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KEYSTONE COMPOSEAL BUTTERFLY VALVES, WAFER STYLE
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Before installation these instructions must be fully read and understood
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.
The CompoSeal wafer butterfly valve is
designed for wafer use only. No dead end
service!
Ensure that valve materials are compatible with
the pipeline fluid. 1.3 Handling
1 STORAGE AND HANDLING
1.1 Protection
Keystone butterfly valves are delivered with
protection in accordance with the Keystone
Engineering Instructions, to protect the valve
from damage. Wrapping and/or covers should
be left in place until installation of the valve.
1.2 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.
1.2.1 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.
Recommendations
1. Temperature: storage temperature below
25°C (77°F), above 0°C (32°F) preferable
below 15°C (60°F).
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.
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.
To prevent damage during handling, 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 vibrations during transport. Any
flange protection needs 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 or
hydraulic actuator or other instruments.
2 INSTALLATION
WARNING
For safety reasons it is important to take the
following precautions before starting to work on the
valve:
1. Personnel making any adjustment 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 the valves should
only be done by personnel that is trained in all
aspects of manual and mechanical handling
techniques.
4. Misuse of the valve is not allowed. The valve,
handles, actuators and other parts may not be
used as ‘climbing tools’.
5. Ensure that valve pressure/temperature
limitations marked on the valves tag plate
are within the service conditions. The trim
number on the valves tag plate 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.
2.1 Visual valve inspection
1. Confirm that the materials of construction
listed on the valve are appropriate for the
service intended and are as specified.
2. Check if valve and actuator are not damaged
during transport or handling.
VCIOM-00786-EN 17/11Emerson.com/FinalControl © 2017 Emerson. All Rights Reserved.
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KEYSTONE COMPOSEAL BUTTERFLY VALVES, WAFER STYLE
INSTALLATION AND MAINTENANCE INSTRUCTIONS
2.2 Flange and pipe compatibility
Check matching of flange drilling pattern of
valve and pipe flange before assembly.
Flanges have to meet the following
requirements (Fig. 1):
- 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.
-
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 O-ring design of the Keystone CompoSeal
eliminates the need for gaskets. If for some
reason required, flange gaskets can also be
used. When flange gaskets are used (min.
1 mm / max. 2 mm thick rubber gaskets are
recommended) the O-rings must be removed
from the body. Use flange bolting in accordance
with the appropriate standard.
2.3 Valve installation
The valves are bi-directional and can 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 discedge opening
downstream (especially for slurry service and
media with a tendency for sedimentation).
For optimum valve control and smooth
performance, it is recommended to have 10 to
20 pipe diameters of straight run inlet piping
and 3 to 5 pipe diameters straight outlet piping.
Do not use the valve as a crow-bar to spread
the flanges, this might lead to damage to
the flange area and/or damage to the O-ring
sealing.
NOTES
- The valve can be installed in the pipeline either with
or without the actuator mounted on top of the valve.
Make sure you are able to turn the disc carefully to a
more closed/open position to prevent the disc edge
from touching the adjacent flanges while positioning
the valve.
- 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 the previous paragraph ‘1.3 Handling’.
- If an actuator or handle (especially the composite
handle) is to be mounted on the valve, apply a little
bit of grease to the shaft to ensure easy assembly.
Avoid hammering or hitting on the handle or
actuator during assembling at all times.
-
Remove the 4 snap-off nibs for installing the valve
between AS2129 E flanges DN 80 (NPS 3) only (Fig. 2).
IMPORTANT
Mating flange faces should be in good condition
and free of dirt and/or inclusions.
Both pipe insides must be well cleaned before
installing the valve.
2.3.1 Existing system
1. Check whether the flange distance meets
the valve face-to-face dimensions. Spread
the flanges with adequate tooling for easy
insertion of the valve.
2. Close the valve so far, that the disc edge is
at least 10 mm within the body flanges.
3. Insert the valve between the flanges, pay
extra attention to the flange sealing O-rings.
Adequate flange spreading is required to
prevent the O-rings from rolling out of its
groove. Place 2 two flange bolts trough the
pipe flanges and the locating lugs of the
valve to support the valve.
4. Check if the flange sealing O-rings are still
in place.
5. Center the valve body and insert all flange
bolts. Tighten the flange bolts hand tight.
6. Slowly open the valve completely. The disc is
in line with parallel flats.
7. Maintain the valve flange alignment while
gradually removing the flange-spreaders
and tighten the flange bolts hand tight.
8. Slowly close and open the valve to check for
adequate disc clearance.
9. Cross tighten all the bolts with the
recommended bolt torque shown in
Table 1. Do not exceed the maximum bolting
torques, as this can lead to overloading of
the composite body!
