Pentair Keystone GR Series User manual

KEYSTONE
Keystone Series GR Resilient Seated Butterfly valves
GRW/GRL Installation & Operation Manual
www.pentair.com/valves Pentair reserves the right to change the contents without notice KEYEW-6269-US-1304
Copyright © 2012 Pentair Valves & Controls. All rights reserved.
1 Storage & 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.
Recommendations
1. Temperature: storage temperature below 77°F (25°C), above 32°F (0°C) preferable below 59°F
(15°C).
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.
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.
Please read these instructions carefully
This symbol indicates important
messages and safety instructions.
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.

Keystone Series GR Resilient Seated Butterfly valves
GRW/GRL Installation & Operation Manual
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3 Installation
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 : NPS or DN
M.P.W.P. : maximum permissible working pressure
Flange compatibility : e.g. ANSI 125/150 PN 10/16
Temperature : e.g. -40/250°F (-40/120°C)
Trim : Materials of construction
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
larger than D max inside diameters or other flange types please contact your local
Pentair 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!
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.
YY D max./min.
Q
Figure 1

Keystone Series GR Resilient Seated Butterfly valves
GRW/GRL Installation & Operation Manual
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Copyright © 2012 Pentair Valves & Controls. All rights reserved.
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 3/8” (10 mm) 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.
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.
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.

Keystone Series GR Resilient Seated Butterfly valves
GRW/GRL Installation & Operation Manual
Pentair reserves the right to change the contents without notice page 4
Copyright © 2012 Pentair Valves & Controls. All rights reserved.
Existing system New system
1. Spread the flanges with the adequate tooling.
Insert some flange bolts to hold 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.
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 > +104°F (+40°C) and < -4°F (-20°C) 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.
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.
Figure 2

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
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Keystone Series GR Resilient Seated Butterfly valves
GRW/GRL Installation & Operation Manual
4 Maintenance for Series GRW/GRL resilient seated butterfly valves
Sizes NPS 2-12 (DN 50-300)
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 3/8”
(10 mm) 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.
3.6 Troubleshooting guide
Symptom Possible cause Resolution
Valve would not rotate Actuator has failed Replace or repair
Valve packed with debris Flush or clean valve to remove debris
Valve leaking Valve not fully closed Close valve, check actuator stop settings
Debris trapped in valve Cycle and flush (with valve open) to remove debris
Seat is damaged Replace seat
Jerky operation Extreme dry application Put some silicone oil on seat or increase size of actuator
Air supply actuator inadequate Increase air supply pressure and/or volume
Table 1 -
Bottom shaft tapped hole dimensions
Valve size Hole dimension
(DN) (NPS)
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

A
A
A
A
11
2
5
11
4
8
11
2
5
11
4
8
3
10
6
9
7
1
3
10
6
9
7
1
Keystone Series GR Resilient Seated Butterfly valves
GRW/GRL Installation & Operation Manual
Pentair reserves the right to change the contents without notice page 6
Copyright © 2012 Pentair Valves & Controls. All rights reserved.
Detail ‘A’
Detail ‘B’ Detail ‘C’
Detail ‘A’
Detail ‘B’
Detail ‘C’
Topview
Topview
Series GRW (Wafer)
NPS 2-12 (DN 50-300)
Series GRL (Lugged)
NPS 2-12 (DN 50-300)
Parts list
Item Description
1 Body
2 Disc
3 Upper shaft
4 Lower shaft
5 Seat
6 Upper bushing
7 Shaft seal
8Plug
9 Shaft circlip
10 Body circlip
11 Upper & lower bearing
Parts list
Item Description
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 & lower bearing
Figure 3
Detail ‘A’
Detail ‘B’ Detail ‘C’
Detail ‘A’
Detail ‘B’
Detail ‘C’

350-400 14-16 140 103
450-500 18-20 270 200
600-800 24-32 470 347
900 36 1270 937
Keystone Series GR Resilient Seated Butterfly valves
GRW/GRL Installation & Operation Manual
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5 Maintenance butterfly valves Series GRW/GRL NPS 14-36 (DN 350-900)
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.
5.4 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.
4. Fit the shaft circlip to the groove in the shaft.
5. Insert the shaft with sufficient (silicone) grease so that it protrudes approximately 3/8” (10 mm)
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.
6. 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.
7. 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)
8. Place the O-ring onto the bottom plug. Place the plug into the body and position it with a
circlip.
9. 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.
10.Mount the actuator.
5.5 Re-installing the valve
See section 3.3.1
Table 2 - Recommended disc screw tightening torques
Valve size Tightening torque
(DN) (NPS) (Nm) (ft. lbs)

5
6
2
4
15
9
8
7
5
6
2
4
15
9
8
7
16
3
11
14
13
10
12
1
15
16
3
11
14
13
10
12
1
15
Keystone Series GR Resilient Seated Butterfly valves
GRW/GRL Installation & Operation Manual
Pentair reserves the right to change the contents without notice page 8
Copyright © 2012 Pentair Valves & Controls. All rights reserved.
Detail ‘A’
Topview
Series GRW (Wafer)
NPS 14-36 (DN 350-900) 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
Figure 4
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
Topview
Series GRL (Lugged)
NPS 14-36 (DN 350-900)
Detail ‘B’
Detail ‘A’
Detail ‘B’
Detail ‘A’
Detail ‘B’
Detail ‘A’
Detail ‘B’