Bray 19-CL User Manual

INSTALLATION - MAINTENANCE MANUAL

Series 19-CL 150, 300, 600

Segmented Ball valve

Size 1” (DN25) thru 12” (DN300)

®

Installation and Maintenance Manual

A Subsidiary of BRAY INTERNATIONAL, Inc. A Subsidiary of BRAY INTERNATIONAL, Inc.

® ®

Series 19 - Segmented Ball Valves

Date: Feb 2013 / Page 2 of 19

Installation and Maintenance Manual

Series 19 - Segmented Ball Valves

Date: Feb 2013 / Page 3 of 19

Table of Contents

Class 150-300

1. DESIGN .......................................................................................................................................................3

2. GENERAL INFORMATION ..............................................................................................................................3

2.1 Use .................................................................................................................................................3

2.2 Operations .......................................................................................................................................3

2.3 Applicability .....................................................................................................................................3

2.4 Terms related to safety .......................................................................................................................3

2.5 Protective clothing ............................................................................................................................. 4

2.6 Qualified personnel ...........................................................................................................................4

2.7 Spare Parts .......................................................................................................................................4

2.8 Service / Repair ...............................................................................................................................4

2.9 Storage ............................................................................................................................................4

3. UNPACKING ................................................................................................................................................4

4. INSTALLATION ............................................................................................................................................. 5

5. QUICK-CHECK .............................................................................................................................................. 5

6. PREVENTATIVE MAINTENANCE ......................................................................................................................6

7. REMOVING VALVE FROM LINE .......................................................................................................................7

8. ACTUATOR ...................................................................................................................................................7

Appendix - A (Class 150/300)

9. DISASSEMBLY AND REASSEMBLY ...................................................................................................................8

9.1 Removing Actuator from Body .............................................................................................................8

9.2 Replacing the Seat ............................................................................................................................8

9.2.1 Detaching the Seat ............................................................................................................................8

9.2.2 Installing the Seat ..............................................................................................................................8

9.3 Dismantling the Valve .........................................................................................................................9

9.4 Inspection of Removed Parts ...............................................................................................................9

9.5 Assembly .........................................................................................................................................9

9.6 Remounting the Actuator ..................................................................................................................11

10. PARTS DIAGRAM .........................................................................................................................................12

Appendix - B (Class 600)

11. DISASSEMBLY AND REASSEMBLY ................................................................................................................14

11.1 Removing Actuator from Body ..........................................................................................................14

11.2 Dismantling the Valve ...................................................................................................................... 14

11.3 Reassembling the Valve ...................................................................................................................16

11.4 Remounting the Actuator .................................................................................................................. 17

12. PARTS DIAGRAM ........................................................................................................................................18

INSTALLATION – MAINTENANCE MANUAL

Series 19 – Segmented Ball valve

Size 1” (DN25) thru 12” (DN300)

1. DESIGN:

The design features of this valve include a one piece
construction body which results in simplified maintenance
and trouble free operation.

The valve features a characterized ball segment for high
rangeability with Splined stem connection for precise control,
maintenance friendly Segment-Stem assembly, Low friction
Stem and thrust bearing for longer life, Integral actuator
mounting pads, and interchangeable seats.

The valve is either soft or metal seated. Tightness derives
from the spring force pressing the seat against segment. The
structure of the valve supplied may vary, depending on the
customer’s requirements.

2. GENERAL INFORMATION

2.1 - USE

The following instructions are designed to assist in the
unpacking, installation, and maintenance as required for
Flow-Tek products. Product users and maintenance personnel
should thoroughly review this manual prior to installing,
operating, or performing any maintenance.

In most cases, Flow-Tek valves, actuators and accessories
are designed for specific applications (e.g. with regard
to medium, pressure and temperature). For this reason,
they should not be used in other applications without first
contacting the manufacturer.

WARNING: Before installing the equipment, confirm that

it is suitable for the intended service. The identification
tags describe the maximum allowable service conditions
for this product. Be sure that the installation is protected
by appropriate pressure control and safety devices to
insure that acceptable limits are not excided.

2.2 - OPERATION

Operation of the valve is done by turning the stem a
1/4 turn (90 degrees turn). Clockwise to close, counter
clockwise to open.