FIGURE 1
YY
Dmax/min
FIGURE 2
Q
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KEYSTONE COMPOSEAL BUTTERFLY VALVES, WAFER STYLE
INSTALLATION AND MAINTENANCE INSTRUCTIONS
TABLE 1
Size
DN (NPS)
40 (1.5) 15 / 50 / 60 130/450/550 20 / 55 / 70 180/500/625 20 / 55 / 70 180/500/625 15 / 50 / 60 130/450/550
50 (2) 15 / 50 / 60 130/450/550 20 / 55 / 70 180/500/625 20 / 55 / 70 180/500/625 20 / 55 / 70 180/500/625
65 (2.5) 20 / 55 / 70 180/500/625 30 / 90 / 110 270/800/975 30 / 90 / 110 270/800/975 30 / 90 / 110 270/800//975
80 (3) 30 / 90 / 110 270/800/975 20 / 55 / 70 180/500/625 20 / 55 / 70 180/500/625 30 / 90 / 110 270/800/975
100 (4) 40 / 130 / 160 350/1100/1400 30 / 90 / 110 270/800/975 30 / 90 / 110 270/800/975 30 / 90 / 110 270/800/975
125 (5) 40 / 130 / 160 350/1100/1400 40 / 130 / 160 350/1100/1400 40 / 130 / 160 350/1100/1400 40 / 130 / 160 350/1100/1400
150 (6) 40 / 130 / 160 350/1100/1400 50 / 170 / 210 450/1500/1800 50 / 170 / 210 450/1500/1800 50 / 170 / 210 450/1500/1800
200 (8) 50 / 170 / 210 450/1500/1800 60 / 240 / 300 550/2125/2650 50 / 170 / 210 450/1500/1800 60 / 240 / 300 550/2125/2650
250 (10) 50 / 170 / 210 450/1500/1800 60 / 240 / 300 550/2125/2650 70 / 240 / 300 625/2125/2650 70 / 240 / 300 625/2125/2650
300 (12) 60 / 170 / 210 550/1500/1800 70 / 240 / 300 625/2125/2650 80 / 240 / 300 700/2125/2650 80 / 240 / 300 700/2125/2650
NOTES
Bolt specifications: minimum class 8.8, coarse thread, friction thread and nut-flange friction: 0.14
PN 6 PN 10 PN 16 ASME 150
Minimum / Recommended / Maximum flange bolt torque Nm (lbs in)
2.3.2 New system
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 (do not exceed the maximum
tightening moments, see table 1).
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.
5. Finish-weld the flanges to the pipe and
allow the flanges to cool completely.
6. Install the valve according the procedure for
installing in the existing system.
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 composite body
and the flange sealing rubber O-ring.
2.4 Valve verification
Check the operation of the valve by operating it
from ‘fully open’ to ‘completely closed’ position.
To verify the valve operation, the disc position
indicator on the actuator or the handle should
rotate between the ‘fully open’ and ‘completely
closed’ indicators on the actuator or throttling
plate. Generally the valve disc travels clockwise
to close.
2.5 Sources of possible danger
2.5.1 Mechanical
When manual operators are used, available
space should be checked to prevent the risk of
jamming hands.
IMPORTANT
Use pliers to snap-off the nibs and wear eye
protection to prevent hand and eye injuries.
2.5.2 Electrical
The composite material can be electro
statically charged by a fluid passing on the inand/or outside of the valve. When discharging
a spark might rise. Behavior of the valve is not
different from plastic piping.
2.5.3 Thermal
A. If the valve is used in applications with a
fluid temperature greater than 40°C (104°F)
or less than -20°C (-4°F) precautions should
be taken to prevent injury from touching
the valve outer surface. Also, the handle
or operator of the valve might be extreme
hot or cold. Personnel should use proper
personal protection equipment to prevent
injuries. For example: protection gloves.
B. Hot surfaces can be a potential source of
ignition of the environment.
2.5.4 Operational
A. Closing a valve too fast may result in
water hammer in the upstream part of the
pipeline. Water hammer results in excessive
stresses in the valve and will cause severe
damage. Water hammer should be avoided
in all circumstances.
B. A fluid passing the disc of a butterfly
valve has the tendency to close the valve
disc. Take care when unlatching the valve
operating mechanism.
2.6 TROUBLESHOOTING GUIDE
Symptom Possible cause Resolution
Valve would not rotate Actuator has failed Replace or repair
Valve packed with debris Flush or clean valve to remove debris
Valve leaking Valve not fully closed Close valve
Debris trapped in valve Cycle and flush (with valve open) to remove debris
Seat is damaged Replace valve
Jerky operation Debris trapped in valve Cycle and flush (with valve open) to remove debris
Air supply actuator inadequate Increase air supply pressure and/or volume
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KEYSTONE COMPOSEAL BUTTERFLY VALVES, WAFER STYLE
INSTALLATION AND MAINTENANCE INSTRUCTIONS
3 MAINTENANCE
The Keystone CompoSeal is 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. Only personnel
trained in all aspects of manual and mechanical
handling techniques must carry out handling of
the valves.
Parts identification
1 Body
2 Disc stem
3 Seat
4 O-ring
3.1 Routine maintenance
Routine maintenance or lubrication is not
required other than periodic inspection to
ensure satisfactory operation and sealing.
3.2 Removing the valve
1. Turn the disc to nearly closed position.
(The disc is in line with the parallel flats).
2. Loosen all flange bolts and remove the
bolts.
3. Spread the flanges with adequate tooling,
and remove the valve.
3.3 Valve disassembly
Disassembly is not possible. The body halves
are fixed by a one way connection.
Parallel flats
Flange locating holes
Top view
Mounting holes
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The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by
our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without
notice.
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