Emerson KEYSTONE OPTISEAL F16, KEYSTONE OPTISEAL F15, KEYSTONE OPTISEAL F14, KEYSTONE OPTISEAL F17 Installation And Maintenance Instructions Manual

KEYSTONE OPTISEAL F14/16 - 15/17 AND BREWSEAL BUTTERFLY VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Before installation these instructions must be fully read and understood

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

IMPORTANT

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

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

2. Rubber 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,

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.

thevalves should be lifted by hand or using
appropriate lifting equipment. 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 can not be
guaranteed if third party spare parts are used.

Recommendations

1. Temperature: storage temperature below
25°C, above 0°C preferable below 15°C.

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

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

www.valves.emerson.com © 2017 Emerson. All rights reserved.

VCIOM-00747-EN 15/05

KEYSTONE OPTISEAL F14/16 - 15/17 AND BREWSEAL BUTTERFLY VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

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.
All required personal protection means
shouldbe worn.

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

3. Installation and handling of valves should be
done only by personnel that is trained in all
aspects of manual and mechanical handling
techniques.

4.

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

5. Ensure that valve pressure/temperature
limitations marked on the identification tag
are within the service conditions. The trim
number on the valve’s tagplate identifies
the valve materials. See Product Manual for
valve specific P/T diagram and trim number
definition.

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

7. For DVGW-Gas approved lugged valves,
through threaded rods must be used instead
of flange bolts.

- 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 agreement with
appropriate standard.

Do not use flange gaskets, these lead to
valvedamage!

3.3 Valve installation

The valves are bi-directional and may be
fitted 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 down-stream. (Especially for
slurry service and media with a tendency for
sedimen tation). 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 no crow-bar. Do not use the valve
to spread the flanges. Seat damage might be
theresult.

YY

D max./min.

Q

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
Fig.: e.g. OptiSeal 14-112
JOB: Job number
Nominal size: DN
M.P.W.P.: maximum permissible

working pressure
Flange compatibility: e.g. PN 10/16
Temperature: e.g. -40/120°C
Body: e.g. GJL 250.

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:

- 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 EN 1092-1, table 8, type 11.
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.

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KEYSTONE OPTISEAL F14/16 - 15/17 AND BREWSEAL BUTTERFLY VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

NOTES

• The valve can be installed in the pipe-line either with

or without the actuator mounted on top of the valve.
Make sure that you can turn the disc cautious so you
can feel a mismatch resulting from a disc touching
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. Both pipe
insides to be well cleaned.

3.3.1 Existing system (see sketch)

1. Check whether the flange distance

meets the valve face-to-face dimensions.
Spreadwith adequate tooling the flanges
foreasy insertion of the valve.

2. In case of a wafer valve, insert some flange

bolts in the pipe flanges, to help you bear
the valve after insertion.

3. Close the valve so far, that the disc edge is

at least 10 mm 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 stem 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.

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.
Generallythevalve disc travels clockwise
toclose.

3.3.2 New system (see sketch)

1. With the disc in 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.

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KEYSTONE OPTISEAL F14/16 - 15/17 AND BREWSEAL BUTTERFLY VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

3.5 Sources of possible danger

This section contains some examples of
possible foreseen danger sources.

3.5.1 Mechanical

A. When manual operators are used, available

space should be checked in order to avoid
hands being clamped.

B. Mechanical sparks caused on impact of

valve and e.g. tooling, are a potential source
of ignition of surrounding atmosphere.

3.5.2 Electrical

If static charges or stray electrical currents
can initiate explosions, the valve should be
grounded to earth.

3.5.3 Thermal

A. Isolation should be used on valves with

application temperatures > +40°C and
<-20°C to prevent them from being touched
(to avoid burning).

B. If the valve is used in hot gas/fluid

applications that might give exothermic
reactions, precautions must be taken so
that the valve surface can not lead to danger
for people or the direct environment. In dust
and possible explosion zones, the operation
temperatures and ignition temperatures
fordust should be reviewed.

