Emerson Keystone 990 Technical Document

KEYSTONE FIGURE 990/991 BUTTERFLY VALVES

InstallatIon, operatIon and maIntenance InstructIons

1 INTRODUCTION

Keystone Figure 990/991 is a rubber lined

butterfly valve suitable for use on all fluids

except those designated as ‘unstable’

according to the Pressure Equipment Directive,

97/27/EC.

Figure 990 is available in sizes 25 mm to

300mm and has a maximum working pressure

of 10 barg over a temperature range of -10°C

to+150°C. Figure 990 has a cast iron body of

two piece design which enables the use of a

one piece disc stem.

Figure 991 is available in sizes 25 mm to

150mm and has a maximum working pressure

of 10 barg over a temperature range of -10°C

to +150°C. Figure 991 has a cast stainless

steel body of two piece design complete with

an integral notch plate for handlever use, and

this body also enables the use of a one-piece

discstem.

The one piece disc stem provides the minimum

possible flow restriction when the valve is

fullyopen.

Potentially dangerous practices:

• disregarding instructions

• improper use of product

• use of insufficiently qualified personnel

Application pressure/temperature must not be

higher than the pressure/temperature limits

shown on the datasheet.

Application medium must be in accordance

with the Keystone Chemical Compatibility list.

2 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.

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.

Recommendations

1. Temperature: storage temperature below

25°C, above 0°C preferable below 15°C.

2. Humidity: storage conditions should be such

that condensation does not occur, store in

a dry environment. Maximal 50% relative

humidity.

3. Light: valve rubbers 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 being installed or used the

following actions are recommended.

1. Valves/parts have to be inspected and

thoroughly cleaned if required.

2. Rubber 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.

Before installation these instructions must be fully read and understood

QYY

Installation in an existing system

(seediagrams)

1. Check that the gap between the flanges

can accommodate the valve face to face

dimension.

2. Spread the flanges using suitable tooling

such as flange spreaders to enable ease of

insertion of the valve between the flanges.

WARNING

Do not use the valve as a lever for this purpose.

3. Open the valve until the disc is free of the

seat but still contained within the face to

face of the valve.

4. Loosely insert two or more flange bolts

through the holes in the lower part of the

flanges to help support the valve.

5. Carefully slide the valve between the

flanges, center the valve body with the

pipeline axis, and insert the remaining

flange bolts.

6. Open the valve fully, checking that the disc

edge does not interfere with the pipeline

bore.

7. Remove any flange spreaders that have

been used and at the same time tighten

the flange bolts ‘hand tight’. Ensure that

the valve remains centered to the pipeline

axis by slowly closing the valve (clockwise

rotation of the disc stem) to check that

adequate clearance has been maintained

between the disc edge and the pipeline bore.

8. Re-open the valve (counter clockwise

rotation of the disc stem) and tighten all

flange bolts to the recommended torque

of the bolt supplier using the diagonal

sequence method.

9. Operate the valve to the desired position.

4 INSTALLATION

Installation in pipeline

Figure 990/991 valves are bi-directional and

there is no need to identify upstream and down

stream orientation.

Figure 990/991 valves can be installed in

vertical or horizontal pipelines and any

intermediate orientation.

There is no restriction on the valve stem

position (vertical, horizontal or oblique),

although for slurry service and media, which

have a tendency to deposit sediment, the

recommended installation position is with

the stem horizontal and the lower disc edge

opening downstream.

3 FLANGE AND PIPELINE COMPATIBILITY

Figure 990/991 valves are suitable for use with

flanges according to PN 10, PN 16, ANSI 150

and BS table E. Figure 990/991 is a wafer type

valve and is intended to be clamped between

flanges attached to the pipeline.

The minimum allowable pipeline bore at the

flanges shall be the ‘Q’ dimension shown in the

valve data sheet plus adequate allowance to

ensure the disc edge does not interfere with the

pipeline bore.

D max.: The optimum inside diameter (ID) is

equal to the inside diameter of flange

standard EN 1092-1, table 8, type 11.

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.

For flanges with a raised face the diameter of

the raised face shall be a minimum of 10 mm

larger than the ‘YY’ dimension shown in the

data sheet.

Do not use flange gaskets, these lead to valve

damage!

D max./min.

Flow

Open

KEYSTONE FIGURE 990/991 BUTTERFLY VALVES

InstallatIon, operatIon and maIntenance InstructIons

EXISTING SYSTEM NEW SYSTEM

1. Spread the flanges with the adequate tooling.

Insert some flange bolts to bear the valve.

1. Center a flange-valve-flange assembly between

the pipes.

2. Open the valve and remove the flange spreads. 2. Tack weld the flanges to the pipes.

3. Close the valve clockwise, return to open position

and cross-tighten all bolting.

3. Remove the valve and finish weld. Install the valve

according to the procedure in the left column.

Installation in a new system (see diagrams)

It is common practice to use the valve to help in alignment of the flanges

prior to welding the flanges into the pipeline. In such cases, the following

instruction applies:

1. Open the valve until the disc is free of the seat but still contained

within the face to face of the valve.

2. Align both mating flanges with the valve center line and secure in

position using the flange bolts.

3. Position the flange/valve/flange assembly in the pipeline.

4. Tack weld the flanges to the pipeline.

5. Remove the flange bolts and the valve.

6. Finish weld the flanges to the pipeline and allow to cool fully.

7. Follow the procedure for installation in an existing system.

KEYSTONE FIGURE 990/991 BUTTERFLY VALVES

InstallatIon, operatIon and maIntenance InstructIons

WARNING

Do not finish weld the flanges to the pipeline with the valve still assembled

to the flanges as this will result in serious damage to thevalveseat.

