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KEYSTONE HILOK HIGH PERFORMANCE BUTTERFLY VALVE
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Before installation these instructions must be fully read and understood
1 GENERAL INFORMATION ON THE
INSTALLATION AND MAINTENANCE
INSTRUCTIONS
These installation and maintenance
instructions contain the information necessary
for safe and correct installation and operation
of the fitting. If any difficulties are encountered
during installation or operation which cannot
be solved with the aid of the installation and
maintenance instructions, please contact the
supplier/manufacturer for more information.
These installation and maintenance
instructions comply with the relevant applicable
EN safety standards. When installing the fitting,
the operator or the person responsible for
thedesign of the installation must ensure that
applicable national regulations are complied
with. The manufacturer reserves all rights to
make technical changes and improvements at
any time. We recommend that all maintenance,
installation and operation personnel will
understand these instructions, which are
accessible via
Emerson.com/FinalControl
2 SAFETY
Please also read through these notes carefully.
2.1 General potential danger due to:
a. Failure to observe the instructions
b. Improper use
c. Insufficiently qualified personnel
2.2 Correct use
2.2.1 Area of application
HiLok valves are valves that are used for the
isolation, throttling and regulation liquids,
together with gases, pastes and powdery
products in pipelines, vessels, apparatus etc.
The area of use of the fitting is the responsibility
of the system designer. Special characteristics
of the fitting must be taken into account.
A very wide selection of product-wetted
components parts is available which allows
suitable combination for the optimal solution
to your specific application. Always consult
themanufacturer when the fitting is to be used
with media that require or preclude the use of
certain materials.
2.2.2 Method of operation
The valve is opened or closed by turning the
valve spindle. The angle of rotation is 90°.
2.2.3 Performance data
Pressure range: see table
Temperature range: see table
Nominal diameter range: DN 50 - 900
Test pressure: 1.5 x PN
2.2.4 Usage restrictions
The product-wetted components must be
classified as resistant to the product to be
conveyed. Refer to appropriate literature or
consult the manufacturer or distributor for
advice on this.
2.2.5 Modification prohibition
Mechanical modifications to the valves or
theuse of other manufacturers’ parts for repair
purposes are not permissible. Safety is not
guaranteed if this requirement is disregarded.
Repair work must only be carried out by
themanufacturer’s trained personnel.
2.2.6 Warning about foreseeable misuse
Valves and their accessories (e.g. operating
elements) must not be misused as climbing
aids.
2.2.7 Duty to comply with the instructions for
operation, maintenance and servicing
These instructions are part of the delivery
package and must be kept clean and made
accessible to the user.
Emerson.com/FinalControl
VCIOM-00722-EN 18/01© 2017 Emerson. All Rights Reserved.
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KEYSTONE HILOK HIGH PERFORMANCE BUTTERFLY VALVE
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FIGURE 1 - PRESSURE/TEMPERATURE DIAGRAM
Pressure
(bar)
Note A
Standard version
Stainless steel only
NOTE A
PN 40 only liquids and not suitable for dangerous media such as explosive, flammable,
toxic or oxidizing media
PP metal seat
DN 50 to DN 400
Valve mounting with shaft downstream
DN 50 to DN 400 wafer
DN 50 to DN 300 lugged
Valve mounting with shaft downstream
PTFE
RTFE
Saturated
steam
Liquid
HT metal seat, DN 50 to DN 400
Valve mounting with shaft upstream
3 TRANSPORT/STORAGE
The valve is supplied with protective covers.
Do not remove the protective covers until
immediately prior to installation.
3.1 Transport
• Transport temperature -20°C to +65°C
• Protect against external force (impact, shock,
vibration)
3.2 Storage
• Storage temperature -20°C to +65°C, dry and
dust-free
• A drying agent or heating is required in damp
storage areas to protect against condensation
• Keep the valve disc in a closed position
3.3 Handling prior to installation
• With versions with protective covers, only
remove the covers immediately prior to
installation!
• Protect against the effects of weather, such
as dampness (or else use a drying agent)
• Proper treatment prevents damage
2.3 Sources of danger
2.3.1 Mechanical
When using the hand lever, it should be
ensured that there is still sufficient clearance
for the hands at the end position of the
handle, so that there is no risk of trapping.
Excessiveoscillation and vibration should be
avoided, toprevent the bolts loosening.
2.3.2 Electrical
None for a bare shafted valve
FIGURE 2 - TAGPLATE
W = wafer, L = lugged
Trim
Product
Body material
JOB number
Manufacturing in
Category
2.3.3 Thermal
Due to the range of operating temperatures
between -50°C and +400°C, surface
temperatures from -20°C to over +400°C can be
present on the valve body. Suitable precautions
should be taken to protect against burns due
to high or freezing temperatures. In particular,
insulated gloves should be worn when using
the hand lever, for example.
Diameter
Working pressure and limit temperature
Flange connection
Face to face
Maximum working pressure onto pipework
0038 Lloyd’s notified body number
Maximum working pressure in end of
line (seat installed upstream only)
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KEYSTONE HILOK HIGH PERFORMANCE BUTTERFLY VALVE
INSTALLATION AND MAINTENANCE INSTRUCTIONS
4 IDENTIFICATION
Additional identification on the valve in
accordance with EN 19, such as: DN, PN,
manufacturer’s logo. The valve body material is
cast onto the valve.
5 DIMENSIONS AND WEIGHT
Refer to the product documentation for
dimensions and weights.
