Large Dia. Butterfly Valve

OPERATION & MAITANANCE MANUAL
Doc. No. REL-HRTPP-NE-100-W-1000

SECTION – II
BALANCE OF PLANT
VOLUME –26: LARGE DIA BUTTERFLY VALVE
HARYANA POWER GENERATION CORPORATION,

PANCHKULA, HARYANA
DESEIN PVT.LTD.
CONSULTING ENGINEER
DESEIN HOUSE, GK-II
NEW DELHI-110048
CENTRAL ELECTRICITY AUTHORITY

SEWA BHAWAN, R K PURAM,
NEW DELHI
RELIANCE INFRASTRUCTURE LIMITED,

EPC BUSINESS GROUP, NOIDA - 201 301 (U.P.)
DEVELOPMENT CONSULTANTS PRIVATE LIMITED

CONSULTING ENGINEERS
24B PARK STREET, KOLKATA - 700 016, INDIA
tyco
Flow Control TYCO VALVES & CONTROLS INDIA PVT.LTD.
150, HALOL-KALOL, GODHARA ROAD
PO- MEGHASAR, HALOL
DIST- PANCHMAHAL (GUJRAT)
PIN CODE- 389350
2x600 MW RGTPP, HISAR
INDEX
LARGE DIA. BUTTERFLY VALVES
Sl.No. Description Page No.

A F631 PN 10/16 Heavy Duty Waterworks Valve
1 Valve Overview 2
2 Materials of Construction 5
3 Installation 7
4 Assembly 8
B Butterfly valves Figure 56
1 Storage and Handling 1
2 Installation 2
3 Maintenance 3
4 Part list 4
F631 PN10/16 Heavy Duty Waterworks Valve
tyco
Flow Control
KEYSTONE
Installation Operation &
Maintenance Manual
SECTION 1 VALVE OVERVIEW
SECTION 2 MATERIALS OF
CONSTRUCTION
SECTION 3 INSTALLATION
SECTION 4 ASSEMBLY
F631 PN10
F631 PN16
A Division of tyco Flow Control Pacific

Page 1
Valve Overview
Size Range
Nominal bores - 100, 150, 200, 250, 300, 350, 400, 450, 500, 600, 700, 750, 800, 900, 1000, 1050 and 1200.
Flange Standard
The valve is designed to accommodate a wide range of flange drillings and consequently the diameter and thickness of the flange will not
exactly comply to a specific flange standard.
eg An AS 2129 table ‘D’ drilling pattern may have the flange outside diameter and flange thickness of an ANSI 150 ......... so the true
description is “drilled in accordance with ...........”
Each size valve flange has been designed to have the maximum outside diameter and maximum thickness of the nominated flange standards
i.e. worst case.
NOTE: Use flat face flanges only.
Flange Standards
Standard Rating
AS2129 Table C
Table D
Table E
Table F
ANSI B16.1 Class 125
Class 150
JIS B2210 PN10
AS4087 Class 14
Class 16
Class 21
DIN 2501-Part 1/ PN10
BS 4504-Section 3.2 PN16
Face to Face
The standard valve will have a face to face in accordance with BS 5155 short and ISO 5752 table 4.
To clarify, some specifications shall reference the face to face as ISO 5752 short, ISO 5752 table 4 short, ISO 5752 series 13 or BS 5155 - all
these are identical references.
The only sizes of the re-designed valves which do not comply are 750 N/B and 1050 N/B which are non-standard size in accordance with ISO
5752 and therefore are based on historical information ie F627.
Overall Dimensions
Refer to respective size Drawings
Seat Design
The F631 seat design meets the requirements of seat replaceability but also solves the problem of internal protection of the valve body as the
seat encapsulates the wetted area.
The seat is of a moulded construction which fits easily into the body, covering the entire interior of the valve body and extending onto the
grooved flange faces.
The seat has a peripheral band which seats in a bed-groove in the body to hold the seat securely in place when the disc is closing and
attempting to displace the seating surface.
In the shut-off position, the disc seals on the crown surface of the disc by means of interference fit with the liner. Due to compression by the
disc, the bed-groove feature of the seat minimises tension or pull on the liner; consequently there is a minimum of displacement as the
polymer is being pushed to the corner of the bed-groove adjacent to the direction of the disc closing. Under compression the seat forms a
positive seal between the flats on the seat and the disc hub referred to as the primary seal therefore preventing leakage at the shaft. In
addition the valve has a secondary shaft seal by means of a dynamic O-ring encapsulated in a stainless steel ring which is located on outer
side of the seat.
A Division of tyco Flow Control Pacific Page 2

