Emerson KEYSTONE FIGURE PCS17 Instruction, Operation And Maintenance Manual

KEYSTONE FIGURE PCS17 KNIFE GATE VALVES

INSTRUCTION, OPERATION AND MAINTENANCE MANUAL

Before installation these instructions must be fully read and understood

FIGURE 1

Inspect and tighten
packing gland nuts
to stop any leakage

FIGURE 2

Bolt holes in the chest
or upper flange area
are blind tapped

GENERAL INFORMATION

The Keystone PCS17 knife gate is a
bi-directional shut-off valve. It can be installed
without concern over direction of flow. Itwill
shut-off equally with in either direction.
Allvalves should be operated within the design
pressure and temperature ranges. Do not
exceed 100% of the maximum pressure rating
of the valve at any time during its operation.
Pressure spikes beyond the valve’s pressure
rating are solely the responsibility of the user.

Initial inspection

1. Examine entire valve and report any damage
or discrepancies immediately.

2. Accessories, if any, including solenoids,
limit switches, positioners, etc., are
tested for functionality prior to shipment.
Examinecarefully for damage which may
occur during shipment.

3. Operators: Standard manual handwheels
may be shipped loose for field installation.
It is necessary to use a pipe wrench or large
crescent wrench to properly tighten the
handwheel retaining nut. Be sure to fully
tighten.

4. Packing Assembly: The packing gland bolts
should be checked and adjusted to obtain
afirst time packing seal. Packing gland
nuts may become slightly loose when valve
is shipped. Field adjustment is expected
and desired. (Figure 1. Tighten just enough
to stop any leakage. Overtightening may
increase valve operating torque and shorten
packing life).

INSTALLATION INSTRUCTIONS

Please take note of the specific installation
tags provided with each valve.

1. The mating line flanges must be properly
aligned prior to attempting installation.
Slipon or weld flanges can be used.
Nevertry to make up for misaligned pipe
flanges by the line bolting. Pipe supports
and/or expansion joints should be used
tominimize pipe loads on valves.

2. Flange gaskets suitable for the application
are required, sized to fit the raised face of
the valve.

3. The port flanges of the PCS17, DN 50 to
600(NPS 2 to 24) are drilled and tapped
to ASME B16.5/150, DN 750 (NPS 30) is
per MSS-SP44 with the face to face per
MSS-SP81. The bolt holes in the chest
or upper flange area are blind tapped,
see Figure 2.

NOTE

Care must be taken when installing studs or bolts
in the tapped holes of the flange in the chest area
to prevent damage, see Figure 2 and Figure 3.

4. Cap screws or bolts that are too long can
pinch the valve body, thereby forcing the
body wall into the gate, springing the gate
out of line, see Figure 3. Additionaldamage
can occur on the gate face, such as scoring
or scratching of the gate. This type of
damage normally requires the valve be
returned to our shop for repair.

5. To avoid damage, it is recommended that
studs be used on all tapped bolt holes,
especially the upper chest holes. If cap
screws are used, be sure that they do not
enter beyond the depth of the tapped hole
when fully tightened.

NOTES

1. All knife gate valves are designed and
manufactured to be installed in applications where
no more than 1g (0.04 oz.) of force In excess of
gravity is applied to the valve in any direction. This
1g (0.04 oz.) force can be an effect of traffic, wind,
or earthquake. Allpiping systems should contain
independent support mechanisms and should not
utilize the valve as a sole means of support.

2. If the valve is supplied with an actuator other
than the standard handwheel operator, additional
support may be required. Especiallyif the valve is
not installed in the vertical position. See page 8 for
further details.

3. Accessories,ifany, including solenoids, limit
switches, positioners, etc., are tested for
functionality prior to shipment.

4. Examinecarefully for damage which may occur
during shipment.

© 2017 Emerson. All Rights Reserved.Emerson.com/FinalControl VCIOM-02874-EN 19/05

KEYSTONE FIGURE PCS17 KNIFE GATE VALVES

INSTRUCTION, OPERATION AND MAINTENANCE MANUAL

OPERATION

1. To close the valve and provide isolation,
the actuator (handwheel, bevel gear,
air/hydraulic cylinder or electric actuator)
moves the gate in a linear motion through
the packing box until the gate is seated
against the resilient seat. To open, reverse
the operation and the gate moves up and out
of the packing box, opening the valve port.

2. The valve packing assembly requires
occasional adjustment. Frequency of
adjustment is dependent application
conditions including but not limited to
pressure, temperature and number
ofcycles.

3. All valves should be operated within the
design pressure and temperature ranges.
Under no circumstances should the valves
be operated at conditions outside these
parameters.

4. The operator of any valve should have an
understanding of the effects of opening/
closing the valve with regards to its role
in the overall piping system. Operators of
valves under pressure should take Caution
to ensure that the valve is in good operating
condition prior to operating it under
pressure.

