Keystone Series V30/V32 Marine High Performance Butterfly Valves, Keystone-EN Manuals & Guides

KEYSTONE SERIES V30 / V32 MARINE HP BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

Before installation these instructions must be fully read and understood

they were not damaged in handling. This is
especially important in the case of valves with
‘fail- open’ actuators.

2.4

Confirm that the materials of construction
listed on the valve body are appropriate for the
service intended and are as specified.

2.5

Locate the directional arrow on the valve name
plate that defines the preferred mounting
orientation in respect to the pressure. In most

1 GENERAL

Suggested installation orientation is with valve
shaft horizontal or inclined from vertical. Unless
otherwise recommended by Emerson, mount
the valve in the preferred direction with the
directional arrow pointing to the lower pressure
side so that the front face of the disc will be
upstream when the valve is in the closed position.
Thermal insulation of the body is mandatory for
operating temperatures above 200 °C (392 °F).
The Keystone marine high performance butterfly
valve offers the following body styles: Series V30
for wafer style and Series V32 for lug style.

2 INSPECTION

2.1

cases, the valve is properly installed when the
actual fluid flow or high pressure is acting on the
front face of the disc when the valve is closed.

2.6

Ensure that the packing seal cover screws are tight.

CAUTION

The valve should be installed in the closed position
to insure that the seat and disc are not damaged
during installation. Particular care should be taken
with valves equipped with ‘fail open’ actuators.
Failure to insure proper handling may result in
damage to the valve. If the pipe is lined, confirm
that the disc rotation does not contact the lining
during the opening stroke. Failure to confirm that
the disc rotation does not contact the lining may
result in damage to the valve.

Carefully remove the valve from the shipping
package (box or pallet) to avoid any damage to
the valve and, in the case of automated valves,
to the electric or pneumatic/hydraulic actuator
or instrumentation.

2.2

Prior to installation, clean the inside of the
valve. Insure that there are no solid objects
such as pieces of wood, plastic or packing
materials within the valve or on the valve seat.

2.3

Inspect the seat and disc edge to insure that

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IMPORTANT

Whenever possible, install the valve with the shaft
in the horizontal position and, if possible, with the
cast-in disc stop located top-side of the pipe. If the
shaft cannot be positioned horizontally, position
the shaft so that it is not on the vertical centerline
in a horizontal pipe run. This will minimize any
depositing of solid particles present in the fluid
into the lower bearing.

Keystone is either a registered trademark of Emerson
International Service AG or its affiliates in the United
States and/or other countries. All other brand names,
product names, or trademarks belong to their
respective holders.

© 2017 Emerson. All rights reserved. VCIOM-02541-EN 20/08

KEYSTONE SERIES V30 / V32 MARINE HP BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

3 INSTALLATION

The valves are shipped with flange gasket
surface protection. Before installing the valve,
remove the protection and carefully clean and
de-grease both surfaces with a solvent.

3.1 SERIES V32 - LUG STYLE

3.1.1 Orient the valve with the directional flow
arrow (preferred direction) pointing in the
proper direction.

3.1.2 Insert the valve between the flanges until
the two bottom holes in the valve align
with the two lower flange holes.

3.1.3 Insert a bolt or stud through the flange
and thread it into the holes in the valve
body. This will allow the valve to center
itself properly for the installation of the
flange gaskets.

3.1.4 Install the flange gaskets and the
remaining flange bolting.

3.1.5 Use the crossover method to tighten all
flange bolts.

3.2 SERIES V30 - WAFER STYLE

3.2.1 Orient the valve with the directional flow
arrow (preferred direction)pointing in the
proper direction.

3.2.2 Insert the valve between the flanges until
the alignment holes at either side of the
valve match the corresponding holes in
the flanges.

3.2.3 Insert a long bolt or stud through
the flange and thread it through the
alignment hole. This will allow the valve to
center itself properly for the installation
of the flange gaskets.

3.2.4 Install the flange gaskets and the
remaining flange bolting.

3.2.5 Remove the long bolts/studs from the
lower alignment holes and replace with
correctly-sized bolts.

3.2.6 Using the crossover method, tighten all
flange bolts.

4 VALVE CHECKOUT

4.1

Tighten the packing seal screws just enough to
prevent shaft leakage.

