Emerson KEYSTONE F580, KEYSTONE F583 Installation And Repair Instructions

KEYSTONE FIGURE 580 AND 583 BALLCENTRIC VALVES

INSTALLATION AND REPAIR INSTRUCTIONS

Complete storage, installation, disassembly and assembly instructions for
Eccentric style, round ported plug valves:

• F580 - DN 80 to 100

• F583 - DN 150 to 300

STORAGE PROCEDURES

The valves should be stored on a pallet or 'skid'
in a clean, dry warehouse. If outdoor storage is
necessary the unit should be wrapped in plastic
(not supplied by Emerson) and be kept off the
ground and high enough to avoid standing
water or exposure to extreme conditions.
The valves should be stored with the disc/plug
fully open and ensure all flange protectors are
kept in place.

INSTALLATION

Straightway ballcentric valves are asymmetrical
in design. On all valves, one end flange is
marked 'seat' and this marking should be used
to identify the valve ends.
Some valves also have an arrow case on the
body. This arrow points towards the seat end,
and does not always indicate the preferred fluid
flow direction.
In general, straightway ballcentric valves will
seal against higher differential pressures when
the pressure is applied from the end opposite
to the seat end. If sealing against pressure
applied from the seat end is critical, then this
must be specified when ordering and the valves
then tested for this condition.
With normal gas and liquid service, the shut-off
direction and flow direction will commonly be
the same and the valve should then be installed
with the seat end downstream. In some
applications, such as pump output shut-off
valve, the purpose of the valve is to stop reverse
flow when normal flow ceases; in this case the
valve should be installed with the normal flow
from the seat end so that the pressure against
which the valve is to shut-off is applied from the
end opposite the seat. In cases where shut-off
is required in both directions, the valve should
be installed so that the highest differential
pressure at shut-off, or that against which the
sealing is most critical, is applied to the end
opposite the seat.

MAINTENANCE

the need for replacement is expected, this can
usually be scheduled at plant shut downs or
done with pressure removed from the line in
which the valve is installed.

OPERATION

Wrench actuated valves

Wrench actuated straightway ballcentric valves
close by 90° clockwise rotation. Indication
marks are provided on the actuating stem to
show the plug position at any time and stops
are provided to limit the plug travel.

Gear actuated valves

Gear actuated valves cannot creep or slam.
The worm gear actuators used are designed to
prevent creep or slam (when properly adjusted)
in extreme or in intermediate (throttle)
positions. The valves are closed by turning
the actuator/operator input shaft clockwise.
The valve opens by turning the operator input
shaft counterclockwise. Indication marks are
provided to show the plug position at any time.

SAFETY PRECAUTIONS

The valve is a pressure vessel.
The valve must be depressurized prior to
performing maintenance.
When the service is of a clogging type, likely
to build up in the valve body space, it is best to
arrange for the pressure to be shut-off from
the seat end of the valve. In cases of extreme
clogging, and when the pipeline is horizontal,
thevalve should be positioned so the valve stem
is horizontal and the plug rises into the top of the
body on opening. In vertical pipe runs, the valve
should be installed with the seat end flange up.
Valves to be buried should be opened and closed
under pressure at least once before installation.
This is required to verify that no parts have
become loose or damaged during shipment.
After the valves have been installed in line and
before use, gear actuator lubrication should
be checked (see the appropriate operator
maintenance manual).

The stem seals on the ballcentric valves are
long life items and will not, under normal
circumstances require replacement during the
life of the valve. When the service is such that

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VCIOM-02966-EN 17/01

KEYSTONE FIGURE 580 AND 583 BALLCENTRIC VALVES

INSTALLATION AND REPAIR INSTRUCTIONS

DISASSEMBLY INSTRUCTIONS

CAUTION

Never attempt to remove or perform maintenance
on a valve that is pressurized and ensure that
pipeline is isolated.

ACTUATOR REMOVAL

All figure 580/583 valves allow for direct
mounting of actuators/gear operators.
Removalof these may be accomplished by
removing the mounting bolts used to hold the
actuator on the top plate of the valve and then
sliding the entire actuator assembly off of the
valve stem.

1. On DN 150 and smaller valves, open
valvefully.

2. Remove cap screws (7) in a diagonal
pattern.

3. Lift cap (3) away from valve body.

NOTE: When cap is removed from body, plugwill

remain attached to cap.

4. Using a rubber mallet, drive plug (2)
outofcap (3).

5. Remove o-ring (6) from valve body cap
counter bore.

6. Remove packing (12) and grit excluder.

7. Remove upper spacer (9) from upper plug
trunnion.

8. Remove retaining ring (11)
fromstemgroove.

NOTE: Care should be taken when removing

retaining ring. Use properly sized circlip pliers and
wear appropriate safety glasses.

9. Remove bushing (10) from upper plug stem.

10. Remove stem packing seal (12) from upper
plug stem.

11. Remove lower packing and grit excluder (8).

12. Remove lower spacer (9) from
lowerplugtrunnion.

13. Check that bearings are not unduly pitted,
galled or worn. If so, they will require
replacement.

14. Using a bearing puller if required, pull the
lower bearing (4) from the body bore and
thetop bearing from the cap bore.

15. If the lower bearing cannot be easily
removed, fill the stem hole with grease
and drive a plug of the same diameter
as the stem into the bearing bore.
The hydraulic forces generated will push
out the lower bearing. Thoroughly clean all
components and inspect all metal parts and
valve bore for corrosion. Checktheplug
for nicks or wear on the rubber seating
surface. Checkall packing for cuts or
deformation. Replace any parts needed.
The seat area ofthe body should be
inspected carefully fordamage.

