Butterfly valves OmniSeal, OptiSeal Fig. 14/16 and Fig.
15/17
Installation & Maintenance Instructions
Please read these instructions carefully. 1. Storage & handling
This symbol indicates important 1.1 Protection
messages and safety instructions. Keystone butterfly valves are delivered with protection in accordance with the Keystone
Engineering Instructions, to protect the valve seats and disc from damage. Wrapping and/or
Hazard potentials: covers should be left in place until immediately before fitting to the pipe.
• disregarding of instructions
1.2 Storage
• improper use of product
When valves are to be stored for some time before being fitted, storage should be in the
• insufficiently qualified personnel
original delivery crates or cases. Storage should be off the ground in a clean, dry indoor area.
Valve application to be within the 1.3 Handling
pressure/temperature limits indicated in the 1.3.1 Packed valves
P/T diagram. Lifting and handling of the packed valves in crates should be carried out by appropriate lifting
equipment. If a fork lift truck is used, appropriate fork hitches are required.
Essential points and functions of the valve The lifting and handling of packed valves in cases will be carried out in the lifting points.
should be inspected on a regular basis. The transportation of all packed material should be carried out safely and according the local
safety regulations.
When the valve is used in an end-of-line 1.3.2 Unpacked valves
function, PED Cat-I applications are allowed The lifting and the handling of these valves has to be carried out by using appropriate means
only. For other categories, contact factory. and by respecting the carrying limits. The handling must, preferably, be carried out on pallets,
protecting the machined surfaces and seat to avoid damage. When lifting the large
dimension valves, the sling and the hooking of the load must be carried out by using the
appropriate tools (brackets, hook, fasteners) and load balancing tools in order to prevent the
valves from falling or moving during the lifting and handling. The valve may be lifted only by
slings attached to the flange holes or valve body; never to the actuator or the valve opening.
2. 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. Personnel trained in all aspects of manual and mechanical handling techniques must carry
out handling of the valves.
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 tagplate 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.
2.1 Valve inspection
1. Carefully remove the valve from the shipping package (box or pallet) avoiding any damage
to the valve or, in case of automated valves, to the electric or pneumatic/hydraulic actuator
or instrumentation.
2. Confirm that the materials of construction listed on the valve nameplate are appropriate for
the service intended and are as specified.
3. It is not allowed to use third party spare parts. In case of third party spare parts, safe
operation is not guaranteed.
2.2 Flange and pipe compatibility
Check matching of flange drilling pattern of valve and pipe before assembly.
Flanges have to meet the following requirements:
- The face inside diameter should be:
D min. : The valve Q-dimension + adequate disc clearance.
D max. : The inside diameter (ID) of standard pipe for the nominal size ISO 4200.
D max./min.
- 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.
Q
The use of the flange-gaskets is not allowed since it might damage the valve.
YY
The Keystone seat-face design eliminates the need for the gaskets.
Use flange bolting in agreement with appropriate standard.
Do not use flange gaskets!
Tyco reserves the right to change the contents without notice EBPJV-0747-EN-0201
Butterfly valves OmniSeal, OptiSeal Fig. 14/16 and Fig. 15/17
Installation & Maintenance Instructions
2.3 Valve installation
The valves are bi-directional and may be fitted 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 no crow-bar. Do not use the valve to spread the flanges. Seat damage might be
the result.
Notes
• The valve can be installed in the pipe-line either with or without the actuator mounted on
top of the valve. Make sure that you can turn the disc cautious so you can feel a mismatch
resulting from a disc touching the adjacent piping.
• Do not use the valve as a support of the pipe line construction.
• 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 paragraph “1.3 Handling”.
Important
Mating flange faces should be in good condition and free of dirt and/or inclusions. Both pipe
insides to be well cleaned.
2.3.1. Existing system (see sketch)
1. Check whether the flange distance meets the valve face-to-face dimensions. Spread with
adequate tooling the flanges for easy insertion of the valve.