4.2

4.3

For automated valves, set the air pressure/
electrical voltage for at least the minimum
given to operate the actuator. For pneumatic
actuators, do not apply more than 1.25 times
the pressure for which the actuator was
designed.

NOTE

For spring return actuators with positioners,
overpressure will cause excessive time delay in the
spring movement for the valve disc to travel out of
the seat.

5 OPERATION

The Series V30/V32 has been designed to
require a minimum of maintenance. Generally,
only maintenance on the packing seal box is
required.

6 MAINTENANCE

If shaft leakage is observed through the packing
box, replace the packing seal O-rings.

7 DISASSEMBLY

To begin disassembly, refer to the part lists and
proceed as follows:

WARNING

Depressurize the valve and associated piping
before disassembly. Failure to do so may cause
serious personal injury and/or equipment
damage.

1. Remove the valve from the line. Clean
the valve according to proper cleaning
procedures as outlined by the plant or
according to a prescribed procedure.

2. Remove the actuator and relevant
connecting key. Note the actuator position
relative to the valve.

CAUTION

Throughout disassembly and assembly, always
use cardboard or brass shims to protect the
valve body, disc, flange and sealing surfaces from
damage. Failure to do so may result in serious
damage to the valve.

7.1 REMOVING THE DISC-TO-SHAFT TAPERED
PIN CONNECTIONS

7.1.1 Open the valve disc to its full open
position.

NOTE

On valve sizes DN 250 (NPS 10) and larger, it is
recommended that two workers perform the disc
tapered pin removal process.

7.1.2 Place the disc in a vise

7.1.3 Using a tool steel punch, locate the punch
on the small end of the disc taper pin
and then strike the punch with a heavy
hammer.

NOTE

Some of the weld on the taper pins may need to be
removed by grinding.

WARNING

When placing the valve into the bench vise, make
sure the small end of the disc taper pin faces the
assembler. Hold the punch with a punch holder
or a pair of vise grips. Otherwise, serious injury
may occur.

7.2 REMOVING THE BOTTOM COVER

ASSEMBLY (APPLICABLE ABOVE DN 300
(NPS12))

To disassemble the bottom cover assembly,
remove the following bottom cover assembly
components:

• bottom cover plate

• washer

• bolts

Check the operation of the valve by stroking
it to ‘full open’ and ‘full close’. To determine
the valve orientation of the disc, keyways are
aligned with the disc. The valve disc travels
clockwise to close.

2

KEYSTONE SERIES V30 / V32 MARINE HP BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

7.3 REMOVING THE PACKING SEAL COVER
ASSEMBLY

7.3.1 Untighten the packing seal screws.

7.3.2 Remove the packing seal cover.

7.4 REMOVING THE SHAFT AND DISC

7.4.1 When removing the shaft from the disc,
clamp the vise jaws on to the shaft area
above the valve body top plate.

7.4.2 Once the vise jaws are secure against
the shaft, drive the wedge-shaped
chisel/punch between the valve body top
plate and the bench vise.

7.4.3 As the valve body moves away from the
bench vise, the shaft is removed from the
disc hubs.

7.4.4 Continue to reposition the valve body with
the bench vise so as to allow removal of
shaft.

CAUTION

Physically hold the disc to prevent from falling and
becoming damaged during removal. When shaft is
removed from the disc, the disc is unsupported.

WARNING

Smaller discs may be removed by hand DN 50 to
DN 200 (NPS 2 to NPS 8). Remove larger discs
with proper hoisting equipment. Failure to do
so may result in personal injury or damage to
equipment.

7.5 REMOVING THE SEAT RETAINER RING

Remove the seat retainer ring by removing the
hex socket screws from the seat retaining ring
inserted into the body.

7.6 REMOVING THE SEAT ASSEMBLY

To remove the seat assembly.