5. Certain processes utilize flammable,
caustic and/or otherwise unstable
media. Careshould be taken in these
circumstances to ensure the operator is
aware of the specific health and safety risks
associated with that medium. Additionally,
Caution should be taken around all valves
as injury or damage may occur from the
leakage of hot, high pressure and/or caustic
materials from a gasket and/or packing
joint. Packing and/or gasket leaks may
cause external corrosion damage to the
valve.

6. Take care in the manual actuation of
valves used in applications with elevated
temperatures. Ensure the individual
operating the valve does not come
in contact with any hot areas of the
valve. Inmany elevated temperature
applications, the handwheel may be too hot
to handle, take reasonable preCautions.
Severetemperature applications may
require optional insulation the valves
toprotect operators from the heat.

7. When operating the valve stand clear of any
moving parts such as the spindle and/or
gate assembly, use of gloves is suggested
when operating manual valves to minimize
the risk of injury.

8. All manually operated valves are designed
for hand input. Do not apply excessive input
torque via pipe wrenches, “cheater bars”,
or other devices. If a manual handwheel
actuated valve is difficult to operate due to
torque requirements, it is recommended
that the valve be supplied with or converted
to a bevel gear, air/hydraulic cylinder or
electric motor actuator.

9. Electric motor actuated valves should be
left in their factory set condition, unless
the system operating parameters dictate
a change. If changes are necessary, they
should be performed in small increments
using the lightest/lowest setting possible
to achieve the desired performance and
then the valve/actuator function inspected.
Excess torque and/or thrust in the motor
settings may damage or lockup the valve.
Never remove a motor operator, gear
operator or manual operating assembly
from a valve while it is pressurized unless
gate has been secured from movement and
lockout/tagout applied per company safety
procedures and policies. The valve must be
completely relieved of all pressure prior to
disassembly or removal from pipeline.

10. Motorized PCS17 valves are position
seated and should never be torque seated.
Donotuse the motor torque settings to seat
the valve.

11. Care should be taken to ensure that
electrical motors are wired correctly to the
power source. Incorrect phasing of 3-phase
wiring may cause valve/motor damage.

FIGURE 3

Cap screw

Wrong Right

NOTE

Body can be deformed or fractured if flange bolting
is too long or overtorqued.

Stud with nut

TABLE A - MAX. FLANGE BOLT TORQUE

Bolt size Torque

Imperial Metric lb/ft Nm

⅝" M16 55 75
¾" M20 65 88
⅞" M22 110 149
1" M25 135 183
1⅛" M30 150 203
1¼" M30 200 271
1½" M40 250 339

2

KEYSTONE FIGURE PCS17 KNIFE GATE VALVES

INSTRUCTION, OPERATION AND MAINTENANCE MANUAL

FLANGE DIMENSIONS

Valve size
DN (NPS) Flange Bolt circle Dia. Quantity O.D. flange Dia. Bolt size Raised face Dia. Face-to-face Valve flange OD

50 (2) SP-81 120.65 (4.75") 4 152.4 (6") 15.875 (⅝" - 11) 91.948 (3.62") 47.752 (1.88") 165 (6.496")

TBL D 114 4 150 M16 90 47.752 165
TBL E 114 4 150 M16 90 47.752 165

80 (3) SP-81 152.4 (6") 4 190.5 (7.5") 15.875 (⅝" - 11) 127 (5") 50.8 (2") 190.5 (7.5")

TBL D 146 4 185 M16 122 50.8 190.5
TBL E 146 4 185 M16 122 50.8 190.5

100 (4) SP-81 190.5 (7.5") 8 228.6 (9") 15.875 (⅝" - 11) 157.226 (6.19") 50.8 (2") 228.6 (9")

TBL D 178 4 215 M16 154 50.8 228.6
TBL E 178 8 215 M16 154 50.8 228.6

150 (6) SP-81 241.3 (9.5") 8 279.4 (11") 19.05 (¾" - 10) 215.9 (8.5") 57.15 (2.25") 285.1 (11.224")

TBL D 235 8 280 M16 211 57.15 285.1
TBL E 235 8 280 M20 207 57.15 285.1

200 (8) SP-81 298.45 (11.75") 8 342.9 (13.5") 19.05 (¾" - 10) 269.748 (10.62") 69.85 (2.75") 342.9 (13.5")

TBL D 292 8 335 M16 268 69.85 342.9
TBL E 292 8 335 M20 264 69.85 342.9

250 (10) SP-81 361.95 (14.25") 12 406.4 (16") 22.225 (⅞" - 9) 323.85 (12.75") 69.85 (2.75") 406.4 (16")

TBL D 356 8 405 M20 328 69.85 406.4
TBL E 356 12 405 M20 328 69.85 406.4

300 (12) SP-81 431.8 (17") 12 482.6 (19") 22.225 (⅞" - 9) 381 (15") 76.2 (3") 482.6 (19")

