Emerson K-LOK 36, K-LOK 37 Installation Manual

KEYSTONE K-LOK® SERIES 36 AND 37 HIGH PERFORMANCE BUTTERFLY VALVE

ISO VERSION INSTALLATION AND OPERATION MANUAL

Before installation, these instructions must be carefully read and understood.

3. Inspect the seat and disc edge to insure 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.

6. Ensure that the packing gland nuts and

GENERAL

bottom cover bolts are tight.

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 direc tional arrow pointing to the lower pres sure 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 392°F [200°C]. K-LOK offers the following body styles:

Series 36 and 37 – Wafer style Series 36 and 37 – Lug Style

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.

2. Prior to installation, clean the inside of the valve. Insure that there are no solid objects such as pieces of wood, plastic or packing materials within the valve or on thevalveseat.

CAUTION

The valve should be installed in the closed position to insure that the seat and disc are not damaged during installation. Particular care should be taken with valves equipped with ‘fail open’ actuators. Failure to insure 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 36 AND 37 HIGH PERFORMANCE BUTTERFLY VALVE

ISO VERSION INSTALLATION AND OPERATION MANUAL

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 36 and 37 – 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.

Series 36 and 37 – 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.

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 1.25times 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 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 4) 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.

3. Removing the Bracket and Adapter

To disassemble adapter and bracket remove

the following components

: Bracket (28) : Adapter (26) : Washers (29, 31) : Bolts (30) : Set screw (32) : Key (25) : Nuts (16)

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.

Figure 1 - Valve properly clamped in place.

Removing the disc-to-shaft tapered pin connections

1. Open the valve disc (2) to its full open position.

Note: on valve sizes NPS 10 (DN 250) and larger, it is recommended that two workers perform the disc tapered pin (5) removal process.

2. Place the disc in a vise.

3. Using a tool steel punch, locate the punch on the small end of the disc taper pin (5) and then strike the punch with a heavy hammer.

Note: some of the weld on the taper pins (5) may need to be removed by grinding.

WARNING

When placing the valve into the bench vise, make sure the small end of the disc (2) taper pin faces the assembler. (see Figure 1)

Hold the punch with a punch holder or a pair of vise grips. Otherwise, serious injury may occur.

KEYSTONE K-LOK® SERIES 36 AND 37 HIGH PERFORMANCE BUTTERFLY VALVE

ISO VERSION INSTALLATION AND OPERATION MANUAL

Removing the bottom cover assembly

To disassemble the bottom cover assembly, remove the following bottom cover assembly components:

• bottom cover plate (18)

• bottom cover gasket (17)

• washer (19)

• screw (20)

Removing Bottom cover gasket

Remove the Bottom cover gasket (17). Use pick and hook tool to remove the gasket that may have adhered to gasket groove in bottom cover.

Removing the lower shaft assembly

CAUTION

1. Spray penetrating oil into the disc hub where it meets the shaft connection.

2. Insert an eyebolt into the lower shaft (4) and use it to pull the lower shaft (4) out of the disc (2). See chart below for proper eyebolt size.

Valve size Tap

NPS 2 to NPS 6 (DN 50 to 150) M6 X 1 NPS 8 to NPS 12 (DN 200 to 300) M10 X 1.5 NPS 14 to NPS 36 (DN 350 to 900) M14 X 2

3. Lightly strike the backside of the disc hub area with a hammer if the shaft is resistant to removal.

Removing the upper shaft and disc

Figure 2 - How the upper shaft is removed from

the upper disc hub.

CAUTION

Physically hold the disc to prevent the disc from falling and becoming damaged during removal. When both the upper shaft (3) and lower shaft (4) are removed from the disc (2), the disc is unsupported.

WARNING

Smaller discs may be removed by hand (NPS 2 to NPS 8 (DN 50 to DN 200)). Remove larger discs with proper hoisting equipment. Failure to do so may result in personal injury or damage to equipment.

Removing the seatretainer ring

Remove the seat retainer ring (23) by removing hex socket screws (24) from the seat retaining ring for the lugged body or the retainer plate screw (34) from the locating plates (33) and/or clips (35) for the wafer body. (see Figure 3)

Figure 3 - Seat retainer ring and parts.

Removing the packing assembly

Method 1: for packing replacement with shaft inbody

1. Remove the packing gland bolts (14) nuts and belleville washer (15,16) packing gland bridge (13), packing gland follower (12) and shaft retention ring (11). Using the screws, grab and remove each packing ring, one at a time.

Note: to remove the packing set (10) with the upper shaft (3) still in the valve body (1), two long, slender screws are required. The screws must not have a diameter greater than ¼” and must be at least six inches long. The most commonly used screws are ‘drywall screws’.

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 vise teeth to prevent damage and to eliminate potential for packing leakage.

1. When removing the upper shaft (3) from the disc (2), clamp the vise jaws on to the upper shaft (3) area above the valve body top plate.

2. Once the vise jaws are secure against the upper shaft (3), drive the wedge-shaped chisel/punch between the valve body (1) top plate and the bench vise. (see Figure 2)

3. As the valve body (1) moves away from the bench vise, the upper shaft (3) is removed from the upper disc (2) hub.

4. Continue to reposition the valve body (1) with the bench vise so as to allow removal of upper shaft (3).

Removing the seatretainer gasket

Remove the seat retainer gasket (22). Use a powered wire brush tool to remove the gasket material that may have adhered to the mating body surfaces.

Removing the seatassembly

To remove the seat assembly, treat the seat (21) and its associated components as a single assembly by removing the following:

• seat (21.1)

• wire wrap (21.2)

• seat backing ring (21.3)

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