Keystone 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.
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.

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.
Allrequired 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

PN10/16

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 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!

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

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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.

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KEYSTONE SERIES GR RESILIENT SEATED BUTTERFLY VALVES GRW/GRL

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.

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KEYSTONE SERIES GR RESILIENT SEATED BUTTERFLY VALVES GRW/GRL

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. Cycle and flush (with valve open) to remove
debris

3. Seat is damaged 3. Replace seat

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

of actuator

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

TABLE 1 - Bottom shaft tapped hole dimensions

Valve size

50 2 M6
65 2½ M8
80 3 M8
100 4 M8
125 5 M10
150 6 M10
200 8 M10
250 10 M12
300 12 M12

Hole dimensionDN NPS

4 MAINTENANCE FOR SERIES GRW/GRL
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 GRW/GRL 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. Turn the disc to almost open position.

2. Remove actuator.

3. Remove the circlip from the top of the body.

4. Pull the upper shaft out of the body.

5. Remove the bushing, shaft seal and circlip
from the shaft.

6. Unscrew and remove the plug from the
bottom of the body.

7. Pull the lower shaft out of the body
(athreaded hole is provided in the end of
the shaft). (See Table 1 for tapped hole
dimensions)

8. Remove the disc by pulling or ‘rolling’ out of
the seat bore.

9. Remove the seat from the body: pry under
both seat edges at one point, collapse the
seat into the shape of a round bottom heart
configuration and pull the seat out of the
body bore.

10. Remove bearings from shaft bores.

4.4 Valve assembly (see Figure 3)

1. Clean all parts. Use silicone grease on the
disc to facilitate the assembly.

2. Mount the two shaft bearings close to the
bore of the body.

3. If removed before, re-assemble the packing
in the body.

4. Collapse the seat in the shape of a round
bottom heart and firmly place the ‘bottom’
part of the seat into position in the body.
Align the holes in the seat properly with the
holes in the body.

5. Fit the circlip to the groove in the upper
shaft.

6. Insert the upper shaft with sufficient
(silicone) grease so that it protrudes
approximately 10 mm (⅜”) into the inside
bore of the seat. Insert the lower shaft with
sufficient (silicone) grease so that it is flush
with the inside bore of the seat. Install the
disc, with the hexagonal bore to the top.
Insert the disc in the seat with the shaft bore
on the topside against the shaft, leaving
the bottom part of the disc just outside
the seat. Ensure the keyway or parallel

flats on shaft are aligned to the disc edge.

Pushthebottom part of the disc in place
with a twisting motion.

7. Insert the shafts completely using a rotating
pressure on the shaft, and a rotating motion
on the disc. Pay special attention in order
that the seat is not damaged due to any
misalignment of stem holes.

8. Put some sealant on the plug and screw it
into the lower shaft bore.

9. Fit the bushing over the top of the shaft and
into the top of the body. Retain it in place
with the circlip.

10. Mount the actuation.

4.5 Re-installing the valve

See section 3.3.1

5

A

A

A

A

KEYSTONE SERIES GR RESILIENT SEATED BUTTERFLY VALVES GRW/GRL

INSTALLATION AND OPERATION MANUAL

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

Topview

Detail ‘A’

Detail ‘B’

Detail ‘C’

PARTS LIST

Item Description

3

10

6

9

7

1

Detail ‘A’

11

2

1 Body
2 Disc
3 Upper shaft
4 Lower shaft
5 Seat
6 Upper bushing
7 Shaft seal
8 Plug
9 Shaft circlip
10 Body circlip
11 Upper and lower bearing

5

11

4

8

SERIES GRL (LUGGED)
DN 50-300 (NPS 2-12)

Topview

Detail ‘A’

Detail ‘B’

Detail ‘B’

Detail ‘C’

PARTS LIST

Item Description

3

10

6

9

7

1

Detail ‘A’

11

2

1. Body

2. Disc

3. Upper shaft

4. Lower shaft

5. Seat

6. Upper bushing

7. Shaft seal

8. Plug

9. Shaft circlip

10. Body circlip

11. Upper and lower bearing

5

11

4

FIGURE 3

8

Detail ‘C’

Detail ‘B’ Detail ‘C’

6

KEYSTONE SERIES GR RESILIENT SEATED BUTTERFLY VALVES GRW/GRL

INSTALLATION AND OPERATION MANUAL

5 MAINTENANCE BUTTERFLY VALVES SERIES
GRW/GRL DN 350-900 (NPS 14-36)

The Keystone Series GRW/GRL butterfly
valves are designed to require a minimum of
maintenance.