7.7 REMOVING THE PACKING SEAL

ASSEMBLY FOR PACKING SEAL
REPLACEMENT WITH SHAFT IN BODY

7.7.1 Using the screws, grab and remove each
packing seal.

7.8 REMOVING THE SHAFT BEARINGS
(ABOVEDN300 (NPS 12))

NOTE

A special bearing removal/installation tool is required
to remove or install the shaft bearings (5). The tool
O.D. dimension should be as near in size as the valve
shaft bore I.D. dimension and have a Class 3 fit. Any
Machinist Handbook can provide Class 3 tolerances.

7.8.1 Insert the removal tool in the valve body
top plate area and down the shaft journal
until the tool contacts the upper bearings.

7.8.2 Remove the upper bearings by striking
the tool with a hammer.

7.8.3 Insert the removal tool in the valve body
bottom plate area and down the shaft
journal until the tool contacts the lower
bearing.

7.8.4 Strike the tool until the lower bearing (5)
is clear of the lower body shaft journal.

7.9 INSPECTING THE VALVE COMPONENTS

7.9.1 After disassembly, visually inspect the
seat retainer ring and the bottom cover
plate.

7.9.2 Make sure all body sealing surfaces:

• are flat

• are free of corrosion damage

• have a smooth surface

• are free of burrs.

Remove any burrs with fine grit

sandpaper.

7.9.3 Inspect for scratches around disc edges:

• If scratched, smooth the edge with

fine grit sandpaper (220/400 wet/dry
sandpaper)

• Remove the scratch by using a blending

motion and extend the smoothed area
at least two inches above, below and
around the original scratch

• To polish the disc edge, use a powered

wire brush

• Finish sand or polish the edge on a

lathe, as required.

7.9.4 Check to see that the shaft-to-bearing
contact locations are free of galling.

7.9.5 Check to see that the shaft-to-packing
seal contact area is free of scratches.

FIGURE 1

FIGURE 2

FIGURE 3
Seat retainer ring and screws

NOTE

To remove the packing seal with the shaft still in the
valve body, two long, slender screws are required.
must be at least eighty millimeter long. The most
commonly used screws are ‘drywall screws’.

NOTE

If scratched or galled, these surfaces should be
polished or replaced.

3

KEYSTONE SERIES V30 / V32 MARINE HP BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

SERIES V30 / V32 WAFER AND LUG
DN 50 (NPS 2) - DN 300 (NPS 12)

PARTS LIST

Item Description

1 Body
2 Disc
3 Shaft
4 Seat
5 Seat retaining ring
6 Packing seal cover
7 Packing seal
8 Bearing
9 Spacer
10 Disc taper pin
11 Hex socket screw
12 Hex socket screw
13 O-ring (packing seal)
14 Key

See detail

Detail

4

KEYSTONE SERIES V30 / V32 MARINE HP BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

SERIES V30 / V32 WAFER AND LUG
DN 350 (NPS 14) - DN 900 (NPS 36)

PARTS LIST

Item Description

1 Body
2 Disc
3 Shaft
4 Seat
5 Seat retaining ring
6 Packing seal cover
7 Packing seal
8 Bearing
9 Spacer
10 Botom cover
11 Disc taper pin
12 Hex socket screw
13 Hex bolt and washer
14 Hex socket screw
15 O-ring (packing seal)
16 O-ring (bottom cover)
17 Key

See detail

Detail

5

KEYSTONE SERIES V30 / V32 MARINE HP BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

8 ASSEMBLY

8.1 INSTALLING SHAFT BEARING

8.1.1 Insert the body into a vice as shown
below. Protect the body flange surfaces
from the vise clamping surfaces with
cardboard or brass shims.

8.1.2 To avoid damaging the shaft bearing,
gently press the bearing into the shaft
body journal by lightly striking the bearing
with a rubber mallet.

8.1.3 Once the shaft bearing has been partially
inserted into the valve body journal, insert
the installation/removal tool against the
upper bearing.

8.1.4 Strike the tool with a hammer to continue
inserting the shaft bearing until it is flush
with the body flowpath surface.

8.2 INSTALLING THE DISC/SHAFT ASSEMBLY

CAUTION

To prevent damage to the disc, do not allow the
disc edges to contact the body flowpath surface.

8.2.1 Install the shaft into the valve body shaft
journals with the pinning grooves position
on top of the shaft side view.

