Emerson KEYSTONE V30 Series User manual

Series V30/V32 installation, operation, maintenance and

troubleshooting

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.

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 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 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 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.

Emerson reserves the right to change the contents without notice KVKEW-0149-EN-1309

Keystone Marine High Performance Butterﬂy Valves

Series V30 / V32 Installation & Operation Manual

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.

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

www.valves.emerson.com

Keystone Marine High Performance Butterﬂy Valves

Series V30 / V32 Installation & Operation Manual

Emerson reserves the right to change the contents without notice page 2

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 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.

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 (page 4 & 5) 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.

Keystone Marine High Performance Butterﬂy Valves

Series V30 / V32 Installation & Operation Manual

Emerson reserves the right to change the contents without notice page 3

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.

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

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.

Fig. 1

Fig. 2

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.

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.

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.

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.

Emerson reserves the right to change the contents without notice page 4

Keystone Marine High Performance Butterﬂy Valves

Series V30 / V32 Installation & Operation Manual

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.

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’.

Fig. 3 - Seat retainer ring and screws

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.

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

Keystone Marine High Performance Butterﬂy Valves

Series V30 / V32 Installation & Operation Manual

Emerson reserves the right to change the contents without notice page 5

Series V30 / V32 wafer & lug

DN 50 (NPS 2) - DN 300 (NPS 12)

See detail

Detail

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

Emerson reserves the right to change the contents without notice page 6

Keystone Marine High Performance Butterﬂy Valves

Series V30 / V32 Installation & Operation Manual

Series V30 / V32 wafer & lug

DN 350 (NPS 14) - DN 900 (NPS 36)

See detail

Detail

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 & washer

14 Hex socket screw

15 O-ring (packing seal)

16 O-ring (bottom cover)

17 Key

Keystone Marine High Performance Butterﬂy Valves

Series V30 / V32 Installation & Operation Manual

Emerson reserves the right to change the contents without notice page 7

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.

Fig. 4

Fig. 5

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.

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 & ‘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.

Fig. 6

Fig. 7

Fig. 8

Emerson reserves the right to change the contents without notice page 8

Keystone Marine High Performance Butterﬂy Valves

Series V30 / V32 Installation & Operation Manual

Symptom Possible cause Resolution

Valve won’t rotate 1. Actuator has failed 1. Repair or replace

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

Shaft packing seal leaking 1. Packing seal O-ring damaged 1. Depressurize valve and replace packing seal O-rings smooth

the contact surface of O-rings

Bottom cover leaking 1. O-ring damage 1. Remove valve from service and replace O-rings smooth the

contact surface of O-rings

Valve leaking 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

Jerky operation 1. Shaft/bearing damaged 1. Disassemble valve and inspect for damage, repair or

replacedamaged parts, reassemble

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

3. Air supply inadequate 3. Increase air supply pressure

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® Monel®

Inconel® Monel®

Fig. 9

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