25 M6 6.0

40 M6 6.0

50 M8 8.0

65 M8 8.0

80 M8 8.0

100 M10 14.5

125 M10 14.5

150 M12 20.0

200 M12 20.0

250 M16 50.0

300 M16 50.0

5 MAINTENANCE

Routine maintenance is not normally necessary

for Figure 990/991 valves. If, however, the valve

does need to be serviced or repaired for any

reason, the following applies.

Removing valve from pipeline

1. Turn the disc to the almost closed position

(approximately 5° before closed). The

parallel flats or the keyway on the stem

arein line with the disc.

2. Loosen all the flange bolts and remove

enough bolts to allow the valve to be

withdrawn from between the flanges.

3. Spread the flanges using appropriate

tooling and carefully remove the valve

frombetween the flanges.

Valve disassembly

1. Turn the disc to the open position.

2. Remove the screws that fix the two body

halves together.

3. Remove the lower body half by inserting

flat ended levers into the opposite splits

between the body halves and force the body

halves apart. Broad bladed flat head screw

drivers are acceptable tools.

4. Remove the disc stem and seat from the top

body half.

5. Remove the bushing and packing from the

neck bore of the top body half.

6. Deform the seat into a long oval, which is

sufficient to release the bottom (short) end

of the stem from the seat hole.

7. Pull the long end of the stem from the other

seat hole using a twisting action if required.

Valve assembly

1. Clean all components and replace any

damaged components.

2. If the seat is TFE lined, it is necessary to

immerse the seat in near boiling water

(90°C to 98°C) for 30 minutes to give

enoughflexibility for assembly.

RECOMMENDED TIGHTENING TORQUES FOR BODY SCREWS

Valve size (DN) Bolt size Tightening torque (Nm)

KEYSTONE FIGURE 990/991 BUTTERFLY VALVES

InstallatIon, operatIon and maIntenance InstructIons

3. Insert the long end of the stem into one of

the transverse seat holes using a twisting

action. If possible, a smear of silicone

grease on the stem will ease this operation.

4. Deform the seat into a long oval sufficient

to clear the short end of the stem and push

the short end of the stem into the remaining

transverse seat hole.

WARNING

Protective gloves should be worn for this

procedure especially if a TFE lined seat is being

fitted as this will be very hot after immersion in

near boiling water.

5. Fit the long end of the disc stem into the top

half of the body and ensure that the seat is

properly located in the dovetail recess of the

body half.

6. Insert the bushing and packing into the top

end of the body neck bore.

7. Fit the bottom body half over the short end

of the disc stem and to the top body half,

ensuring that the seat is properly located in

the dovetail recess of the body half, and that

the small rectangular bosses on each body

half are aligned to each other.

8. Secure the top and bottom body halves

together using the two hexagon socket cap

screws, which should be tightened to the

recommended torque.

Abrasive fluids

Where abrasive fluids are used in the valve,

the condition of the seat and disc should be

carefully checked at each maintenance period.

Generally, tears or scores in the seat of more

than 1 mm deep would require the seat to be

replaced. Scores at the sealing edge of the disc

of more than 0.5 mm deep would require the

disc/stem to be replaced.

45°

6 SAFETY RELATED INFORMATION

1. If in any doubt regarding any aspect of

figure990/991 valves, contact your local

Emerson sales office for guidance.

2. Only use properly qualified personnel for

installation and maintenance.

3. Ensure that the pipeline is fully drained or

vented before removing the valve from the

pipeline.

4. Use appropriate protective equipment /

clothing, such as goggles, safety shoes,

industrial gloves.

5. When used on line fluids with a temperature

of 80°C or more, the valve body can become

very hot and should not be handled without

appropriate protection.

6. The body material is grey cast iron, which is

a known brittle material and heavy impacts

such as blows with a steel headed hammer

should be avoided. The piping design should

preclude the occurrence of water hammer

at the valve.

7. Where water hammer is a potential

problem, ensure that the opening and

closing speed will not cause this to occur.

8. These valves are not to be used for end of

line service.

9. This product is not intended for use in areas

where external fire is a potential hazard.

10. The piping design must take into account

the following factors and any other factors

which are not listed here, but known to

be relevant to the safe operation of the

installation.

Parts list

1Bushing

2Shaft seal

3Upper body

4Seat

5Disc stem

6Lower body

7Body screws

7 OPERATION

1. F990/991 valves are opened and closed by

turning the top of the stem through 90°

using a lever or a gearbox or a quarter turn

actuator.

2. Conventionally, the stem is turned 90°

counter clockwise to open the valve and 90°

clockwise to close the valve.

3. The valve position is indicated by the

orientation of the flats or key on the top of

the valve stem.

If the flats or the centerline of the key are

transverse to the pipeline axis, then the

valve is closed. If the flats or the centerline

of the key are in line with the pipeline axis,

then the valve is open.

4. When actuators or gearbox are used

to operated the valve, the operating

instructions of the actuator or gearbox

mustbe complied with.

KEYSTONE FIGURE 990/991 BUTTERFLY VALVES

InstallatIon, operatIon and maIntenance InstructIons

10.1. Valve weights which are shown in

thedata sheets.

10.2. Formation of condensate in gas

pipelines.

10.3. Elimination of turbulence and vortex

potential at the valve.

10.4. Pipeline vibrations.

11. The valve design has not taken into account

earthquake loading or traffic vibration.

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.

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