Keystone Series 60 Butterfly Valve IOM, Keystone-EN Manuals & Guides

KEYSTONE SERIES 60 BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

Before installation these instructions must be fully read and understood

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.

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.

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.

1.2 Handling

To prevent damage during handling, the valves
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.

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

VCIOM-03761-EN 15/08

KEYSTONE SERIES 60 BUTTERFLY VALVES

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.

2. Allrequired personal protection means should
be worn.

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

4. Installation and handling of valves should be
done only by personnel who are trained in all
aspects of manual and mechanical handling
techniques.

5.

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

6. 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.

7. See Product Manual for valve specific P/T
diagram and trim number definition.

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

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 ASME B16.5, table 8, Weld
Neck, dimensions B. 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 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!

FIGURE 13 INSTALLATION

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
Model: Series 60
Nominal size: DN or NPS
M.P.W.P.: Maximum permissible

working pressure
Flange compatibility: e.g. ASME 125/150
Temperature: e.g. -28°/120°C

(-20°/250°F)
Trim:

Materials of

construction

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 down­stream (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 crowbar. Do not use the valve to
spread the flanges. Seat damage may result.

2

KEYSTONE SERIES 60 BUTTERFLY VALVES

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 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

KEYSTONE SERIES 60 BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

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 (+104°F)
and < -20°C (-4°F) 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 cannot 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 hold 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 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.
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.

FIGURE 2

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

4

KEYSTONE SERIES 60 BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

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, check actuator stop settings

2. Debris trapped in valve 2.

3. Seat is damaged 3. Replace seat

Jerky operation 1. Extreme dry application 1. Put some silicone oil on seat or increase size

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

Cycle and flush (with valve open) to remove debris

of actuator

4 MAINTENANCE FOR SERIES 60
RESILIENT SEATED BUTTERFLY VALVES
SIZES DN 50 - 300 (NPS 2 -12)

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 Series 60 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 shaft).

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 Figure 3)

1. After removal of valve from the piping
system, open the valve fully.

2. Remove the handle or actuator.

3. On sizes 50 mm - 300 mm (2” - 12”), remove
the stem retaining pins (7).

4. Pull out the upper shaft (4).

5. Pull out the lower shaft (5).

6. Remove the disc (3) from the liner (2). Do not
damage the disc edge.

7. Remove the liner (2).
Note: Liner can only be removed in the

direction away from the retention lip in the
body (1)

8. If valve has bearings (6), remove by tapping
with blunt instrument.

9. Inspect all components for wear and replace
as required.

4.4 Valve assembly (see Figure 3)

1. Clean all reusable parts.

2. If valve has bearings (6), tap one in from top
of valve neck flange until it is about 6 mm
(¼”) from top surface. Tap the other in from
inside the body seat bore into the bottom
of the valve neck flange - about 6 mm (¼")
from the bottom surface.

3. Apply a lubricant or soapy solution
compatible with the elastomer to facilitate
assembly.

4. Insert liner (2) into body by pressing it into
the body evenly. Be certain to line up the
shaft holes and to place the elastomer free
phenolic side of the liner so that it contacts
the retention lip in the body when inserted
on lug style bodies.

5. Insert disc (3) in open position into liner.
Make certain broached end of the disc with
internal drive flats, is at the upper stem end
of the body.

6. Coat the upper shaft (4) with a general
purpose elastomer compatible lubricant and
install into body.

7. Install lower shaft (5).

8. Install retaining pins (7) to both shafts.

9. Install the operator.

10. Check assembly by opening and closing the
valve several times.

11. Follow installation instruction for
reinstalling the valve in the piping system.

4.5 Re-installing the valve

See section 3.3.1

5

A

A

7

A

A

7

KEYSTONE SERIES 60 BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

SERIES 60 (WAFER)
DN 50 - 300 (NPS 2 - 12)

Topview

Detail ‘A’

Detail ‘B’