ASSEMBLY INSTRUCTIONS

NOTE: When installing new parts supplied by

Emerson, all machine surfaces are coated with Pro­Coat to prevent rust. This coating can easily removed
with paint thinner.

1. Make sure the lower trunnion hole is free
ofany foreign matter.

2. Using the proper bearing installation tool
(relative to the size of the valve) tap lower
bearing into body bore flush withinside
machined counter bore on bottom
ofvalvebody.

3. Verify that lower plug trunnion if free
offoreign matter.

4. Lubricate lower plug trunnion diameter
witha coat of lubricant-never-seize.

5. Place lower spacer (9) on lower trunnion
up to the rubber coated portion of
plug. Thelower spacer should be with
counter bore facing away from rubber
coatedportion.

6. Lubricate lower packing and grit excluder(8)
with a coat of lubricant-silicone grease.

7. Place lower packing and grit excluder (8)
on lower trunnion so that it will seat in the
groove of the spacer.

8. Make sure the inside diameter of the
lower bearing (5) is clean and free of dirt,
gritorany other foreign matter.

9. Install plug into valve body by placing
the lower trunnion into the bearing that
has been placed in bottom of valve body.
Turnplug while forcing down until plug
bottoms out.

10. Lubricate upper plug trunnion with a coat
oflubricant-never-seize.

11. Place upper spacer (9 on upper inset)
onupper trunnion up to the rubber coated
portion of plug.The upper spacer should
be with counter bore facing away from
therubber coated portion.

12. Lubricate upper packing (grit excluder) (8)
with a coating of lubricant-silicone grease.

13. Place upper packing (grit excluder) (8)
onthe upper trunnion so that it will seain
the groove of the spacer.

14. Place upper bearing (4) on the upper
trunnion until it shoulders against the upper
spacer.

15. Lubricate cap o-ring (6) with a coating of
lubricant-silicone grease and fit cap o-ring
in valve body cap counter bore.

16. Install cap (3) over plug stem rotating
clockwise to ensure proper orientation.

17. Insert cap screws (7) into cap holes and
tighten by hand. Use appropriate torque
wrench and a diagonal pattern to tighten
cap screws to the recommended torque
value (appropriate for the valve size)
listedbelow

13
11

10
12

3
7

6
1

RECOMMENDED CAP SCREW TORQUES

Valve size DN Torque (Nm)

80 62.7
100 167
125 200
150 200
200 303
250 395
300 400

2

4

5

2

KEYSTONE FIGURE 580 AND 583 BALLCENTRIC VALVES

INSTALLATION AND REPAIR INSTRUCTIONS

NON-ADJUSTABLE STEM PACKING SEAL
INSTALLATION (Standard)

1. Lubricate stem packing seal with a coating
of lubricant-silicone grease.

2. Install stem packing seal (12) on upper
plug stem and into cap counter bore with
the "U" shaped side facing valve interior.
Usethebushing to (4) push the seal into
thestem bore.

NOTE: Use thin strapping material inserted in

between stem diameter and stem seal inside
diameter to help release air trapped under stem
seal.

3. Install retaining ring (11) in stem grove
tohold bushing (4) in place.

NOTE: Care should be taken when installing

retaining ring. Use only properly sized snap ring
pliers and wear appropriate safety glasses. Take
care so that the retaining ring does not spring out
and hit you.

ADJUSTABLE PACKING GLAND AND
BRIDGEINSTALLATION (Optional)

1. Place packing gland (16) on upper plug stem
over stem bushing.

2. Insert packing bridge studs (15) into body
cap holes (Note: one end of the studs is
a left handed thread and one end is right
handed - the left handed thread should be
inserted in the cap) and rotate CCW until two
(2) to three (3) threads have been engaged.

3. Place packing bridge (17) on upper plug
stem over packing bridge studs and stem
packing gland. Place nuts on packing bridge
studs and tighten by hand. Use appropriate
tool and adjustment nut to further tighten
studs until snug.

ASSEMBLY INSPECTION AND
TESTING THE VALVE

1. Rotate plug to ensure proper operation by
hand, wrench, or operator.

2. Visually check to ensure full contact of
plugand seat.

3. Valve assembly is now ready to be tested.

Rotate the valve to the full close position.
Applywater pressure to the inlet side of the
valve and check for leaks at the stem seal
andplug.

TROUBLESHOOTING

Symptom Probable cause Solution

Leakage past the flange face Flange bolts are not evenly torqued Loosen the flange bolts and re-tighten the to correct torque per

Improper flanges Confirm mating flange type by referring to AS2129
Leakage in the closed position
(leakage in the pipeline)

Leakage at the valve stem Packing (grit excluder) failure Refer to plug installation
Excessively high torque Obstruction in the pipeline Remove valve from pipeline and remove obstruction

The plug is not closing fully

Actuator is not properly adjusted

Damage or improperly aligned plug Follow 'Plug Installation' procedures or replace plug if damaged.

Line pressure exceeds valves working pressure Reduce line pressure to valve working pressure.

Valve stem or plug is bent Replace plug/stem assembly (check for water hammer or freezing

Scale build-up on stem or seat Open and close the valve several times. Operate the valve at least

ASME requirements. Loosen the flange bolts and re-tighten the to
correct torque per ASME requirements.

Refer to actuator adjustment procedures.

of line material)

once a month.

3