2. In case of a wafer valve, insert some flange bolts in the pipe flanges, to help you bear the
valve after insertion.
3. Close the valve so far, that the disc-edge is at least 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 stem
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.
2.3.2. New system (see sketch)
1. With the disc in 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.
2.4. 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. Generally
the valve disc travels clockwise to close.
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Butterfly valves OmniSeal, OptiSeal Fig. 14/16 and Fig. 15/17
Installation & Maintenance Instructions
Existing system New system
1. Spread the flanges with the adequate tooling. 1. Center a flange-valve-flange assembly between
Insert some flange bolts to bear the valve. 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 3. Remove the valve and finish weld.
cross-tighten all bolting. Install the valve according to the procedure in the
left column.
2.5. Sources of possible danger
This section contains some examples of possible foreseen danger sources.
2.5.1. Mechanical
When manual operators are used, available space should be checked in order to avoid
hands being clamped.
2.5.2. Electrical
If static charges can initiate explosions, the valve should be grounded.
2.5.3. Thermal
If the valve is used in applications with a fluid temperature above 40°C the outside of the
body might be hot. Sufficient measurements should be taken to avoid burning.
A manual operated valve should be opened and closed with sufficient protection for the
personnel operating the valve. For example: protecting gloves.
2.5.4. Operational
Closing a valve too fast may result in waterhammer in the upstream part of the pipeline.
Waterhammer results in excessive stresses in the valve and will cause severe damage.
Waterhammer 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.
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Butterfly valves OmniSeal, OptiSeal Fig. 14/16 and Fig. 15/17
Installation & Maintenance Instructions
2.6. 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
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 silicon oil on seat or increase size of actuator
Air supply actuator inadequate Increase air supply pressure and/or volume
3a. Maintenance butterfly valves OmniSeal, OptiSeal Fig. 14/16
The Keystone butterfly valves OmniSeal, OptiSeal Fig. 14/16 are designed to require a minimum of
maintenance.
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.
Only personnel trained in all aspects of manual and mechanical handling techniques must
carry out handling of all valves.
3.1 Routine maintenance
Routine maintenance or lubrication is not required other than periodic inspection to ensure
satisfactory operation and sealing.
3.2 Removing the valve
1. Turn the disc to nearly closed position. (The disc is in line with the parallel flats in the stem).
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.
3.3 Valve disassembly (See sketch)
1. Turn the disc to almost open position.
2. Remove actuator.
3. Remove the body-screws.
4. Remove the lower part of the body. This is more or less held by the seat lip and groove.
Use two screwdrivers in the body-splits to separate the body halves and pull the bottom-
part off with a rotating motion.
5. Pull the discstem and seat out of the body top part.
6. To remove the disc-stem from the seat, deform the seat into a long “oval” sufficient to clear
the end of the short stem, move the short stem-end out off the seat bore, and pull the long
end from the seat stem hole, using a rotating motion.
7. The body top part contains a top bushing and dirt scraper. Generally there is no need to
remove these parts .
8. For some versions of the OptiSeal only, the bodies are equipped with bearings. If required
these can be removed.
3.4 Valve assembly (See sketch)
1. Clean all parts. Use silicone grease on the discstem to facilitate the assembly.
If the valve has to be provided with a TFE-lined-seat preheat this seat during half an hour
in nearly boiling water before assembly.
2. If required assemble (shaft)-bushing.
3. For some versions of the OptiSeal, mount the bearings and split seals.
4. Take the discstem and insert the long stem-end into a hole of the seat, using a twisting motion.
5. Deform the seat into a long “oval” sufficient to clear the end of the short stem. With the
disc-stem simulating an open position, move the short stem-end into the elongated seat-
bore and assemble the short stem-end into the other seat stem-hole by releasing the
distorted seat. Do not put oil or grease between body and seat.
6. Push the long stem-end of the disc-stem/seat unit into the body top part. Push the seat lip
and groove in place.
7. Assemble the bottom part of the body. Take care of the positioning of the bottom part. The
little rectangular cast on indicator near the body split should correspond to the indication
on the bottom part. Install the body screws and tighten securely. Take care that the body
parts are aligned securely.