TBL D 406 12 455 M20 378 76.2 482.6
TBL E 406 12 455 M24 374 76.2 482.6

350 (14) SP-81 476.25 (18.75") 12 533.4 (21") 25.4 (1" - 8) 412.75 (16.25") 76.2 (3") 533.4 (21")

TBL D 470 12 525 M24 438 76.2 533.4
TBL E 470 12 525 M24 438 76.2 533.4

400 (16) SP-81 539.75 (21.25") 16 596.9 (23.5") 25.4 (1" - 8) 469.9 (18.5") 88.9 (3.5") 596.9 (23.5")

TBL D 521 12 580 M24 489 88.9 596.9
TBL E 521 12 580 M24 489 88.9 596.9

450 (18) SP-81 577.85 (22.75") 16 635 (25") 28.575 (1⅛" - 7) 533.4 (21") 88.9 (3.5") 641.4 (25.25")

TBL D 584 12 640 M24 532 88.9 641.4
TBL E 584 16 640 M24 552 88.9 641.4

500 (20) SP-81 635 (25") 20 698.5 (27.5") 28.575 (1⅛" - 7) 584.2 (23") 114.3 (4.5") 715 (28.149")

TBL D 641 16 705 M24 609 114.3 715
TBL E 641 16 705 M24 609 114.3 715

600 (24) SP-81 749.3 (29.5") 20 812.8 (32") 31.75 (1¼" -7) 692.15 (27.25") 114.3 (4.5") 840 (33.071")

TBL D 756 16 825 M27 720 114.3 828.8
TBL E 756 16 825 M30 717 114.3 828.8

750 (30) SP-81 914.4 (36") 28 984.25 (38.75") 31.75 (1¼" -7) 857.25 (33.75") 117.348 (4.62") -

TBL D 845 20 910 M27 809 117.348 ­TBL E 845 20 910 M30 806 117.348 -

NOTES

1. These dimensions duplicate ASME B16.5 150 flange drilling

2. Flange thickness includes 1.5 mm (

3. Through bolt flange drilling is bolt size plus 3.1 mm (⅛")

1

/

16") raised face

3

KEYSTONE FIGURE PCS17 KNIFE GATE VALVES

INSTRUCTION, OPERATION AND MAINTENANCE MANUAL

GENERAL MAINTENANCE

We recommend that all Keystone PCS17 knife
gates be inspected at least every 60 days.
The following points should be examined and
corrected as required (Figure 4):

1. Exterior overview: As piping system
components are subject to certain levels of
erosion and corrosion, periodic inspections
should be made as valves/components
may wear over time. Regular inspection
of the valve body and gate should be
performed, check for general signs of
corrosion, component wear and/or damage
caused by process media, i.e. wire draw,
steam cutting. If possible, check body wall
and gate thicknesses using calibrated
measuring devices such as micrometers
and/or ultrasonic thickness gauges.
Severe applications may require additional
inspection types and/or frequency.

2. Valve spindles, extension spindles, and
spindle nut: Look for excessive corrosion,
galling or lack of lubrication. If valve
spindle requires lubrication, utilize the
grease fitting provided and pump standard
bearing grease through the yoke hub
to lubricate the spindle and spindle nut
assembly. Additionallubrication may be
applied directly onto spindle or spindle
threads. (Use material which meets
ASTM4950GBLB.)

3. Stop nut adjustment (manual valves):
Checktightness of stop nut on valve spindle

4. Packing gland: Check for leaks or worn
packing. If leakage is occurring around the
packing gland, tighten the packing gland
bolts, being careful not to overstress the
bolting. If the valve requires repacking,
you may use any standard square braided
packing as suitable for your service.
Seeadditional instructions for repacking
on page 5.

5. If possible stroke the valve through the full
open and closed position to make sure it is
functioning properly.

SPARE PARTS

The following spare parts are recommended:

Cylinder operator (if applicable)

1 - Repair kit

Valves

1 - Replacement seat (Figure 6)
1 - Replacement packing set.

1. When ordering replacement parts for a
Keystone product or cylinder operator,
please include valve or cylinder size
andcomplete description including
serialnumber with your request.

2. Additional replacement parts such as
handwheels, spindle nut assemblies,
retainers, yoke posts, spindles, packing
glands, and gates are available from factory.
Again, please provide complete description
with serial number when ordering.

FIGURE 4

Stop nut

Spindle

Spindle nut
(under retainer)

Grease fitting

Packing gland

FIGURE 5

FIGURE 6

Stop nut

Retaining nut

Handwheel

Spindle nut

Spindle
assembly

Retainer

Retainer bolt

Packing

NOTES

1. Stop all small packing or seat leaks as soon as
possible as considerable damage can be done
tothe valve and the surrounding area if leakage
isallowed to continue to grow.

2. Replacement parts including handwheel and yoke
assemblies, gates, packing glands, seats and
packing canbe provided from our factory.

Seat

Packing

4