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: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
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: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
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: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
© 2012 Flow-Tek, Inc.
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
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 6 of 19
Installation and Maintenance Manual
Series 19 - Segmented Ball Valves
Date: Feb 2013 / Page 7 of 19
6. PREVENTATIVE MAINTENANCE
UÊAt least once every six months, check for proper
operation by following the preventative maintenance
steps outlined below. These steps may be performed
while the valve is in line and without interrupting service.
If an internal problem is suspected, refer to section “9”
for class 150/300 and “11” for class 600.
UÊLook for signs of gasket leakage through the end flanges
and post. If necessary, re-torque end flanges and post
cover.
UÊExamine the valve for damage caused by corrosive
fumes or process drippings.
UÊClean the valve and repaint areas of severe oxidation.
UÊCheck the packing-box for proper tightness. If there is
a persistent leak, change the packing after referring to
sections “9.3” class 150/300 and “11.2” class 600
for dismantling the valve, “9.5” class 150/300 and
“11.3” class 600 for Reassembling the valve.
CAUTION: Do not over tighten packing. This can cause
excessive packing wear and high friction that may
impede stem movement.
UÊIf the valve is equipped with a lubricator, add lubricant
if necessary.
UÊIf possible, stroke the valve and check for smooth, full
stroke operation. Unsteady stem movement may indicate
an internal valve problem.
UÊCheck the calibration of the positioner/controller if
available. For further preventative maintenance, see the
instructions in the installation, operation and maintenance
manual for the applicable positioner/controller.
UÊEnsure all accessories, brackets and bolting are securely
fastened.
UÊIf possible, remove power source (air supply/electrical
signal) and observe actuator for correct fail-safe action.
UÊCheck the actuator and all air connections for leaks.
UÊIf an air filter is supplied, check and replace the cartridge
if necessary.Table 1: Flange Bolting Specifications
Size
(in)
1
1½
2
3
4
6
8
10
12
(1) Torque values are recommended for low and intermediate strength
bolting per ANSI B16.5 ¶5.3.2. Higher torques may be used with high
strength bolting (ANSI B16.5 ¶5.3.1). In all cases the user must verify the
selected bolting‘s ability to seat the joint under expected operating condition.
Long thru-bolted joints generally require higher strength bolting and torque
values than shorter flanged bolting depending on operating conditions.
(2) Lengths are based on ANSI B16.5 stud bolts and raised face ends.
(3) Lengths are for the shorter studs used in treaded holes. Refer General
Assembly drawing for the quantities.
ANSI
CLASS
RATINGS
150 65 31 82
300 75 63 165
600 90 / 80
150 70 31 82
300 90 110 295
600 110 / 90
150 85 63 165
300 90 63 165
600 110 / 95
150 90 63 165
300 110 110 295
600 125 / 110
150 90 63 165
300 115 110 295
600 145 / 125
150 100 110 295
300 120 110 295
600 170 / 150
150 110 110 295
300 140 179 478
150 115 179 478
300 160 270 720
150 120 179 478
300 170 401 1069
Bolt Length
(2)
(mm)
(3)
(3)
(3)
(3)
(3)
(3)
Torque (N-m)
Low
Strength
63 165
110 295
63 165
110 295
179 478
270 720
(1)
Intermediate
Strength
7. REMOVING VALVE FROM LINE
1. If an internal problem is suspected with the valve and
disassembly is required, remove the valve from the line
by proceeding as follows.
WARNI NG : Depressurize line to atmospheric pressure,
drain all process fluids and decontaminate the valve (if
caustic or hazardous materials are present). Failure to
do so can cause serious injury. Make sure the valve is in
closed condition.
2. Attach a hoist or some means to support the valve.
3. Remove line bolting. Do not attempt to pry line flanges
apart by pushing or pulling on the valve or actuator.
4. Slide the valve carefully from the line. To avoid damage
to the gasket surfaces, do not twist the valve.