Bearings (600-1200mm Valves Only)

The bearing material is Orkot, and is manufactured from medium weave fabrics with excellent mechanical strength and possessing
dimensional stability when immersed in water, fluids or chemical solutions. The grade we have selected – TLM.
The TLM grade is impregnated with molybdenum disulphide for improved performance in dry running applications.
Physical Properties
Property Value
Tensile strength 55 N/mm²
Compressive strength normal to laminate - 345 N/mm²
parallel to laminate - 97 N/mm²
Shear strength 83 N/mm²
Density 1.25 gm/cm³
Swell in water < 0.1 % wall thickness
Minimum operating temp -40° C
Maximum operating temp 130° C
Paint
(for Customer Specific Paint Details - see attached G/A Drawings)
The F631 is supplied with the following paint specifications:
Keystone Acrylic Urethane - Standard

Preparation – Clean and free from dirt, oil and grease.
Primer – Croda 940 Fast Epoxy Primer to a dry film thickness of 25 microns.
Top Coat – Croda 670 Crylane Two Pack Acrylic Urethane to a dry film thickness of 75 microns.
Colour – RAL 5150 Blue
High Build Solventless Epoxy - Option

Preparation – Blast clean to AS1627 part 4 class 3
Primer – Jotun Penguard Special Zinc Phosphate Primer to a dry film thickness of 50 microns.
Top Coat – Jotun Jotacoat 412 High Build Solventless Epoxy Paint to a dry film thickness of 250 microns.
Colour – Black
Buried Service - Option

Preparation – Blast clean to AS1627 part 4 class 3
Primer – Jotun Penguard Special Zinc Phosphate Primer to a dry film thickness of 50 microns.
Second Coat – Jotun Jotacoat 412 High Build Solventless Epoxy Paint to a dry film thickness of 250 microns.
Second Coat – Jotun Jotacoat 412 High Build Solventless Epoxy Paint to a dry film thickness of 350 microns.
Colour – Black

Kv Values
Disc Angle - Degrees Open
Size 10° 20° 30° 40° 50° 60° 70° 80° 90°
mm
100 5 25 54 95 150 240 400 620 710
150 15 52 120 220 340 550 950 1380 1630
200 21 95 220 380 590 950 1550 2410 2840
250 33 155 340 610 950 1550 2580 3960 4640
300 49 220 510 860 1460 2320 3780 5850 6880
350 65 290 660 1200 1890 2920 4820 7740 8600
400 86 380 860 1550 2410 3870 6360 9460 11200
450 110 490 1120 1980 3100 4990 8260 12900 15500
500 130 610 1380 2490 3960 6190 10300 15500 18900
600 190 865 1986 3460 5536 8650 14273 22490 25950
700 254 1156 2568 4510 7500 11540 18910 29100 34230
750 294 1298 3114 5363 8564 13840 22490 34600 40655
800 322 1610 3578 6277 10120 15820 25930 40520 47670
900 433 2249 4498 7872 12975 19895 32870 51900 60550
1000 540 2770 5830 9610 15480 24910 42120 62280 73510
1050 580 2595 6055 10380 16868 26815 44115 69200 80445
1200 753 3460 7785 13840 21625 34600 57090 88230 103800
Kv = The volume of water in m3/hr that will pass through a given valve opening at a pressure of 1 bar (100 kPa)
End of Line Service

The F631 is not designed for end of line service. Should the need arise it is recommended that a ring flange is bolted to the valve where the
removed pipework was, to ensure the valve has full compression on the flange faces on both sides of the valve.
Operating Conditions
PN10
Property Value
Maximum Differential Pressure 1000 kPa
Vacuum 1” Hg to atmosphere
Maximum Temperature 120°C
Maximum Flow Velocity 5 m/s
PN16
Property Value
Maximum Differential Pressure 1600 kPa
Vacuum 1” Hg to atmosphere
Maximum Temperature 120°C
Maximum Flow Velocity 5 m/s