6 INSTALLATION IN THE PIPELINE
The recommended installation position is with
the spindle horizontal, with the lower sealing
strip opening in the direction of flow. A butterfly
valve is not a crowbar! Please do not use it to
force the flanges apart, as this would lead to
damage to the ring bellows and seat. To avoid
damage to the disc and bellows, the protective
covers should only be removed immediately
prior to installation. It is not advisable to use the
valve for positioning pipelines in new systems.
Sparks which occur during spot welding can
damage the seat. Use adjusting pieces instead.
Final welding of the flange with the valve in
position will lead to severe damage to the valve
seat due to the high temperature. Always use
all flange bolts, even on low pressure systems.
The valve should never be pressurized if one
of the flange bolts is missing. The pipe flanges
should comply with the dimensions as indicated
in the below mentioned table.
6.1 Step-by-step valve installation
1. Check that the distance between flanges
matches the face-to-face dimension of the
butterfly valve. Before installing the valve,
spread the flanges sufficiently apart using a
suitable tool.
2. Ensure that the disc is fully closed.
3. Put the gaskets between flanges and body.
4. Center the valve by bolting the 4 locators
first.
5. Progressively tighten bolts by alternating
sides until you have full compression of
flange gaskets.
6. Check: operate valve from fully open
position to fully closed position to ensure
that nothing obstructs the disc.
7. Unidirectional end of line service with seat
mounted upstream.
6.2 Final checks
Inspection of the valve position as far as the
fully open position. Cleaning and flushing the
pipeline before the first closure.
Repeated opening and closing of the valve to
ensure unrestricted movement of the valve
disc.
7 REPAIR INSTRUCTIONS
Seat and packing maintenance can be conducted
on site based on the following instructions.
(partnumbers refer to the drawing)
7.1 Seat replacement
1. Remove valve from line (closed disc).
2. Remove retaining ring (3).
3. Extract the seat (6).
4. Gently clean:
• disc edge (2)
• seat pocket.
5. Put new seat in position (still closed disc).
6. Rescrew retaining ring.
7. Reset valve between flanges and wait
15minutes before any operations.
8. Valve is now ready.
7.2 Packing replacement
Remove all pipeline pressure from the valve.
The operation can be done directly on the valve
without removing it from line.
Procedure
1. Unscrew gland follower (8) and lift packing
gland (7).
2. Extract packing rings (10).
3. Clean upper stem (4) and packing chamber.
4. Reinstall packing rings.
5. Reset gland follower and packing gland.
6.
Adjust packing compression to avoid leakage.
ø D1
VALVE DIMENSIONS
50 65 80 100 125 150 200 250 300 350 400 450 500 600 700
ø D min 49 59 74 97 122 146 194 243 289 333 381 428 477 574 676
ø D1 in accordance with EN 1092-1
ø D min.
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KEYSTONE HILOK HIGH PERFORMANCE BUTTERFLY VALVE
INSTALLATION AND MAINTENANCE INSTRUCTIONS
8 C
AUSE AND REMEDY OF OPERATING FAULTS
If the valve function or operating action is
faulty, a check should be made to ensure that
the assembly and installation work has been
carried out and completed in accordance with
the installation and maintenance instructions.
The information relating to material, pressure,
temperature and direction of flow should be
compared with the installation diagram of
thepipeline system. Furthermore, it should be
checked whether the installation conditions
correspond to the technical data given in
thedata sheet or on the rating plate.
The safety regulations should always be
observed when troubleshooting.
9 DECOMMISSIONING
Removal of the valve for repair or servicing is
often carried out carelessly, as the valve has to
be repaired or replaced in any case. However, it
is recommended that the valve be removed with
care, so that the possible cause of damage can
be determined after removal.
WARNING
Check that the pipe is depressurized and drained.
With corrosive, inflammable, aggressive or toxic
media, ventilate the pipeline system.
10 DISPOSAL
Hand in the correctly cleaned valve to the scrap
material recycling plant. Badly cleaned valves
can cause severe burning of the hands and
other parts of the body. If the valve is passed
on to a third party, the manufacturer does not
guarantee the safety of the valve.
11 VALIDITY OF THE INSTALLATION AND
MAINTENANCE INSTRUCTIONS
These instructions are valid until the next
revision of these instructions.
12 CUSTOMER SERVICE
For further information or technical advice,
please contact your local Emerson sales
organization see Emerson.com/FinalControl
16
9
8
7
10
1
11
4
3
2
11
15
15
11
6
11
14
5
12
13
1. Only allow assembly work to be carried out
by qualified personnel (see section 2.3)
2. Almost completely close the butterfly valve
(the disc is in line with the flat faces of the
operating shaft).
3. Loosen all flange bolts and withdraw them
until the valve can be removed.
4. Spread the flanges apart using a suitable
tool and withdraw the valve.
Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product.
Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
Keystone is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions, Emerson
and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.
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.
Part Number Designation
1. 1 Body
2. 1 Disc
3. 1 Seat retaining ring
4. 1 Upper stem
5. 1 Lower stem
6. 1 Seat
7. 1 Gland
8. 1 Gland follower
9. 1 Position indicator
10. 3/4/5 Packing (depending on size)
11. 4 Bearing
12. 1 Disc locating shoulder
13. 1 Bottom end cover
14. 1 Bottom seal
15. 2/3 Pin (depending on size)
16. 1 Circlip/bolt
Emerson.com/FinalControl
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