CLOSED CLOSED
Figure 1
5. After the valve is completely removed from the line,
slowly relieve air pressure from the actuator.
8. ACTUATOR
The valve closed and open position are indicated by the
position of double “D” on the stem. Refer below figure.
If possible, install the valve so that the actuator can be
disconnected without removing the valve from the piping.
The actuator must not touch the pipe line, because pipeline
vibration may damage it or interfere with its operation.
In some cases, for instance when a large-size actuator is
used or when the pipe line vibrates heavily, supporting the
actuator is recommended.
OPEN OPEN
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
© 2012 Flow-Tek, Inc.
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
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 8 of 19
Installation and Maintenance Manual
Series 19 - Segmented Ball Valves
Date: Feb 2013 / Page 9 of 19
APPENDIX - A
CLASS 150/300
9. DISASSEMBLY AND REASSEMBLY
9.1 - Removing Actuator from Body
Refer to relevant actuator installation, operation, and
maintenance instructions, and proceed.
UÊSupport the actuator assembly before disconnecting it
from the body assembly.
UÊUnbolt mounting bracket from body and lift actuator
assembly off stem.
9.2 - Replacing the Seat
Refer to parts listing on pg. 12 & 13.
9.2.1 - Detaching the Seat
UÊThe valve must be removed from the pipeline.
Figure 3
UÊLubricate the flow port, seat (2) and O-ring (4) and the
seat spring (3) with a volatile lubricant. Make sure that
the lubricants are compatible with the medium.
UÊPlace the seat spring (3) on the seat (2).
UÊWhen the valve is opened, the ends of the spring must
be by the V-shaped opening.
UÊPlace a screwdriver on each visible spring angle one
after the other and knock the spring into the groove.
UÊTurn the segment (5) 180° clockwise and knock the rest
of the spring angles into the groove.
UÊUse a plastic spindle to ensure that the seat (2) is correctly
placed and can move freely.
Figure 7
9.3 - Dismantling the Valve - See Pg. 10 diagrams
UÊTurn the valve into the closed position.
CAUTION: Take special care to not damage the splined
end of stem (8) during disassembly.
UÊRemove the Segment
UÊRotate the segment (5) inside the body (1) so the non-
splined end of the segment (5) is toward the downstream
port of the body (1) and remove the segment (5) straight
out of the body (1) (See diagram on pg. 10)
CAUTION: Be extremely careful not to gall or scratch
the sealing surface of the segment (5) when removing
it from body (1). Scratches may later cause excessive
leakage and seal wear.
UÊRemove the bearings (6 and 7) and clean the bearing
spaces.
UÊRemove the seat (2) by pushing it evenly inside the
body (1)
9.4 Inspection of Removed Parts
UÊClean the removed parts
Figure 2
UÊTurn the segment (5) so that it does not touch the seat (2).
UÊ1” (DN25) – 4” (DN100) valves can be dismantled, as
described in “Dismantling the valve” section to make
the replacement of the seat easier.
UÊTap the seat (2) with a soft spindle all around the
circumference from the upstream side to make it fall
into the body (1).
UÊTurn the valve and lift the seat (2) from the body (1)
through the downstream flow port.
9.2.2 - Installing the Seat
Clean the flow port that houses the seat. Remove any burrs.
Round off the edges using a fine abrasive paper and clean
the flow port carefully, see below figure.
UÊPlace the seat O-ring (4) on to the seat (2).
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
Figure 4
UÊPlace the seat package into the body.
Figure 5
UÊCheck that the spring angles extend to the control face.
Figure 6
© 2012 Flow-Tek, Inc.
UÊRemove the gland retainer (15) by removing both packing
nuts (18) and washers (17). Removing the studs (16)
is not necessary
UÊRemove the post cover (20) by dismantling the nuts (23)
and washers (22) and then pushing with Screwdriver.