2.2A Valve open position
The double “D” parallel to pipeline (figure 1)

2.2B Valve closed position
The double “D” perpendicular to pipeline (figure 1)

CAUTION:

actuator - valve alignment. Misalignment will result in high
operational torque and damage to valve stem and seals.

Valves with actuators should be checked for

2.3 - APPLICABILITY

The following instructions are applicable to the maintenance
and installation of Flow-Tek Segmented ball valves. These
instructions cannot claim to cover all details of all possible
product variations, nor can they provide information for every
possible example of installation, operation or maintenance.
This means that the instructions normally include only the
directions to be followed by qualified personal using the
product for its defined purpose. If there are any uncertainties
in this respect, particularly in the event of missing product
related information, clarification must be obtained via the
appropriate Flow-Tek sales office.

2.4 - Terms related to safety

The terms DANGER, WARNING, CAUTION, and NOTE
are used in this document to highlight particular dangers
and/or to provide additional information on points which
may not be clearly obvious.

DANGER:

and/or substantial property damage will occur if proper
precautions are not taken.

Indicates that death, severe personal injury

FLOW-TEK, Inc. Tel: [phone]
8323 N. Eldridge Pkwy #100 Fax: [phone]
Houston, Texas 77041 www.flow-tek.com

© 2012 Flow-Tek, Inc.

WARNING: Indicates that danger of death or severe

personal injury and/or property damage can occur if
proper precautions are not taken.

FLOW-TEK, Inc. Tel: [phone]
8323 N. Eldridge Pkwy #100 Fax: [phone]
Houston, Texas 77041 www.flow-tek.com

© 2012 Flow-Tek, Inc.

Installation and Maintenance Manual

A Subsidiary of BRAY INTERNATIONAL, Inc. A Subsidiary of BRAY INTERNATIONAL, Inc.

® ®

Series 19 - Segmented Ball Valves

Date: Feb 2013 / Page 4 of 19

Installation and Maintenance Manual

Series 19 - Segmented Ball Valves

Date: Feb 2013 / Page 5 of 19

CAUTION: Indicates that minor personal injury and/or

serious damage to property can occur if the appropriate
precautions are not taken.

NOTE: Indicates and provides additional technical

information which may not be obvious, even to qualified
personnel.

Compliance with other notes, which may not be particularly
emphasized, with regard to transport, assembly, operation
and maintenance and with regard to technical documentation
(e.g. in the operating instructions, product documentation,
or on the product itself) is essential, in order to avoid faults,
which can directly or indirectly cause severe personal injury
or property damage.

2.5 - Protective clothing

Flow-Tek products are often used in critical applications (e.g.
under extremely high pressures with dangerous, toxic or
corrosive mediums). When performing service, inspection,
or repair operations, always ensure that the valve and the
actuator are depressurized and that the valve has been
cleaned, and that it is free of harmful substances. In such
cases, pay particular attention to personal protection (e.g.
protective clothing, gloves, glasses, etc.).

2.6 - Qualified personnel

Qualified personnel are people who on account of their
education, experience, training, and knowledge of relevant
standards, specifications, accident prevention, and operating
conditions have been authorized by those responsible for
the safety of the plant to perform the necessary work, and
recognize and avoid possible dangers.

2.7 - Spare Parts

Use only Flow-Tek original spare parts. Flow-Tek cannot
accept responsibility for any damages that occur from using
spare parts or fastening materials from other manufacturers.
If Flow-Tek products (especially sealing materials) have been
on store for long periods of time, check them for corrosion
or deterioration before putting them into use.

2.8 - Service / Repair

To avoid possible injury to personnel or damage to products,
safety terms must be strictly adhered to. Modifying this
product, substituting non-factory parts, or using maintenance
procedures other than those outlined in these Installation,
Operation and Maintenance Instructions could drastically
affect performance, be hazardous to personnel and
equipment, and may void existing warranties. Apart from
the operating instructions and the obligatory accident
prevention directives valid in the country of use, all recognized
regulations for safety and good engineering practices must
be followed.

WARNING: Before products are returned to Flow-Tek for

repair or service, Flow-Tek must be provided with a certificate
that confirms that the product has been decontaminated
and is clean.