8.2.2 Insert the disc locating spacers into the
grooves on both sides of the disc. Align
the spacer flat surface with the body flat
surface on the shaft journals.

8.2.3 While holding the disc with the backside
of the disc facing up and the double pin
hub facing toward the body shaft journal,
position the disc in the body.

8.2.4 Push the shaft through the spacers and
into the disc hub shaft holes.

8.2.5 If required, rotate the shafts until the
shaft tapered pin holes are in alignment
with the disc hub tapered pin holes.

8.2.6 Manually push the disc tapered pins to
install them through the disc hub tapered
pin holes.

8.2.7 Install the packing seal (see ‘Installing
the packing seal’).

8.2.8 Carefully drive the tapered pins firmly into
the connection with a punch and hammer.

8.4 INSTALLING THE BOTTOM COVER
ASSEMBLY (APPLICABLE ABOVE DN 300
(NPS12))

8.4.1 Set O-ring in the bottom cover.

8.4.2 Align the bottom cover plate with the body
bottom surface.

8.4.3 Tighten the bolts and washers.

8.5 INSTALLING NBR, EPDM AND

FLUOROELASTOMER (FKM) SEATS

8.5.1 Place the upper marking (size and
material and ‘FRONT’ letter) of the seat
seen into the body seat pocket.

8.5.2 Install the seat with the smallest inside
diameter down. If the seat is incorrectly
installed, it will ride higher on the disc
than if installed correctly.

8.6 INSTALLING THE SEAT RETAINER RING

8.6.1 Check to make sure the disc is in the
closed position against the body disc stop.

8.6.2 Place the seat retainer ring on the
seat pocket. Align the holes in the seat
retainer ring with the holes in the body.

8.6.3 Install and tighten screws according to
cross tightening.

NOTE

The two tapped holes allow the use of eye bolts so the
seat retaining ring can be lifted to and from the body.

FIGURE 4

FIGURE 5

FIGURE 6

FIGURE 7

8.3 INSTALLING THE PACKING SEAL

8.3.1 Install the packing seal with O-rings, and
packing seal cover into the upper journal
of the valve body.

8.3.2 Keeping the disc assembly in the closed
position, tighten the packing seal cover
screws have been correctly tightened
when the packing seal cover is contacted
enough to the surface of valves body.

FIGURE 8

6

KEYSTONE SERIES V30 / V32 MARINE HP BUTTERFLY VALVES

INSTALLATION AND OPERATION MANUAL

CAUTION

The standard seat retainer screws provide enough
force to press the seat retainer ring for shipment
and installation.

8.7 TIG WELDING OF THE DISC TAPER PINS

8.7.1 After assembling and testing the valve,
lock the disc/shaft taper pins by forcefully
driving the tapered pins in place with a
hammer and steel punch.

8.7.2 TIG weld the disc taper pins. Weld using
filler rod referenced in table 1.

TABLE 1

Shaft and pin material Filler rod

431 stainless steel 316 stainless steel
K Monel 500
Inconel

Symptom Possible cause Resolution

Valve won’t rotate

Shaft packing seal leaking

Bottom cover leaking

Valve leaking

Jerky operation

®

®

Actuator has failed 1. Repair or replace

1.

2.

Valve packed with debris 2. Flush or clean valve to remove debris

3.

Shaft key has sheared 3. Determine cause of shearing and correct, replace

1.

Packing seal O-ring damaged 1. Depressurize valve and replace packing seal O-rings smooth the contact surface

1.

O-ring damage 1. Remove valve from service and replace O-rings smooth the contact surface of

1.

Valve not fully closed 1. Close valve

2.

Debris trapped in valve 2. Cycle and flush to remove debris

3.

Seat or disc edge damaged 3. Remove valve from service and replace seat and/or repair or replace disc

4.

Actuator mechanical closure stop incorrect 4. Adjust the stop to allow further closure

1.

Shaft/bearing damaged 1. Disassemble valve and inspect for damage, repair or replacedamaged parts,

2.

Actuator/shaft adapter misaligned 2. Remove actuator mounting and realign

3. Air supply inadequate 3. Increase air supply pressure

Monel
Monel

®

®

of O-rings

O-rings

reassemble

FIGURE 9

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