UÊDrive the stem pin (10) and end post pin (11) into the
center of the stem (8) and end post (9) until the outward
end of the pin clears the segment (5). Be careful not
to damage the stem or end post. The pins can then be
punched out of the stem and end post when they are
removed from the valve.
UÊCarefully remove post cover (20) and the gasket (19)
and finally the end post (9). (Inserting a bolt in the jack
screw hole, tapped in the post, will help in removing
the post.)
UÊRemove the stem (8), along with gland ring (14), packing
(13), and thrust washer (12) by pulling out through
packing box side.
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
UÊSee if the stem (8) and bearings (6 and 7) are damaged.
UÊCheck if the sealing surface of the segment (5) and the
seat (2) are damaged.
UÊIf necessary, replace the parts with new.
9.5 Assembly
UÊPut the bearings (6 and 7) in their places.
UÊPosition the segment (5) in the body (1) by lowering it,
splined hole first, into the back of the body (1). Rotate
the segment surface toward the front of the body so that
the splined hole is toward the packing box
CAUTION: Be extremely careful not to gall or scratch
the sealing surface of the segment (5) when replacing
it in the body (1). Scratches may later cause excessive
leakage and seal wear.
UÊInsert the stem (8) through the packing box bore, into
the splined hole of segment (5).
© 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 10 of 19
Installation and Maintenance Manual
Series 19 - Segmented Ball Valves
Date: Feb 2013 / Page 11 of 19
Both pins are driven inside before dismantling
Figure 8
UÊPosition the stem (8) so that the pin hole in the stem (8)
and Segment (5) are in alignment. (Stem flats on the
top and pin holes are perpendicular to each other).
Install the stem pin (10) and drive it firmly into place so
that half is in the Segment (5) and half in the stem (8).
UÊInsert the end post (9) through the out board end of the
body (1). End post has a half circle mark on the end.
Align this mark with the Segment (5). Install the end post
pin (11) and drive it firmly into place so that half is in
the Segment (5) and half is in the end post (9).
UÊInstall the post cover (20) with gasket (19) and tighten
the nuts (23) as per Table-3.
UÊSlide thrust washer (12), packing (13), and gland ring
(14) over the double D end of the stem (8) and into
packing box bore.
NOTE: Always use new packing whenever rebuilding
the packing box.
CAUTION: Since the sealing on V-ring packing takes
place at the feather edge, it is imperative to avoid
damage to that edge.
UÊReinstall the gland retainer (15), packing studs (16),
packing washers (17) and packing nuts (18), tighten
the packing nuts (18) just over finger-tight. Packing nuts
should be tightened as necessary to prevent stem leakage.
9.6 Remounting the Actuator
Before mounting an actuator on the valve body (1), verify
that the Segment (5) rotation matches the actuator rotation
and complies with the air failure requirements. Procedure for
mounting the actuator is as follows
UÊBolt the Bracket (24) on to the body, if it’s removed.
UÊSlide the entire actuator assembly onto the shaft. (Please
refer to the actuator IOM for necessary adjustments on
the assembling with valve for the lever adjustments for
the clamped lever designs etc.)
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
© 2012 Flow-Tek, Inc.
CAUTION: Do not over tighten packing. This can cause
excessive packing wear and high shaft friction, which
may retard shaft rotation.