Materials of Construction
100-500mm F631 PN10
Item Description Material Specification
1 Body Cast Iron AS1830 Gr T260
2 Disc S.G. Iron AS1831 Gr 500-7
Aluminium Bronze AS1565 Gr C95810
316 Stainless Steel ASTM A743 Gr CF8M
3 Shaft 316 Stainless Steel ASTM A276 Gr 316
4 Seat Natural Rubber EM-D1-7
Nitrile EM-D1-16
E.P.D.M. EM-D1-31
5 Seat Insert 316 Stainless Steel ASTM A276 Gr 316
6 Seat Insert ‘O’Ring Nitrile EM-D1-2
7 Disc Screw 316 Stainless Steel ASTM F593 Group 2
8 Disc Screw ‘O’ Ring Nitrile EM-D1-2
9 Shaft Seal Nitrile EM-D1-2
10 Shaft Bush Acetal
11 End Plug 316 Stainless Steel ASTM F593 Group 2
12 End Plug O’ Ring Nitrile EM-D1-2
13 End Plug Circlip
14 Tag 316 Stainless Steel
15 Tag Rivets 18.8 Stainless Steel
600-1200mm F631 PN10

1 Body Cast Iron AS1830 Gr T260
Nitrile EM-D1-16
E.P.D.M. EM-D1-31
7 Disc Pin 316 Stainless Steel ASTM A276 Gr 316
8 Disc Pin Nut 316 Stainless Steel ASTM F593 Group 2
9 Disc Pin‘O’ Rings Nitrile EM-D1-2
10 Bearing Fliment Wound Resin Orkot Gr TLM
11 Gland Ring Leaded Gun Metal AS1565 Gr C93200
12 Gland Ring ‘O’Rings Nitrile EM-D1-2
13 Thrust Pad Leaded Gun Metal AS1565 Gr C93200
14 End Cap Mild Steel
15 End Cap ‘O’ Ring Nitrile EM-D1-2
16 End Cap Bolts Zinc Plated

100-500mm F631 PN16

1 Body S.G. Iron AS1831 Gr 500-7
Nitrile EM-D1-16
E.P.D.M. EM-D1-31
7 Disc Screw 316 Stainless Steel ASTM F593 Group 2
8 Disc Screw ‘O’ Ring Nitrile EM-D1-2
9 Bearing PTFE/Lead/steel Glacier DU
backed
10 Shaft Seal Nitrile EM-D1-2
11 Shaft Bush Acetal
12 End Plug 316 Stainless Steel ASTM F593 Group 2
13 End Plug O’ Ring Nitrile EM-D1-2
14 End Plug Circlip
600-1200mm F631 PN16

1 Body S.G. Iron AS1831 Gr 500-7
Nitrile EM-D1-16
E.P.D.M. EM-D1-31
7 Disc Pin 316 Stainless Steel ASTM A276 Gr 316
8 Disc Pin Nut 316 Stainless Steel ASTM F593 Group 2
9 Disc Pin‘O’ Rings Nitrile EM-D1-2
10 Bearing Fliment Wound Resin Orkot Gr TLM
11 Gland Ring Leaded Gun Metal AS1565 Gr C93200
12 Gland Ring ‘O’Rings Nitrile EM-D1-2
13 Thrust Pad Leaded Gun Metal AS1565 Gr C93200
14 End Cap Mild Steel
15 End Cap ‘O’ Ring Nitrile EM-D1-2
16 End Cap Bolts Zinc Plated

