Keystone Manuals: Series GR resilient seated butterfly valves GRW/GRL, Keystone-EN Manuals & Guides
KEYSTONE SERIES GR RESILIENT SEATED BUTTERFLY VALVES GRW/GRL
INSTALLATION AND OPERATION MANUAL
Before installation these instructions must be fully read and understood
IMPORTANT
Before valves are installed or used the following
actions are recommended.
1. Valves/parts have to be inspected and
thoroughly cleaned if required.
2. Elastomer 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, the valves
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.
Forother categories, please contact the factory.
1 STORAGE AND HANDLING
1.1 Storage
When valves are to be stored for some time
(2months 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.
should be lifted by hand or using appropriate
lifting equipment. Do not fasten lifting devices
around the valve operating shaft, actuator
or through the valve waterway. The valve
should be lifted with chains or slings which
are fastened to rods or bolts which go through
the bolt holes in the body flanges. 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 cannot be
guaranteed if third party spare parts are used.
Recommendations
1. Temperature: storage temperature below
25°C (77°F), above 0°C (32°F) preferable
below 15°C (59°F).
2. Humidity: storage conditions should be such
that condensation does not occur, store in
a dry environment. Maximum 50% relative
humidity.
3. Light: valve elastomers 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.
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VCIOM-06269-EN 18/04
KEYSTONE SERIES GR RESILIENT SEATED BUTTERFLY VALVES GRW/GRL
INSTALLATION AND OPERATION MANUAL
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.
Allrequired 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 who are 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 nameplate 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.
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
Model: Series GRW or GRL
Nominal size: DN or NPS
M.P.W.P.: Maximum permissible
working pressure
Flange compatibility: e.g. ANSI 125/150
PN10/16
Temperature: e.g. -40/120°C
(-40/250°F)
Trim:
Materials of
construction
pressure (see pressure-temperature
diagram). End Of Line (EOL) service
is not recommended for applications
with larger than D max inside
diameters.
- If the flange (or pipe) is provided with a raised
face, the diameter of this shall be at least 8mm
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 accordance with
appropriate standard.
Do not use flange gaskets, as this could lead
to valve damage!
3.3 Valve installation
The valves are bi-directional and may be
installed 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
sedimentation). 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 not a crow-bar. Do not use the valve
to spread the flanges. Seat damage might result.
FIGURE 13 INSTALLATION
YY
D max./min.
Q
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 (see Figure 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
or ASME B16.5, table 8, Weld Neck,
dimensions B. For D max. inside
diameters larger than those listed
previously and smaller than JIS B
2220 flange types SOP, SOH and
SW the max. operational pressure
is reduced to 70% of the valve rated
2
KEYSTONE SERIES GR RESILIENT SEATED BUTTERFLY VALVES GRW/GRL
INSTALLATION AND OPERATION MANUAL
NOTES
• The valve can be installed in the pipe-line either
with or without the actuator mounted on top of the
valve. Make sure to turn the disc slowly in the event
there is a mismatch causing the disc to touch 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 and pipe insides
should be well cleaned.
3.3.1 Existing system (see Figure 2)
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. In case of a wafer valve, insert some flange
bolts in the pipe flanges, to help you hold the
valve after insertion.
3. Close the valve so that the disc edge is at
least 10 mm (⅜”) 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 shaft
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. For normal installation
the valve disc travels clockwise to close.
3.3.2 New system (see Figure 2)
1. With the disc in the 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.
3
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