UÊMount the Seat (2) as explained in “Installing the Seat
for Class 150 & 300 Design”
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
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 12 of 19
Installation and Maintenance Manual
Series 19 - Segmented Ball Valves
Date: Feb 2013 / Page 13 of 19
ITEM # Component
Figure 9 Figure 10
1 BODY
2 SEAT
3 SEAT SPRING
4 SEAT O-RING
5 SEGMENT
6 STEM BEARING
7 POST BEARING
8 STEM
9 END POST
10 STEM PIN
11 END POST PIN
12 THRUST WASHER
13 PACKING
14 GLAND RING
15 GLAND RETAINER
16 PACKING STUD
17 PACKING WASHER
18 PACKING NUT
19 GASKET
20 POST COVER
21 POST COVER STUD
22 POST COVER WASHER
23 POST COVER NUT
24 MOUNTING BRACKET
25 BRACKET WASHER
26 BRACKET SCREW
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8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
ITEM # Component
1 BODY
2 SEAT
3 SEAT SPRING
4 SEAT O-RING
5 SEGMENT
6 STEM BEARING
7 POST BEARING
8 STEM
9 END POST
10 STEM PIN
11 END POST PIN
12 THRUST WASHER
13 PACKING SET
ITEM # Component
14 GLAND RING
15 GLAND RETAINER
16 PACKING STUD
17 PACKING WASHER
18 PACKING NUT
19 GASKET
20 POST COVER
21 POST COVER STUD
22 POST COVER WASHER
23 POST COVER NUT
24 MOUNTING BRACKET
25 BRACKET WASHER
26 BRACKET SCREW
METAL SEAT SOFT SEAT
© 2012 Flow-Tek, Inc.
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
© 2012 Flow-Tek, Inc.
Installation and Maintenance Manual
Series 19 - Segmented Ball Valves
Date: Feb 2013 / Page 14 of 19
Installation and Maintenance Manual
Series 19 - Segmented Ball Valves
Date: Feb 2013 / Page 15 of 19
® ®
A Subsidiary of BRAY INTERNATIONAL, Inc. A Subsidiary of BRAY INTERNATIONAL, Inc.
FLOW-TEK, Inc. Tel: 832.912.2300
© 2012 Flow-Tek, Inc.
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
FLOW-TEK, Inc. Tel: 832.912.2300
© 2012 Flow-Tek, Inc.
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
11. DISASSEMBLY AND REASSEMBLY
11.1 Removing Actuator from Body
1. Refer to relevant actuator installation, operation, and
maintenance instructions, and proceed.
2. Support the actuator assembly before disconnecting it
from the body assembly.
3. Remove mounting bracket bolts from body and lift
actuator assembly off stem.
11.2 Dismantling the Valve
Refer to parts listing on pg. 18 & 19.
1. Turn the valve into the closed position and remove from
pipeline.
2. Place the valve on a flat surface with seat retainer (2A)
facing up.
3. Loosen the screwed-in seat retainer (2A) by turning it
counterclockwise and removing it from the body (1)
along with the retainer O-rings (4A, 4B). (A special
cross-wrench tool may be ordered from the factory).
4. Once the seat retainer is removed, remove the seat (2),
wave springs (3) and shims (3A) along with the seat
O-ring (4).
5. Remove the gland retainer (15) by removing both
packing nuts (18) (Removing the packing studs (16) is
not necessary).
6. Remove the post cover (20) by dismantling the post cover
nuts (23) and pushing with Screwdriver.
7. Drive both the stem and end post pins(10, 11) into the
center of the stem and post until the outward end of the
pin clears the segment (5). Be careful not to damage the
stem or post. The pins can then be punched out of the
stem and post when they are removed from the valve.
Carefully remove post cove (20) and the gasket (19) and
finally the post (9). (Inserting a bolt in the jack screw
hole, tapped in the post, will help in removing the post).
8. Remove the stem (8) by pushing it out through the post
end of the body.
CAUTION: Take special care to not damage the splined
end of valve stem during disassembly.
Figure 11
Removing the retainer with special tool
Both pins are driven inside before dismantling
9. Rotate the segment (5) inside the body so the non-splined end of the
segment is toward the downstream port of the valve and remove the
segment straight out of the body.
CAUTION: Be extremely careful not to gall or scratch the sealing
surface of the segment when removing it from body. Scratches may
later cause excessive leakage and seal wear.
APPENDIX - B
CLASS 600
Figure 12
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 16 of 19
Installation and Maintenance Manual
Series 19 - Segmented Ball Valves
Date: Feb 2013 / Page 17 of 19
12. Push packing (13) and bearings (6, 7) out of the body
using a soft metal (bronze) dowel with the appropriate
diameter. Push packing out of the body from the center
of the valve.