Installation
Safety Precautions
Whenever a valve is being installed or removed from the pipeline, ensure the line is not pressurised and any hazardous material is drained
away.
Flange Bolts
The flanges are designed that bolts be installed from the pipe flange side of the valve, as inserting from the valve side of the flange is
restricted by the body neck and lower shaft hubs and limited clearance between valve flanges. All flange bolt holes are drilled through with the
exception of bolt holes local to the hubs on some sizes which are a hole tapped through to the relevant flange standard.
All drilled through flanged holes have no back spot facing as flanged taper is under 1° which eradicates the need for spot facing.
Flange Face
The valve having an encapsulating seat design results in the actual seat wrapping up onto the flange face which provides the interface
between valve and pipe flange therefore eliminating the need for gaskets. The seat is also reinforced by the moulded ‘O’ ring in the seat face
to aid in flange sealing.
Installation Instructions
The F631 PN10/16 valves are bi-directional and will control flow in either direction of flow. In most horizontal pipe installations it is
recommended that the valve be installed with its shaft horizontal and the lower disc edge opening downstream.
The valve disc position is in line with the keyway or flats on the operator end of the valve shaft.
To protect disc edges during installation, removal or storage of valves, ensure the disc is in the nearly closed position (about 5° open) and
within the confines of the valve body, but NOT fully closed as incorrect seat compression may occur. With suitable tooling spread the flanges
clear of the valve and seat, insert valve and flange bolts. Before fully cross tightening bolts, check flange alignment and operate valve slowly
to ensure disc clearance and seat compression is correct.
Do not weld near valve.
Do not use flange gaskets.
Ensure pipe end on flange internal diameter is greater than the open valve disc (‘Q’ dimension) particularly on cement, rubber lined or heavy
wall pipe.
Maintenance Instructions
No routine maintenance or lubrication is required.
Removal Instructions
The F631 PN10/16 valves are field repairable. If it is necessary to replace components, the valve must be removed from the pipe. Partially
open valve (5° open); disconnect power supplies; remove operator on larger valves; remove flange bolts; spread flanges and remove valve.

Assembly
Dismantling Valve (100 to 500 diameter inclusive)
A) Turn disc to the almost open position.
B) Remove the actuator from the valve
C) Remove disc screws.
D) Remove circlip plug and plug ‘O’ ring from the shaft at the opposite end to the actuator end of shaft.
E) Remove shaft bush and shaft seal from actuator end of shaft.
F) Extract shaft carefully, ensuring not to scrape ‘shaft’ against the shaft bore.
Note - position of Keyway in relation to the actuator.
G) Twist disc to the fully open position then roll the disc out of the seat ensuring not to damage the disc edge.
H) Collapse seat to the centre of the valve bore at the ‘O’ ring housing spigots (shaft holes) and gently lever one side of the seat from the
flange face, then pull through when the seat is clear of the bed groove. Do not use any sharp implements to aid removal of seat.
I) It is recommended that all ‘O’ rings be replaced and all seats, bushes, plugs etc are free from damage burrs etc.
Assembly Instructions (100 to 500 diameter inclusive)

A) Check all components are clean and free of any damage.
B) Insert ‘O’ rings into stainless steel spigots encapsulated in the seat (300 to 500 only).
C) Collapse seat and push into the bore of the valve aligning the SS spigots with the shaft bore. Ensuring ‘O’ rings are still in position, locate
spigot in shaft bore at the hub end, then gently push seat into the bedgroove simultaneously on both sides working your way up to the
top shaft bore. Then ensure the remaining spigot is correctly positioned. Inspect the seat to ensure the seat is sitting evenly in the
bedgroove and apply pressure with thumbs at the spigots to ensure correct fitment and that the seat is sitting evenly on the flange face.
D) Insert bushing and seal. Then insert shaft into neck of valve and stop prior to entering the valve bore.
E) Roll disc into the seat leading with the disc edge (ensuring not to damage the edge) with the disc screw holes closest to the neck of the
valve, then twist disc until the shaft holes are aligned.
F) Push shaft downwards through the disc into the hub of the valve until the disc screw holes are aligned counterbore side towards disc. A
twisting motion while pushing down will aid with the smooth insertion.
G) Insert disc screws with their ‘O’ rings and tighten to 16 Nm.
H) Push plug and plug ‘O’ ring into position at the hub end of the valve shaft bore and lock into position with the circlip.
I) Actuate valve a few times to ensure all components are free and correctly aligned.
Dismantling Valve (600 to 1200 diameter inclusive)

A) Turn disc to the almost open position.
B) Remove the actuator from the valve.
C) Undo disc pin nuts then remove disc pins.
D) Remove end cover by undoing the four (4) end cover bolts and then remove end cover ‘O’ ring and thrust washer.
E) Remove gland bush ‘O’ ring outer gland bush and gland bush ‘O’ ring inner.
F) Extract shaft carefully, ensuring not to scrape shaft against the shaft bore. Note position of keyway in relation to the actuator.
G) Twist disc to the fully open position then roll the disc out of the seat ensuring not to damage the disc edge.
H) Collapse seat to the centre of the valve bore at the ‘O’ ring housing spigots (shaft holes) and gently lever one side of the seat from the
flange face, then pull through when the seat is clear of the bed groove. Do not use any sharp implements to aid removal of seat.
I) Remove upper and lower bearings if they are damaged.
J) It is recommended that all ‘O’ rings be replaced and all seats, bushes, plugs etc are free from damage burrs etc.

