Emerson Keystone K-LOK H Series, Keystone K-LOK H2W, Keystone K-LOK H1W, Keystone K-LOK H2L, Keystone K-LOK H1L Installation, Operation And Maintenance Instructions
KEYSTONE K-LOK SERIES H HIGH PERFORMANCE BUTTERFLY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Before installation these instructions must be read fully and understood
2. Prior to installation, clean the inside of
the valve. Ensure that there are no solid
objects such as pieces of wood, plastic or
packing materials within the valve or on
thevalveseat.
3 Inspect the seat and disc edge to ensure
that they were not damaged in handling.
This is especially important in the case of
valves with ‘fail-open’ actuators.
4. Confirm that the materials of construction
listed on the valve nameplate are
appropriate for the service intended and
are as specified.
5. Locate the directional arrow on the body
that defines the preferred mounting
orientation in respect to the pressure. In
most cases, the valve is properly installed
when the actual fluid flow or high pressure
is acting on the front face of the disc when
the valve is closed.
GENERAL
Suggested installation orientation is with
valve shaft horizontal or inclined from vertical.
Unless otherwise recommended by Emerson,
mount the valve in the preferred direction with
the directional arrow pointing to the lower
pressure side so that the front face of the disc
will be upstream when the valve is in the closed
position.
Thermal insulation of the body is mandatory for
operating temperatures above 200°C (392°F).
H-series K-LOK offers the following body
styles:
Series H1W and H2W - Wafer
Series H1L and H2L - Lugged
INSPECTION
1. Carefully remove the valve from the
shipping package (box or pallet) to avoid
any damage to the valve and, in the
case of automated valves, to the electric
or pneumatic/hydraulic actuator or
instrumentation.
6. Ensure that the packing gland bolting nuts
are tight.
CAUTION
The valve should be installed in the closed
position to ensure that the seat and disc are
not damaged during installation. Particular
care should be taken with valves equipped with
‘failopen’ actuators. Failure to ensure proper
handling may result in damage to the valve.
If the pipe is lined, confirm that the disc rotation
does not contact the lining during the opening
stroke. Failure to confirm that the disc rotation
does not contact the lining may result in damage
to the valve.
IMPORTANT
Whenever possible, install the valve with the shaft
in the horizontal position and, if possible, with the
cast-in disc stop located top-side of the pipe. If the
shaft cannot be positioned horizontally, position
the shaft so that it is not on the vertical centerline
in a horizontal pipe run. This will minimize any
depositing of solid particles present in the fluid
into the lower bearing.
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KEYSTONE K-LOK SERIES H HIGH PERFORMANCE BUTTERFLY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
INSTALLATION
The valves are shipped with flange gasket
surface protection. Before installing the valve,
remove the protection and carefully clean and
de-grease both surfaces with a solvent.
Series H1L and H2L - Lug style
1. Orient the valve with the directional flow
arrow (preferred direction) pointing in the
proper direction.
2. Insert the valve between the flanges until
the two bottom holes in the valve align with
the two lower flange holes.
3. Insert a bolt or stud through the flange and
thread it into the holes in the valve body.
This will allow the valve to center itself
properly for the installation of the flange
gaskets.
4. Install the flange gaskets and the remaining
flange bolting.
5. Use the crossover method to tighten all
flange bolting.
Series H1W and H2W - Wafer style
1. Orient the valve with the directional flow
arrow (preferred direction) pointing in the
proper direction.
2. Insert the valve between the flanges until
the alignment holes at either side of the
valve match the corresponding holes in
the flanges.
3. Insert a long bolt or stud through the flange
and thread it through the alignment hole.
This will allow the valve to center itself
properly for the installation of the flange
gaskets.
4. Install the flange gaskets and the remaining
flange bolting.
5. Remove the long bolts/studs from the lower
alignment holes and replace with correctlysized bolts.
6. Using the crossover method, tighten all
flange bolts.
VALVE CHECKOUT
1. Tighten the packing gland bolting just
enough to prevent shaft leakage. Overtightening will decrease packing life and
increase operating torque requirements.
2. Check the operation of the valve by stroking
it to ‘full open’ and ‘full close’. To determine
the valve orientation of the disc, double
D’s and keyways are aligned with the disc.
The valve disc travels clockwise to close.
3. For automated valves, set the air pressure/
electrical voltage for at least the minimum
given to operate the actuator. For pneumatic
actuators, do not apply more than 1.25times
the pressure for which the actuator was
designed.
Note: for spring return actuators with
positioners, overpressure will cause excessive
time delay in the spring movement for the valve
disc to travel out of the seat.
OPERATION
The H-Series K-LOK has been designed to
require a minimum of maintenance. Generally,
only maintenance on the packing box is
required.
MAINTENANCE
If shaft leakage is observed through the packing
box, tighten the gland nuts.
Note: do not over-tighten packing box gland
nuts. Over-tightening will increase the torque
required to operate the valve. When tightening
the gland nuts, use half-turn increments until
leakage has stopped.
DISASSEMBLY
To begin disassembly, refer to the parts list
(Figure 2) and proceed as follows:
WARNING
Depressurize the valve and associated piping
before disassembly. Failure to do so may cause
serious personal injury and/or equipment
damage.
1. Remove the valve from the line. Clean
the valve according to proper cleaning
procedures as outlined by the plant or
according to a prescribed procedure.
2. Remove the actuator and relevant
connecting key. Note the actuator position
relative to the valve.