11.3 - Reassembling the Valve
To r ea ssemble the b od y subassemb ly, ref er t o the P ar t s D iagram.
1. Clean all parts and replace all O-rings and soft seals.
2. Check the segment (5) sealing surface to make sure it is
smooth and free of scoring and scratches.
CAUTION: Damaged or dirty seal surfaces can cause
excessive seat wear and high torque requirements.
Damaged segment should be replaced.
3. Inspect the stem (8) and end post (9) for scratches or
galled surfaces. If damage exists, replace the stem or
contact the factory representative.
NOTE: Segment and stem are interchangeable. Replacing
the segment does not require replacing the stem.
Segment (5) are in alignment. (Stem (8) across flat on
the top and pin holes are perpendicular to each other).
Install the stem pin (10) and drive it firmly into place so
that half is in the Segment (5) and half in the stem (8).
8. Insert the end post (9) into the body. Posts have a half
circle mark on the end. Align this mark with the Segment.
Install the end post pin (11) and drive it firmly into place
so that half is in the Segment and half is in the post.
9. Install the post cover (20) with gasket (19), tighten the
nuts (23) to the required torque per Table-3.
10. Slide thrust washer (12), packing spacer (13A), packing
(13), and gland ring (14) over the double D end of the
stem and into packing box bore.
NOTE: Always use new packing whenever rebuilding
the packing box.
CAUTION: Since the sealing on V-ring packing takes
place at the feather edge, it is imperative to avoid
damage to that edge.
15. Lubricate the seat retainer O-ring (4A) and install into the
Seat Retainer (2A).
16. Lubricate the mating surfaces between the seat (2) and
seat retainer (2A).
17. Place Wave springs (3) & shim (3A) set in the seat
retainer.
18. Place the seat (2) into seat retainer (2A), so the seat is
resting on the shims and wave springs.
19. For metal seat, lubricate the contact surfaces between
the seat and segment.
20. Replace the O-rings (4B) in the seat retainer (2A) (except
on high temperature valves, which do not use O-rings).
Refer to Figure 13. Lubricate the seat retainer threads
and O-rings and reinstall the retainer in the body. Torque
the seat retainer according to Table 2.
21. After the seat retainer is tightened, tighten the packing
nuts (18) just over finger-tight. Packing nuts (18) should
be tightened as necessary to prevent stem leakage.
CAUTION: Do not over tighten packing. This can cause
excessive packing wear and high stem friction, which
may retard stem rotation.
11.4 Remounting the Actuator
1. Before mounting an actuator on the valve body, verify
that the Segment rotation matches the actuator rotation
and complies with the air/signal failure requirements.
Procedure for mounting the actuator is as follows.
2. Bolt the Bracket on to the body, if it is removed.
3. Slide the entire actuator assembly onto the stem by
ensuring the desired actuator orientation. (Please refer
to the actuator IOM for necessary adjustments on the
assembling with valve).
4. Tighten the actuator mounting bolts.
5. Install valve in pipe line as outlined in Section 4.
4. Using a press to install new bearings in the body is
recommended. (Optional post/bearing tool is available
from the factory - See Table 4 on page 17) when
correctly installed, the ends of the body bearings (6, 7)
should be flush with the inside of the body.
5. Position the segment (5) in the body by lowering it,
splined hole first, into the back of the body. Rotate the
segment surface toward the front of the body so that the
splined hole is toward the packing box.
CAUTION: Be extremely careful not to gall or scratch
the sealing surface of the segment when replacing it in
the body. Scratches may later cause excessive leakage
and seal wear.
6. Insert the stem (8) through the post end of body and through
the splined hole of the segment into the packing box.
7. Position the stem so that the pin hole in the stem (8) and
11. Reinstall the gland retainer (15) and packing nuts (18)
and leave loose.
CAUTION: Do not over tighten packing. This can cause
excessive packing wear and stem friction, which may
impede stem rotation.
