Emerson KEYSTONE 60 Installation Manual

KEYSTONE SERIES 60 BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

Before installation these instructions must be fully read and understood

Intended valve use

The valve is intended to be used only in applications within the pressure/temperature limits indicated in the P/T diagram of the product manual.

When the valve is used in an end-of-line function, PED Cat-I applications are allowed only.

For other categories, please contact the factory.

1 STORAGE AND HANDLING

1.1 Storage

When valves are to be stored for some time

(2 months or more) before being fitted, storage should be in the original delivery crates or cases.

1.1.1 Storage conditions

The valves should be stored off the ground in a clean, dry indoor area.

Protect the valve from temperature and humidity extremes, and exposure to excessive dust, moisture, vibration, deformations, sunlight and ozone.

Recommendations

1.Temperature: storage temperature below 25°C (77°F), above 0°C (32°F) preferable below 15°C (59°F)

2.Humidity: storage conditions should be such that condensation does not occur. Store in a dry environment. Maximum 50% relative humidity.

3.Light: valve elastomers should be protected from light, in particular direct sunlight or strong artificial light with high ultra violet.

4.Ozone: storage rooms should not contain any equipment generating ozone. E.g. lamps, electric motors.

IMPORTANT

Before valves are installed or used the following actions are recommended.

1.Valves/parts have to be inspected and thoroughly cleaned if required.

2.Elastomer parts need to be greased with silicone grease if not present anymore.

3.All surfaces in contact with seats have to be thoroughly cleaned and greased with silicone grease if stored for more than 5 months.

1.2 Handling

To prevent damage during handling, the valves should be lifted by hand or using appropriate lifting equipment. Do not fasten lifting devices around the valve operating shaft, actuator

or through the valve waterway. The valve should be lifted with chains or slings which are fastened to rods or bolts which go through the bolt holes in the body flanges. The valves should be protected from external events e.g. bumps, hitting and vibration during transport. Any flange protection caps need to be removed before the valve is mounted in the pipeline.

Lift the valve with great care from the transport package (crate, pallet). While handling or installing the valve, ensure that no damage occurs to the valve, the pneumatic/electrical/- hydraulic actuator or other instrumentation.

2 SPARE PARTS

Only original Keystone spare parts are allowed to be used. Safe operation cannot be guaranteed if third party spare parts are used.

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VCIOM-03761-EN 15/08

KEYSTONE SERIES 60 BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

3 INSTALLATION

WARNING!

For safety reasons, it is important to take the following precautions before you start work on the valve:

1.Personnel making any adjustments to the valves should utilize suitable equipment.

2.All required personal protection means should be worn.

3.The line must be depressurized before installing the valve.

4.Installation and handling of valves should be done only by personnel who are trained in all aspects of manual and mechanical handling techniques.

5.Misuse of the valve is not allowed. For example: the valve, handles, actuators or other parts may not be used as ‘climbing tools’.

6.Ensure that valve pressure/temperature limitations marked on the identification tag are within the service conditions. The trim number on the valve’s nameplate identifies the valve materials.

7.See Product Manual for valve specific P/T diagram and trim number definition.

8.Ensure that valve materials are compatible with the pipeline fluid.

3.1 Visual valve inspection

1.Confirm that the materials of construction listed on the valve nameplate are appropriate for the service intended and are as specified.

2.Tag/name plate identification Manufacturer: Keystone

Model:	Series 60
Nominal size:	DN or NPS
M.P.W.P.:	Maximum permissible
	working pressure
Flange compatibility: e.g. ASME 125/150
Temperature:	e.g. -28°/120°C
Trim:	(-20°/250°F)
Trim:	Materials of
	construction

3.2 Flange and pipe compatibility

Check matching of flange drilling pattern of valve and pipe before assembly.

Flanges have to meet the following requirements (see Figure 1):

-The face inside diameter should be:

D min.: The valve Q-dimension + adequate disc clearance.

D max.: The optimum inside diameter (ID) is equal to the inside diameter of flange standard ASME B16.5, table 8, Weld Neck, dimensions B. For larger than D max inside diameters or other flange types please contact your local Emerson Sales organization, as larger inside diameters might result in reduced valve functionality.

-If the flange (or pipe) is provided with a raised face, the diameter of this shall be at least

8 mm larger than the YY-dimension of the valve.

The use of the flange-gaskets is not allowed since it might damage the valve.

The Keystone seat-face design eliminates the need for the gaskets.

Use flange bolting in accordance with appropriate standard.

Do not use flange gaskets, as this could lead to valve damage!

3.3 Valve installation

The valves are bi-directional and may be installed in either direction relative to the flow. The valve will control flow equally in either direction.

The recommended installation position is shaft horizontal and the lower disc edge opening downstream (Especially for slurry service and media with a tendency for sedimentation). For optimum valve control and smooth performance, it is recommended to have a 10 to 20 pipe diameters of straight run inlet piping and 3 to 5 pipe diameters straight outlet piping.

A valve is not a crowbar. Do not use the valve to spread the flanges. Seat damage may result.

FIGURE 1


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KEYSTONE SERIES 60 BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

NOTES

•The valve can be installed in the pipe-line either with or without the actuator mounted on top of the valve. Make sure to turn the disc slowly in the event there is a mismatch causing the disc to touch the adjacent piping.

•It is the responsibility of the valve user and not the valve manufacturer to ensure that the pipeline system has been built professionally and the valve has been properly installed.

•Adjacent piping must be positioned so that minimal piping stresses are transmitted to the valve flanges during or after installation.

•Handling and lifting of the valves during installation MUST be performed following the same instructions described in previous section ‘1.2 Handling’.

IMPORTANT

Mating flange faces should be in good condition and free of dirt and/or inclusions and pipe insides should be well cleaned.

3.3.1 Existing system (see Figure 2)

1.Check whether the flange distance meets the valve face-to-face dimensions. Spread the flanges with adequate tooling for easy insertion of the valve.

2.In case of a wafer valve, insert some flange bolts in the pipe flanges, to help hold the valve after insertion.

3.Close the valve so that the disc edge is at least 10 mm (⅜”) within the body.

4.Insert the valve between the flanges. Center the valve body, and insert all flange bolts. Tighten the flange bolts hand tight.

5.Slowly open the valve completely. (The disc is in line with parallel flats or keyway in shaft head. Keyway points towards disc edge.)

6.Maintain the valve flange alignment while gradually removing the flange spreaders, and tighten the flange bolts hand tight.

7.Slowly close and open the valve to check for adequate disc clearance.

8.Cross-tighten all bolting to the proper torque. Do not over tighten.

3.3.2 New system (see Figure 2)

1.With the disc in the near closed position, center each mating flange with the valve body. Fix the body with some flange bolts and tighten the bolts.

2.Use the flange-valve-flange assembly for fit-up and centering to the pipe.

3.Tack weld the flanges to the pipe.

4.Remove the bolting and remove the valve from between the flanges.

IMPORTANT

Do not finish-weld the flanges to the pipe with the valve bolted between the flanges as this will result in serious heat damage to the seat.

5.Finish-weld the flanges to the pipe and allow the flanges to cool completely.

6.Install the valve now according to the procedure for installing in existing systems.

3.4 Valve verification

Check the operation of the valve by operating it to ‘full open’ and ‘full close’. To verify the valve operation, the disc position indicator on the actuator or the handle should rotate between the ‘full open’ and ‘full close’ indicators on the actuator or throttle plate. For normal installation the valve disc travels clockwise to close.

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