PARTS LIST

Item Description

1 Body
2 Liner
3 Disc
4 Upper shaft
5 Lower shaft
6 Bearing

4

7 Retaining pin

6

1

Detail ‘A’

6

7

2

5

3

SERIES 60 (LUG)
DN 50 - 300 (NPS 2 - 12)

Topview

Detail ‘C’

Detail ‘A’

Detail ‘B’

Detail ‘B’

PARTS LIST

Item Description

1 Body
2 Liner
3 Disc

4

6

4 Upper shaft
5 Lower shaft
6 Bearing
7 Retaining pin

Detail ‘C’

1

Detail ‘A’

6

7

2

5

3

FIGURE 3

Detail ‘C’

Detail ‘B’ Detail ‘C’

6

KEYSTONE SERIES 60 BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

5 MAINTENANCE FOR SERIES 60
RESILIENT SEATED BUTTERFLY VALVES
SIZES DN 350-600 (NPS 14-24)

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 (see Figure 4)

1. Remove the valve from piping system.

2. Fully open the valve.

3. Remove the actuator.

4. Remove the adjusting screw / plug (6).

5. Remove the thrust washer (10).

6. Remove the retaining screw (9).

7. Pull out the lower shaft (5).

8. Pull out the upper shaft (4).

9. Remove the disc (3).

10. Inspect the bearings (7 and 8) for wear.
Remove if necessary.

11. Inspect the liner (2) for wear. Remove if
necessary by tapping it out using a soft drift.

Note: Liner can only be removed in

thedirection away from the retention lip
inthe body (1)

12. Inspect all components for wear and replace
as required.

6. Lubricate and install the upper shaft (4).

7. Lubricate, and install the lower shaft (5).

8. Install the thrust washer (10).

9. Put a small amount of Loctite
equivalent on the threads of the adjusting
screw / plug (6) and install the screw by
turning it into the body until the bottom shaft
contacts the disc. Do not over tighten.

10. Install retaining screw (9).

11. Follow installation instruction for
reinstalling the valve in the piping system.

5.5 Re-installing the valve

See section 3.3.1

®

#242 or

5.4 Valve assembly (see Figure 4)

1. Clean all reusable parts.

2. Install the bearing (7 and 8) in the body.
Note: the upper shaft bearing is longer of
the two bearings, drill the appropriate size
hole through the upper shaft bearing at the
retention screw hole in the body (1) for the
retaining screw (9).

3. Install liner (2) in the body (1) by locating
the alignment rib on the liner with the
alignment guide in the body and tapping the
liner into the body.

4. Lubricate the sealing surfaces and the shaft
holes of the liner with silicone lubricant.

5. Install the disc (3) in the open position. Make
certain broached end of disc with internal
drive flats, is at the upper stem end of the
body.

7

A

A

KEYSTONE SERIES 60 BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

SERIES 60 (WAFER)
DN 350 - 600 (NPS 14 - 24)

Topview

A

A

Detail ‘A’

Detail ‘B’

Detail ‘C’

PARTS LIST

Item Description

1 Body
2 Liner
3 Disc
4 Upper shaft
5 Lower shaft
6 Plug

4

8

7 Lower bearing

8. Upper bearing

9. Retaining screw

10. Thrust washer

1

Detail ‘A’

9

2

3

7

5

10

6

Detail ‘B’

Detail ‘C’

SERIES 60 (LUGGED)
DN 350 - 600 (NPS 14 - 24)

Topview

FIGURE 4

Detail ‘A’

Detail ‘B’

Detail ‘C’

PARTS LIST

Item Description

1 Body
2 Liner
3 Disc
4 Upper shaft
5 Lower shaft
6 Plug

4

8

7 Lower bearing

8. Upper bearing

9. Retaining screw

10. Thrust washer

1

Detail ‘A’

9

2

3

7

5

10

6

Detail ‘B’

Detail ‘C’

8

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