Assembly Instructions (600 to 1200 diameter inclusive)

A) Check all components are clean and free of any damage.
B) Replace upper and lower bearings if they were removed during dismantling.
C) Insert ‘O’ rings into stainless steel spigots encapsulated in the seat.
D) Collapse seat and push into the bore of the valve aligning the SS spigots with the shaft bore. Ensuring ‘O’ rings are still in position, locate
spigot in shaft bore at the hub end, then gently push seat into the bedgroove simultaneously on both sides working your way up to the
top shaft bore. Then ensure the remaining spigot is correctly positioned. Inspect the seat to ensure the seat is sitting evenly in the
bedgroove and apply pressure with thumbs at the spigots to ensure correct fitment and that the seat is sitting evenly on the flange face.
E) Insert gland bush, inner and outer gland bush ‘O’ ring and then insert the shaft into the neck of the valve and stop prior to entering the
valve bore.
F) Roll disc into the seat leading with the disc edge (ensuring not to damage the edge) with the disc screw holes closest to the neck of the
valve, then twist disc until the shaft holes are aligned.
G) Push shaft downwards through the disc into the hub of the valve until the disc screw holes are aligned. A twisting motion while pushing
down will aid with the smooth insertion.
H) Insert disc pins, push on disc pin ‘O’ ring (one on each side) and tighten disc pin nuts (20 Nm).
I) Replace thrust washer end plate cover and end plate then secure by means of the four bolts.
A) Actuate valve a few times to ensure all components are free and correctly aligned.

Butterfly valves Figure 56
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
• improper use of product 1.2 Storage
• insufficiently qualified personnel When valves are to be stored for some time before being fitted, storage should be in the
original delivery crates or cases. Storage should be off the ground in a clean, dry indoor area.
Valve application to be within the
pressure/temperature limits indicated in the 1.3 Handling
P/T diagram. 1.3.1 Packed valves
Lifting and handling of the packed valves in crates should be carried out by appropriate lifting
Essential points and functions of the valve equipment. If a fork lift truck is used, appropriate fork hitches are required.
should be inspected on a regular basis. The lifting and handling of packed valves in cases will be carried out in the lifting points.
The transportation of all packed material should be carried out safely and according the local
safety regulations.
1.3.2 Unpacked valves

The lifting and the handling of these valves has to be carried out by using appropriate means
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 lifting eyebolts; never to
the actuator or the valve opening.
2. Installation
WARNING!
Strings parallel !! 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 only 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.
Lifting Figure 56 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 flange before assembly.
Flanges have to meet the following requirements:
D max./min.
• The face inside diameter should be:

D min. : The valve Q-dimension + adequate disc clearance.
Q
D max. : The inside diameter (ID) of standard pipe for the nominal size ISO 4200.
• Use appropriate flange-gaskets suitable for the selected valve flanges and pipe flanges.
• Use flange bolting in agreement with appropriate standard.
Tyco reserves the right to change the contents without notice EBPJV-0757-EN-0305
page 1
2.3 Valve installation

The valves are delivered as uni- or bi-directional valve. An uni-directional valve is equipped
with an arrow on the body. The arrow points in the direction from high pressure to low
pressure. The preferred direction in the pipeline is positioning the valve with seat downstream
of the valve shaft. The valve will control flow not exactly equally in both flow directions. 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.
Do not use the valve to spread the flanges.
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 detect 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.
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. Close the valve so far, that the disc-edge is at least 10 mm within the body.
3. Insert the valve with the gaskets between the flanges, center the valve body and insert all
flange bolts.
4. Maintain the valve flange alignment while gradually removing the flange-spreaders and
tighten the flange-bolts hand tight.
5. Slowly open and close the valve to check for adequate disc clearance.
6. Cross-tighten all bolting to the proper torque.
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 manual operator should rotate
between the “full open” and “full close” indicators. Generally the valve disc travels clockwise to
close.
2.5. Sources of possible danger

