body. Incorrect alignment of the valve can cause deformations,
which can lead to difficulties in operation.

The valve can be mounted in any position with regard to the pipe. However, it is advisable to
place it vertically in horizontal pipeline (A) if the installation allows it. (Please consult the technical
department at ORBINOX).

With larger diameters (> 300 mm), heavy actuators (pneumatic, electric, etc.), or with the valve
installed horizontally (B) or at an angle (C) on a horizontal pipeline, the installation will require
the construction of suitable supports. (See the following diagram and consult the technical
department at ORBINOX).

C C
B B

C* C*

A*

* For these positions please consult ORBINOX

The installation of suitable supports is advised when significant vibrations coming from the
piping are present.

In vertical pipelines, the construction of suitable supports is always required (for further
information please consult the technical department at ORBINOX).

Once the valve is installed, test that the flanges have been fastened correctly and that all
electrical and/or pneumatic connections have been properly made.

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First, operate the valve with no flow in the pipeline. Then test operation and valve seal with flow.
It should be noted that the packing material might settle in shipping/storage, which can cause
minor leakage. This can be remedied by tightening the gland follower (5) during installation.
The nuts shall be tightened gradually and crosswise until the leakage stops (see the next figure).
Check that there is no metal contact between the glandfollower (5) and the gate (2).

If the glandfollower nuts are overtorqued, the force needed to operate the valve will increase,
the valve function will be affected and the box packing lifetime will be shortened.

The table below shows the recomemended maximum torques for the glandfollower nuts.

DN Torque (N.m)
50 - 200 15
250 - 300 25
350 - 600 30

Once performance has been tested, the valve can be put into operation.

Approximate weight of the handwheel-operated valve (rising stem):

DN (mm) : kg
200 x 200: 27kg 400 x 400: 66kg
250 x 250: 32kg 450 x 450: 75kg
300 x 300: 38kg 500 x 500: 85kg
350 x 350: 58kg 600 x 600: 110kg

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3. ACTUATORS

For EU Directives and other Certificates, please see the document:

Directives & Certificates Compliance - Knife Gate Valves - IOM

3.1. HANDWHEEL
To open the valve turn the handwheel (12) anticlockwise. To close turn the handwheel
clockwise.

3.2. LEVER
To operate the valve with this device, first loosen the locking clamp located on the top of the
yoke (8). Then either open or close the valve by moving the lever in the desired direction.
Finally, fix the position of the lever with the locking clamp.

3.3. PNEUMATIC
Valves are usually supplied with a double acting pneumatic actuator although, upon request,
we can supply single-acting actuators. In either case the feed pressure can vary between 3,5
and 10 bar. However, the size of the actuator for each valve has been designed for a feed
pressure of 6 bar.

It is essential for a good maintenance of the cylinder that air should be well dried, filtered
and lubricated. Air quality shall fulfil the following requirements:

• ISO 8573-1 Grade 5:4:3 for regular process (ON / OFF services).
• ISO 8573-1 Grade 5:3:3 for regular process at low temperature (-20 °C).
• ISO 8573-1 Grade 3:4:3 for cylinders with positioners.
• ISO 8573-1 Grade 3:3:3 for cylinders with positioners at low temperature (-20 °C)

It is recommended to actuate the cylinder 3-4 times before the start up, once it is installed in
the pipeline.

3.4. ELECTRIC ACTUATOR

Depending on the type or make of the electric actuator, specific instructions (i.e. a
manufacturer’s manual) will be supplied.

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4. MAINTENANCE

For EU Directives and other Certificates, please see the document:

Directives & Certificates Compliance - Knife Gate Valves - IOM

The valve must not undergo any modifications without a previous agreement with ORBINOX.
ORBINOX shall not be liable for any damages that may arise due to the use of non original parts
or components

To avoid personal injury or damage to property from the release of process fluid:
• Those in charge of handling and maintenance 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.

The only maintenance required is to change the gland packing (4) or the seal (3) if the valve is a
resilient seated type.

The life of these elements will depend on the working conditions of the valve such as: pressure,
temperature, abrasion, chemical action, number of operations, etc.

4.1. Replacement of the gland packing (4):

1. Depressurise the circuit and place the valve in close position.

2. Remove the gate guards (for automatically actuated valves only).
3. Release the spindle or stem (9) from the gate (2). Photo 1

Photo 1 Photo 2

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4. Loosen the screws of the yoke (8) and remove it (without loosing the actuator).
5. Loosen the nuts of the gland follower (5) and remove it. (Photo 3)
6. Remove the old packing rings (4) and clean the stuffing box.
7. Insert the new packing rings (4), making sure that the ring joints alternate (the first on one
side of the gate, the next on the other and so on). (Photo 3)
8. Once the necessary packing rings (4) have been inserted, proceed with a steady initial
tightening of the gland follower (5). (Photo 3)
9. Place the yoke (8) (with the actuator) and screw it.
10. Fix the stem (9) to the gate (2). (Photo 1)
11. Remount the gate guards.
12. Carry out some operations with a loaded circuit and then re-tighten the gland follower (5) to
prevent leakage.

Photo 3 Photo 4

Photo 5

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4.2. Replacement of the seal (3) (only applicable to resilient seated valves):

1. Remove the valve from the pipeline.

2. Set the gate (2) in open position.
3. Take off the plates (6), which retain the seals (3).
4. Remove the old seals (3) from the valve and clean the seats.
5. Once the correct length is known, cut the new sets of seals (3).
6. Place the new seal (3) on the top of the body (packing gland side) and secure the top plate (6).
(Photo 4)
7. Place the next seal (3) on the bottom and secure the bottom plate (6). Finally secure the side
plates (6) and side seal (3). (Photo 5)
8. Set the gate (2) in closed position.
9. Check that the seal (3) and the gate (2) are in contact and then retighten all the plates (6).
10. Open and close the valve two or three times prior to reinstallation.

4.3. Lubrication:

Twice a year, it is recommended to remove the protection cap (14) and fill up the stem protector (13)
halfway with a calcium-based grease with the following characteristics: highly water resistant, low
ash content, and excellent adherence.

5. STORAGE

• For long storage periods keep the valves indoors in a safe and dry place and protect it from any
impact and or vibrations

• Storing temperatures: -10ºC to +40ºC

• Valves must be stored in either full open or full closed position

• For any component installed in the valves, electric motors, solenoid valves, etc, please refer to
their own instructions manuals

6. ENVIRONMENTAL CONSIDERATIONS
• The packaging is made from environmentally friendly materials. Dispose of the packaging
through the available recycling channels

• The valve is designed and manufactured with materials that can be recycled by specialised
recycling firms. Once the life of the product is expired, you have to consider a proper disposal of
the product in order to prevent any negative impact on the environment and allows for the
recycling of valuable commodities

• Please follow the local environmental rules in your country for proper disposal

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7. PARTS LIST & DRAWINGS

1. BODY 9. STEM
2. GATE 10. STEM NUT
3. SEAL 11. FRICTION WASHER
4. PACKING RING 12. HANDWHEEL
5. GLAND FOLLOWER 13. STEM PROTECTOR
6. SEAL RETAINER PLATE 14. CAP
7. SLIDER SUPPORT 15. NUT
8. YOKE

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