CAUTION
Throughout disassembly and assembly, always
use cardboard or brass shims to protect the
valve body, disc, flange and sealing surfaces from
damage. Failure to do so may result in serious
damage to the valve.
Removing the disc-to-shaft wedged pin
connections
1. Open the disc to its full open position.
Note: on valve sizes DN 250 (NPS 10) and
larger, it is recommended that two workers
perform the wedged pin (5) removal process.
2. Place the disc in a vice, see Figure 1.
3. Locate a steel punch on the wedged pins
and strike the punch with ahammer.
Note: some of the weld on the three wedged
pins may need to be removed by grinding.
FIGURE 1
Valve properly clamped in place
2
KEYSTONE K-LOK SERIES H HIGH PERFORMANCE BUTTERFLY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
FIGURE 2
Exploded view
17
12
10
11
9
7
18
19
1
8
5
Number 26
H1 DN 250 - 900 (NPS 10 - 36)
H2 DN 200 - 900 (NPS 8 - 36)
27
28
3
6
4
1
2
14
13
15
16
16
15
Bottom cover and disc
stop DN 700 - 900
(NPS28 - 36)
20
21
22
23
PARTS LIST
Pos Description
1 Body
2 Disc
3 Upper shaft
4 Lower shaft
5 Wedge pins
6, 7 Bearings
8 Anti extrusion ring
9 Shaft packing
6
Pos Description Pos Description
10 Packing gland follower
11 Snap ring
12 Gland bridge
13 Seat
14 Seat retaining ring gasket
15 Seat retaining ring
16 Seat retaining ring bolting
17 Gland bridge bolting
18, 19 Gland bridge nut, SRR nut
20* Bottom cover gasket
21* Bottom cover
22, 23* Bottom cover bolting
24* Nut disc stopper
25* Bolt disc stopper
26 Key
27, 28 Tag
* DN 700-900 / NPS 28-36
3
KEYSTONE K-LOK SERIES H HIGH PERFORMANCE BUTTERFLY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
WARNING
When placing the valve into the vice, make sure
the wedged end of the pin faces the assembler.
Hold the punch with a punch holder or a pair of
vice grips. Otherwise, serious injury may occur.
Removing the bottom cover
(onlyDN700-900/ NPS 28-36)
To disassemble the bottom cover assembly,
remove the following components:
• bottom cover (21)
• washers (22)
• bottom cover gasket (20)
• bolts (23)
Removing the packing gland assembly
1. Unthread the nuts (19) from the packing
bridge bolts (17).
2. Remove the gland bridge (12).
Removing the upper shaft
CAUTION
Throughout this operation, make sure the disc
edges remain protected from contact with the
body by installing cardboard at all disc hub areas.
Failure to do so may cause damage to the disc
sealing edge. Protect the shaft from the vice teeth
to prevent damage and to eliminate potential
packing leakage.
CAUTION
Physically hold the disc to prevent the disc from
falling and becoming damaged during removal.
When both the upper shaft and lower shaft are
removed from the disc, the disc is unsupported!
WARNING
Smaller discs may be removed by hand
(DN50-200 / NPS 2-8). Remove larger discs with
proper hoisting equipment. Failure to do so may
result in personal injury or damage to equipment.
Removing the seatretainer ring
Preferably place the valve in horizontal position
with the retaining ring (15) facing upwards.
Remove the seat retainer ring by removing the
bolts (16) and nuts (19), in case of a wafer type
valve).
WARNING
Prevent the retaining ring from falling by holding
the ring by hand (DN 50-200 / NPS 2-8) or by using
proper hoisting equipment. Failure to do so may
result in personal injury or damage to equipment.
Removing the seatretainer gasket
Remove the seat retainer gasket (14). Use a
powered wire brush tool to remove the gasket
material that may have adhered to the mating
body surfaces.
FIGURE 3
Removal of upper shaft
FIGURE 4
Removal of lower shaft
1. When removing the upper shaft (3) from the
disc (2), clamp the vice jaws on to the upper
shaft area above the valve body (1) top plate.
2. Once the vice jaws are secure against
the upper shaft, drive the wedge-shaped
chisel/punch between the valve body top
plate and the vice, see Figure 3.
3. As the valve body moves away from the vice,
the upper shaft is removed from the upper
disc hub.
4. Continue to reposition the valve body with
the vice so as to allow removal of upper
shaft (3).
WARNING
Prevent the body from falling by holding the body
by hand (DN 50-100 / NPS 2-4) or by using proper
hoisting equipment. Failure to do so may result in
personal injury or damage to equipment.
Removing the lower shaft and disc
1. Take a slide hammer puller and screw it
in the threaded hole of the bottom shaft(4)
(For DN 700-900 / NPS 28-36 enter the
bottom shaft on bottom cover side).
2. Gently pull the slide hammer to pull out the
bottom shaft, see Figure 4.
Removing the seatassembly
To remove the seat assembly, treat the seat
(13) and its associated components as a single
assembly by removing the total seat assembly
at once.
Removing the shaft packing (9) with shaft (3)
in body (1)
Two screws with a diameter not greater than
8mm (¼") and a length of at least 150 mm (6”)
are required. The most commonly used screws
are 'drywall screws'. Using the screws, grab
and remove each packing ring, one at the time.
Removing the shaft packing (9) with shaft
removed from body
Use a hook-type tool to grab and remove each
packing ring, one at the time.
Removing the flanged shaft bearings
Use a driving punch and place it against the
end of the flanged bearing (6). Gently tap with a
hammer on the other side of the driving punch
to remove the bearing.
4
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