2.9 - Storage

Flow-Tek products are well protected from corrosion.
Nevertheless, Flow-Tek products must be stored adequately
in a clean, dry, environment. Plastic caps are fitted to protect
the flange faces and prevent the ingress of foreign materials.
These caps should not be removed until the valve is actually
mounted into the system.

3. UNPACKING

While unpacking the valve, check the packing list against the
materials received. Lists describing the valve and accessories
are included in each shipping container.

When lifting the valve from shipping container, use straps
through valve body. Take care to position lifting straps to
avoid damage to the tubing and mounted accessories.

WARNING: Never lift the valve or valve package by the

actuator, positioner, limit switch or their piping. When lifting
a valve be aware that the center of gravity may be above
the lifting point. Therefore, support must be given to prevent
the valve from rotating. Failure to do so can cause serious
injury to personnel and damage to the valve and nearby
equipment.

Contact your shipper immediately if there is shipping damage.

Should any problem arise, call your Flow-Tek representative.

DANGER: Before installation check the order number, serial

number, and/or the tag number to ensure that the valve
and actuator being installed are correct for the intended
application.

CAUTION: Do not insulate extensions that are provided for

hot or cold services.

4. INSTALLATION

Before installing the valve, clean the pipeline of all
contamination, carbon deposits, welding chips, and other
foreign material. Carefully clean gasket surfaces to ensure
a tight seal. Pipelines must be correctly aligned to ensure
that the valve is not fitted under tension.

Fire protection must be provided by the user.

Check the direction of fluid flow to ensure that the valve is
correctly installed. Flow direction is indicated by the arrow
on the body.

DANGER: To avoid serious injury, keep hands, hair,

clothing, etc. away from the segment and seat when the
valve is working.

For valves with pneumatic actuator & accessories:

Connect the air supply and instrument signal lines. Throttling
control valves are equipped with a valve positioner.
Connections are marked for the air supply and the instrument
signal. Check that the actuator and positioner can withstand
the maximum air supply from the network. The required air
supply is indicated on a sticker located on the actuator. An
air regulator will be necessary in certain cases in order to
limit the supply pressure. Air filter is recommended unless
the air supplied is exceptionally clean and dry (air quality
without humidity, oil, or dust as per IEC 770 and ISA-

7.0.01). All connections must be completely tight.

CAUTION: On valves equipped with air filters, the air filter

must point down to perform properly.

For Electrical actuators:

Refer to Installation & maintenance manual of supplied
electric actuator.

Use the bolts indicated in Table 1 on page 6 for installing the
valve in the pipeline, and then tighten alternately according
to good practice. The user must in all cases confirm the
capacity of the bolts to ensure a sufficiently tight gasket seal
for the expected service conditions.

Be sure to provide proper overhead clearance for the actuator
to allow for disassembly of the actuator from the valve
body. Refer to the appropriate general assembly drawing
for proper clearances.

5. QUICK-CHECK

Before commissioning, check the control valve by following
these steps.

Check for full stroke by varying the instrument signal settings
appropriately. Observe the segment position indicator located
on the actuator or the positioner. The segment should change
position with a smooth turning movement.

Check all air connections for leaks. Tighten or replace any
leaking lines.

Check packing box bolting for proper tightness.

CAUTION: Do not over tighten packing. This can cause

excessive packing wear and high stem friction that may
impede stem movement. After the valve has been in service
for a short period, recheck the packing-box nuts. If the packing
box leaks, tighten the nuts just enough to stop the leak.

Make sure the valve fails in the correct direction in case
of air failure. This is done by positioning the valve at mid
stroke and turning off the air supply and observing the failure
direction. If the action is incorrect, see the section “Reversing
the Air-action” in the instructions of the installation, operation
and maintenance manual of the appropriate actuator.

FLOW-TEK, Inc. Tel: [phone]
8323 N. Eldridge Pkwy #100 Fax: [phone]
Houston, Texas 77041 www.flow-tek.com

© 2012 Flow-Tek, Inc.

FLOW-TEK, Inc. Tel: [phone]
8323 N. Eldridge Pkwy #100 Fax: [phone]
Houston, Texas 77041 www.flow-tek.com

© 2012 Flow-Tek, Inc.