EXISTING SYSTEM NEW SYSTEM

1. Spread the flanges with the adequate tooling.
Insert some flange bolts to bear the valve.

2. Open the valve and remove the flange spreads. 2. Tack weld the flanges to the pipes.

1. Center a flange-valve-flange assembly
between the pipes.

3.5.4 Operational

Closing a valve too fast may result in
waterhammer in the upstream part of
thepipeline. Waterhammer results in excessive
stresses in the valve and will cause severe
damage.
Waterhammer should be avoided in all
circumstances.
Due to differential pressure across the valve
disc, butterfly valves have the tendency to be
closed by the flow. Take care when unlatching
the valve operating mechanism.

3. Close the valve clockwise, return to open position
and cross-tighten all bolting.

3. Remove the valve and finish weld.
Installthevalve according to the procedure
inthe left column.

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KEYSTONE OPTISEAL F14/16 - 15/17 AND BREWSEAL BUTTERFLY VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

3.6 TROUBLESHOOTING GUIDE

Symptom Possible cause Resolution

Valve would not rotate 1. Actuator has failed 1. Replace or repair

2. Valve packed with debris 2. Flush or clean valve to remove debris

Valve leaking 1. Valve not fully closed 1. Close valve

2. Debris trapped in valve 1. Cycle and flush (with valve open) to remove debris

3. Seat is damaged 2. Replace seat

Jerky operation 1. Extreme dry application 1. Put some silicon oil on seat or increase size of actuator

2. Air supply actuator inadequate 2. Increase air supply pressure and/or volume

4 MAINTENANCE BUTTERFLY VALVES
OPTISEALFIG. 14/16 AND BREWSEAL

The Keystone butterfly valves OptiSeal Fig.
14/16 and BrewSeal are designed to require
aminimum of maintenance.

WARNING!

Depressurize and, if necessary in case of
dangerous fluids, drain the line and flush with
appropriate cleaning fluid before starting any
maintenance. Failure to do so may cause serious
personal injury and/or equipment damage.
Before disassembling the valve, ensure the valve
has been decontaminated correctly from any
harmful gasses or liquids and that it is within
asafe temperature range for handling.
Personnel making any adjustments to the valves
should utilize suitable equipment. All required
personal protection means should be worn.
We recommend that personnel should be trained
in all aspects of these instructions before carrying
out handling of any valve.

4.1 Routine maintenance

The Keystone OptiSeal Fig. 14/16 and BrewSeal
butterfly valves are designed to require
aminimum of maintenance.
Routine maintenance or lubrication is not
required, we recommend periodic (visual)
inspection to ensure satisfactory operation and
sealing to the environment.

4.2 Removing the valve from thepipesystem

1. Turn the disc to nearly closed position.
(Thedisc is in line with the parallel flats
inthe stem).

2. Loosen all flange bolts and remove the
bolts, which prevent removing of the valve.

3. Spread the flanges with adequate tooling,
and remove the valve.

4.3 Valve disassembly (see sketch)

1. Turn the disc to almost open position.

2. Remove actuator.

3. Remove the body screws.

4. Remove the lower part of the body. This is
more or less held by the rectangular shaped
seat lip and groove. Use two screwdrivers in
the body-splits to separate the body halves
and pull the bottom-part off with a rotating
motion.

5. Pull the disc stem and seat out of the body
top part.

6. To remove the disc stem from the seat,
deform the seat into a long ‘oval’ sufficient
to clear the end of the short stem, move the
short stem-end out off the seat bore, and
pull the long end from the seat stem hole,
using a rotating motion.

7. The body top part contains a top bushing
and dirt scraper. Generally there is no need
to remove these parts.

8. For some versions of the OptiSeal only,
the bodies are equipped with bearings. If
required these can be removed.

4.4 Valve assembly (see sketch)

1. Clean all parts. Use silicone grease on
the disc stem to facilitate the assembly.
Ifthevalve has to be provided with
aTFE-lined-seat preheat this seat during
half an hour in nearly boiling water
beforeassembly.

2. If removed before, re-assemble the top
(shaft)-bushing in the body upper part.

3. For some versions of the OptiSeal, mount
the two shaft bearings and split seals.

4. Take the disc stem and insert the long
stem-end into a hole of the seat, using
atwisting motion.

5. Deform the seat into a long ‘oval’ sufficient
to clear the end of the short stem. Withthe
disc stem simulating an open position,
move the short stem-end into the elongated
seat-bore and assemble the short stem-end
into the other seat stem-hole by releasing
the distorted seat. Do not put oil or grease
between body and seat.