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. Turn the disc to almost open position.

2. Remove actuator.

3. Remove the disc screw with the O-ring from
the disc.

4. Remove the circlip from the top of the body.

5. Pull the shaft out of the body.

6. Remove the bushing, shaft seals and circlip
from the top of the shaft.

7. Remove the disc by pulling or ‘rolling’ out of
the seat bore.

8. Into the shape of a round bottom heart
configuration and pull the seat out of the
body bore.

9. Remove circlip from the bottom body plug
and pull the plug out of the body.

10. Remove the O-ring from the plug.

11. Remove bearings from shaft bores.

5. Insert the shaft completely using a rotating
pressure on the shaft, and a rotating motion
on the disc. Pay special attention in order
that the seat is not damaged due to any
misalignment of stem holes.

6. Align the counter-drilled position of the
shaft with the disc screw hole. Place the
O-ring on the disc screw. Apply thread
locking compound around disc screw
thread. Install the disc screw and tighten
securely. (see Table 2 for suggested
tightening torques)

7. Place the O-ring onto the bottom plug.
Place the plug into the body and position it
with a circlip.

8. Place the shaft seals on the inside and
outside of the bushing then fit it over the
top of the shaft and into the top of the body.
Retain it in place with the circlip body.

9. Mount the actuator.

5.5 Re-installing the valve

See section 3.3.1

5.4 Valve assembly (see Figure 4)

1. Clean all parts.

2. Fit bearings into shaft bores (2 bearings are
to be installed close to the bore of the body
and 2 bearings at the outer ends of the shaft
bores). Collapse the seat in the shape of a
round bottom heart firmly place the ‘bottom’
part of the seat into position in the body.
Align the holes in the seat properly with the
holes in the body.

3. F

it the shaft circlip to the groove in the shaf

4. Insert the shaft with sufficient (silicone)
grease so that it protrudes approximately
10 mm (⅜”) into the inside bore of the seat.
Install the disc, with the disc screw holes
toward the valve top-plate, by inserting
the disc in the seat with the shaft bore on
the topside against the shaft, leaving the
bottom part of the disc just outside the seat.
Pushthe bottom part of the disc in place
with a twisting motion.

TABLE 2 - Recommended disc screw tightening torques

Valve size Tightening torque

DN NPS Nm ft•lbs

350-400 14-16 140 103
450-500 18-20 270 200
600-800 24-32 470 347
900 36 1270 937

t.

7

KEYSTONE SERIES GR RESILIENT SEATED BUTTERFLY VALVES GRW/GRL

INSTALLATION AND OPERATION MANUAL

SERIES GRW (WAFER)
DN 350-900 (NPS 14-36)

Topview

Detail ‘A’

Detail ‘B’

16

3

11

14

13

10

12

1

15

5

6

Detail ‘A’

2

4

15

9

PARTS LIST

Item Description

1. Body

2. Disc

3. Shaft

4. Seat

5. Disc screw

6. Disc screw O-ring

7. Plug

8. Plug circlip

9. Plug O-ring

10. Bushing

11. Body circlip

12. Shaft circlip

13. Body O-ring

14. Shaft O-ring

15. Bearing

16. Parallel key

SERIES GRL (LUGGED)
DN 350-900 (NPS 14-36)

Topview

Detail ‘A’

8

7

Detail ‘B’

PARTS LIST

Item Description

16

3

11

14

13

10

12

1

15

5

6

Detail ‘A’

2

4

1. Body

2. Disc

3. Shaft

4. Seat

5. Disc screw

6. Disc screw O-ring

7. Plug

8. Plug circlip

9. Plug O-ring

10. Bushing

11. Body circlip

12. Shaft circlip

13. Body O-ring

14. Shaft O-ring

15. Bearing

16. Parallel key

FIGURE 4

Detail ‘B’

15

9

8

7

Detail ‘B’

8

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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.

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9