8. Assemble the dirt scraper.
9. Mount the actuation.
3.5 Re-installing the valve
See paragraph 2.3.1.
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Butterfly valves OmniSeal, OptiSeal Fig. 14/16 and Fig. 15/17
Installation & Maintenance Instructions
OptiSeal Figure 14
Parallel flats
Topview
Relief hole
Mounting holes
Parts identification
1. Dirtscraper 5. Seat
2. Shaft bushing 6. Discstem
3. Body 7. Split-seal
4. Bearing (not for grey cast iron body) 8. Body screws
OptiSeal Figure 16
Parallel flats
Topview
Relief hole
Mounting holes
Parts identification
1. Dirtscraper 5. Seat
2. Shaft bushing 6. Discstem
3. Body 7. Split-seal
4. Bearing (not for grey cast iron body) 8. Body screws
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Butterfly valves OmniSeal, OptiSeal Fig. 14/16 and Fig. 15/17
Installation & Maintenance Instructions
OmniSeal (wafer)
Parallel flats
Topview
Mounting holes
Parts identification
1. Body
2. Seat
3. Discstem
4. Body screws
OmniSeal (lugged)
Parallel flats
Topview
Mounting holes
Parts identification
1. Body
2. Seat
3. Discstem
4. Body screws
Tyco reserves the right to change the contents without notice page 6
Butterfly valves OmniSeal, OptiSeal Fig. 14/16 and Fig. 15/17
Installation & Maintenance Instructions
3b. Maintenance butterfly valves Fig. 15/17
The Keystone butterfly valve figure 15 and 17 are designed to require a minimum of maintenance.
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.
Only personnel trained in all aspects of manual and mechanical handling techniques must
carry out handling of all valves.
3.1 Routine maintenance
Routine maintenance or lubrication is not required other than periodic inspection to ensure
satisfactory operation and sealing.
3.2 Removing the valve
1. Turn the disc to nearly closed position. (The disc is in line with the keyway in the stem).
2. Loosen all flange bolts and remove the bolts.
3. Spread the flanges with adequate tooling, and remove the valve.
3.3 Valve disassembly
1. Turn the disc to almost open position.
2. Remove actuator.
3. Remove the disc screw with the O-ring.
4. Pull the shaft out of the body.
5. Remove the disc by pulling or “rolling” out of the seat bore.
6. 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.
7. Remove circlip and pull the plug, containing an O-ring, out of the body.
8. Remove the O-ring from the plug.
9. Remove the dirt scraper and bushing from the body top neck.
3.4 Valve assembly
1. Clean all parts.
2. Insert the bushing in top neck.
3. 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. Insert the shaft with sufficient (silicone) grease so far that it protrudes approximately 10
mm into the inside bore of the seat. Install the disc, with the disc-screw holes toward the
actuator flange, 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.
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 stem screw holes. Place the O-ring on the disc-
screw. Install the disc-screw and tighten securely.
7. Place the O-ring onto the plug. Place the plug into the body and position it with a circlip.
8. Assemble the dirt scraper.
9. Mount the actuator.
3.5 Re-installing the valve
See paragraph 2.3.1.
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Butterfly valves OmniSeal, OptiSeal Fig. 14/16 and Fig. 15/17
Installation & Maintenance Instructions
Figure 15
Flange locating
Topview holes
Through holes for
350 - 600 mm
Tapped holes for
sizes 700 - 900
mm
Mounting holes
Parts identification
1. Body 8. Plug
2. Disc 9. O-ring
3. Seat 10. Circlip
4. Shaft 11. Dirtscraper
5. Disc screw
6. O-ring
7. Bushing
Figure 17
Topview
Mounting holes
Parts identification
1. Body 8. Plug
2. Disc 9. O-ring
3. Seat 10. Circlip
4. Shaft 11. Dirtscraper
5. Disc screw
6. O-ring
7. Bushing
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