This section contains some examples of possible foreseen danger sources.
2.5.1. 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.
2.5.2. Electrical
If static charges or stray electrical currents can initiate explosions, the valve should be grounded
to earth.
2.5.3. Thermal
A) 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.
B) Hot surfaces can be a potential source of ignition of the environment.
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’s body 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. This is called dynamic torque. Take care when unlatching or removing the valve
operating mechanism. The valve might be closed by the dynamic torque created by the flow.
Tyco reserves the right to change the contents without notice page 2
2.6 Trouble shooting 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 leakage Re-adjust seat
Seat is damaged If possible rework seat and re-adjust
Jerky operation Debris trapped in valve Cycle and flush (with valve open) to
remove debris
Air supply actuator Increase air supply pressure
inadequate and/or volume
3. Maintenance
The Keystone butterfly valve figure 56 is 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. If problems occur with valve pressure tightness the seat
can be adjusted or replaced.
3.2 Replacement of seat

It is not necessary to remove the valve from the pipeline in order to replace the seat.
1. Turn the disc to full open position.
2. Remove one segment by untightening one segment and overtightening the nearest
segment until the fork of segment 1 is able to move over the nose of the segment 2 and
remove the segment. Untighten all segment screws and remove all segments.
3. Replace the old seat by a new seat.
4. Mount all segments. For the last segment the seat has to be pulled out of the pocket,
place the last segment and push the seat back on its place.
5. Tighten the segments gradually all around until the seat touches the discedge.
6. Pressurize valve slowly and adjust at places which show leakage.
Note: For detailed seat adjustment contact factory.
3.3 Valve (dis)assembly

Contact factory for complete valve (dis)assembly instructions and illustrated parts.
SS edge (DI only)
Parts list
1. Body
2. Disc
3. Upper Shaft
4. Lower Shaft
5. Actuator flange
6. Cover plate
7. Seat
8. Seat retaining segment
9. Seat adjusting nut
10. Seat retaining screw
11. Disc pin
12. Bearing
13. Sleeve body/shaft
14. Shaft seal
15. Sleeve disc/shaft
16. Seal ring
17. Axial positioning ring
18. Dirtscraper
19. Axial bearing (reinf. PTFE)
20. Travel stop
21. Supporting lug (4x)

Large Dia. Butterfly Valve

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Large Dia. Butterfly Valve

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OPERATION & MAITANANCE MANUAL

Doc. No. REL-HRTPP-NE-100-W-1000

HARYANA POWER GENERATION CORPORATION,

CENTRAL ELECTRICITY AUTHORITY

RELIANCE INFRASTRUCTURE LIMITED,

DEVELOPMENT CONSULTANTS PRIVATE LIMITED

LARGE DIA. BUTTERFLY VALVES

Sl.No. Description Page No.

B Butterfly valves Figure 56

1 Storage and Handling 1

SECTION 1 VALVE OVERVIEW

A Division of tyco Flow Control Pacific

A Division of tyco Flow Control Pacific Page 2

Bearings (600-1200mm Valves Only)

Keystone Acrylic Urethane - Standard

High Build Solventless Epoxy - Option

Buried Service - Option

A Division of tyco Flow Control Pacific Page 3

End of Line Service

A Division of tyco Flow Control Pacific Page 4

600-1200mm F631 PN10

A Division of tyco Flow Control Pacific Page 5

100-500mm F631 PN16

600-1200mm F631 PN16

A Division of tyco Flow Control Pacific Page 6

A Division of tyco Flow Control Pacific Page 7

Assembly Instructions (100 to 500 diameter inclusive)

Dismantling Valve (600 to 1200 diameter inclusive)

A Division of tyco Flow Control Pacific Page 8

Assembly Instructions (600 to 1200 diameter inclusive)

A Division of tyco Flow Control Pacific Page 9

Please read these instructions carefully. 1. Storage & handling

This symbol indicates important 1.1 Protection

1.3.2 Unpacked valves

Lifting Figure 56 2.1 Valve inspection

2.2 Flange and pipe compatibility

• The face inside diameter should be:

2.3 Valve installation

2.4. Valve verification

2.5. Sources of possible danger

2.6 Trouble shooting guide

Valve leaking Valve not fully closed Close valve

3.1 Routine maintenance

3.2 Replacement of seat

3.3 Valve (dis)assembly

SS edge (DI only)

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