6. Push the long stem-end of the disc stem/
seat unit into the body top part. Push the
seat with seat lip and groove in place.

7. Assemble the bottom part of the body.
Takecare of the positioning of the bottom
part. Thelittlerectangular cast on indicator
near the body split should correspond to
the indication on the bottom part. Install the
body screws and tighten securely. Take care
that the body parts are aligned securely.

8. Assemble the dirt scraper.

9. Mount the actuation.

4.5 Re-installing the valve

See section 3.3.1

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KEYSTONE OPTISEAL F14/16 - 15/17 AND BREWSEAL BUTTERFLY VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

OPTISEAL FIGURE 14 AND BREWSEAL

Top view

Relief hole

Mounting holes

Parts identification

1. Dirt scraper 5. Seat

2. Shaft bushing 6. Disc stem

3. Body 7. Split-seal

4. Bearing (not for grey cast iron body) 8. Body screws

Parallel flats

OPTISEAL FIGURE 16 AND BREWSEAL

Top view

Relief hole

Mounting holes

Parts identification

1. Dirt scraper 5. Seat

2. Shaft bushing 6. Disc stem

3. Body 7. Split-seal

4. Bearing (not for grey cast iron body) 8. Body screws

Parallel flats

6

KEYSTONE OPTISEAL F14/16 - 15/17 AND BREWSEAL BUTTERFLY VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

5 MAINTENANCE BUTTERFLYVALVES FIG. 15/17

The Keystone butterfly valve figure 15 and17
are designed to require a minimum of
maintenance.

WARNING!

See section 4!

5.1 Routine maintenance

See section 4.1

5.2 Removing the valve from thepipesystem

See section 4.2

5.3 Valve disassembly

1. Turn the disc to almost open position.

2. Remove actuator.

3. Remove the disc screw with the O-ring.

4. Pull the shaft out of the body.

5. Remove the disc by pulling or ‘rolling’ out
ofthe seat bore.

6. Remove the seat from the body: pry under
both seat edges at one point, collapse
the seat into the shape of a round bottom
heart configuration and pull the seat out
ofthebody bore.

7. Remove circlip and pull the plug, containing
an O-ring, out of the body.

8. Remove the O-ring from the plug.

9. Remove the dirt scraper and bushing from
the body top neck.

7. Place the O-ring onto the plug. Place the
plug into the body and position it with a
circlip.

8. Assemble the dirt scraper.

9. Mount the actuator.

5.5 Re-installing the valve

See section 3.3.1

5.4 Valve assembly

1. Clean all parts.

2. Insert the bushing in top neck.

3. Collapse the seat in the shape of a round
bottom heart firmly place the ‘bottom’
part of the seat into position in the body.
Alignthe holes in the seat properly with
theholes in the body.

4. Insert the shaft with sufficient (silicone)
grease so far that it protrudes
approximately
10 mm into the inside bore of the seat.
Install the disc, with the disc screw holes
toward the actuator flange, by inserting
thedisc in the seat with the shaft bore
on the topside against the shaft, leaving
thebottom part of the disc just outside
theseat. Push the bottom part of the disc
inplace with a twisting motion.

5. Insert the shaft completely using a rotating
pressure on the shaft, and a rotating motion
on the disc. Pay special attention in order
that the seat is not damaged due to any
misalignment of stem holes.

6. Align the counter-drilled position of the
stem screw holes. Place the O-ring on
the disc screw. Install the disc screw
andtighten securely.

7

KEYSTONE OPTISEAL F14/16 - 15/17 AND BREWSEAL BUTTERFLY VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

FIGURE 15

Top view

Mounting holes

Flange locating holes

Through holes for

350 - 600 mm

Tapped holes for sizes

700 - 900 mm

Parts identification

1. Body 7. Bushing

2. Disc 8. Plug

3. Seat 9. O-ring

4. Shaft 10. Circlip

5. Disc screw 11. Dirt scraper

6. O-ring

FIGURE 17

Top view

Mounting holes

Parts identification

1. Body 7. Bushing

2. Disc 8. Plug

3. Seat 9. O-ring

4. Shaft 10. Circlip

5. Disc screw 11. Dirt scraper

6. O-ring

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