12. Place the valve on a flat surface with the threaded
(retainer) port facing up and pull the stem (8) toward
the actuator until it is fully against the thrust washer (12).
13. Make certain the segment surface facing up and
position the segment as close as possible in the center
of the body‘s inside diameter. (The pinned connection
between the segment and stem is not a tight connection.
The design includes a considerable amount of axial play
between the segment and stem.)
14. Lubricate the seat O-ring (4) and install into the seat (2).
Table 2: Retainer Torques
Valve Size
(inches)
Torque Value
(N-m)
1, 1.5, 2 200-240
3 340-410
4, 6 750-820
Table 3: Lubricated Screw Tightening Torques
Stud Size
A193-B7
& B7M
A193-B8
1/4”-20 UNC 5 Nm 2 Nm
5/16”-18 UNC 10 Nm 4.5 Nm
3/8”-16 UNC 18 Nm 8 Nm
Table 4: Assembly Tools (Optional upon request)
Valve Size Retainer Tool Part No.
Stem Bearing Press
Tool Part No.
Post Bearing Press
Tool Part No.
1” (DN 25) 9N-0000-00466 9N-0000-00471 9N-0000-00476
1.5” (DN 40) 9N-0000-00467 9N-0000-00472 9N-0000-00477
2” (DN 50) 9N-0000-00468 9N-0000-00473 9N-0000-00478
3” (DN 80) 9N-0000-00445 9N-0000-00448 9N-0000-00449
4” (DN 100) 9N-0000-00469 9N-0000-00474 9N-0000-00479
6” (DN 150) 9N-0000-00470 9N-0000-00475 9N-0000-00480
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
© 2012 Flow-Tek, Inc.
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
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.
® ®
ITEM # Component
1 BODY
2 SEAT
2A SEAT RETAINER
3 SEAT SPRING
3A SEAT SHIM
4 SEAT O-RING
4A O-RING (SEAT-RETAINER)
4B O-RING (BODY-RETAINER)
5 SEGMENT
6 STEM BEARING
7 POST BEARING
8 STEM
9 END POST
10 STEM PIN
11 END POST PIN
12 THRUST WASHER
13 PACKING SET
13A PACKING SPACER
14 GLAND RING
15 GLAND RETAINER
16 PACKING STUD
17 PACKING WASHER
18 PACKING NUT
19 GASKET
20 POST COVER
21 POST COVER STUD
22 POST COVER WASHER
23 POST COVER NUT
24 MOUNTING BRACKET
25 BRACKET WASHER
26 BRACKET SCREW
Figure 13 Figure 14
1 1
2A 2A
2
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
Series 19 - Segmented Ball Valves
Date: Feb 2013 / Page 18 of 19
Metal SeatSoft Seat
© 2012 Flow-Tek, Inc.
ITEM # Component
1 BODY
2 SEAT
2A SEAT RETAINER
3 SEAT SPRING
3A SEAT SHIM
4 SEAT O-RING
4A O-RING (SEAT-RETAINER)
4B O-RING (BODY-RETAINER)
2
55
5 SEGMENT
6 STEM BEARING
7 POST BEARING
8 STEM
9 END POST
10 STEM PIN
11 END POST PIN
12 THRUST WASHER
FLOW-TEK, Inc. Tel: 832.912.2300
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
Installation and Maintenance Manual
Series 19 - Segmented Ball Valves
Date: Feb 2013 / Page 19 of 19
ITEM # Component
13 PACKING SET
13A PACKING SPACER
14 GLAND RING
15 GLAND RETAINER
16 PACKING STUD
17 PACKING WASHER
18 PACKING NUT
19 GASKET
20 POST COVER
21 POST COVER STUD
22 POST COVER WASHER
23 POST COVER NUT
24 MOUNTING BRACKET
25 BRACKET WASHER
26 BRACKET SCREW
© 2012 Flow-Tek, Inc.
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