Bray 5000, 6000 User Manual

A Subsidiary of BRAY INTERNATIONAL, Inc.

5000/6000 SERIES BALL VALVES

INSTALLATION - MAINTENANCE MANUAL

Installation and Maintenance Manual

®

Series 5000 and 6000 Ball Valves

Date: August 2011 / Page 1 of 6

DESIGN

The design features three piece construction and a “free

B. VALVE IN CLOSED POSITION

The handle is perpendicular to the pipeline.
floating” ball allowing ease of maintenance without
special tools.

Valves with actuators should be checked for actuator

-valve alignment. Misalignment will result in high

The ball is not fixed, but is free to move with the line

operational torque and damage to valve stem and seals.
pressure. These valves are capable of tight shut-off
with flow in either direction regardless of the position
of the valve in the line.

STEM SEAL ADJUSTMENT:

Stem seal leakage may be corrected without disassembly

by tightening the packing gland nut gradually until the
The downstream seat, opposite the pressurized side of

a closed valve, must carry the load exerted by the line
pressure on the ball, while the upstream seat is subject

leakage stops. If the leakage continues after adjustment

or the valve operating torque becomes excessive, the

seals are worn and should be replaced.
to little load or wear. For this reason, it is sometimes

possible to increase useful seat life by turning the valve
end-for-end in the pipeline.

1. USE:

3. GENERAL INFORMATION FOR ON-SITE

INSTALLATION:

Please read completely and understand all instructions

provided prior to beginning installation or maintenance.
The valve should be inspected regularly as part of

a preventative maintenance program. Flow-Tek’s
recommended pressure, temperature and corrosion
limits should be followed to ensure a long service life.

The pipes must be flushed clean of dirt, burrs, and

welding residues before installing the valve, or the

seats and ball surface will be damaged.
During shipment, storage, and in operation, the valve
should be fully open or fully closed (“open” is preferred
for shipping and storage). Do not use in throttling
service without investigating the consequences of flow
and pressure conditions to the valve.

WARNING: Before installing this equipment, confirm
that it is suitable for the intended service.

The identifications 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 ensure that
acceptable limits are not exceeded.

2. OPERATION:

Operation of the valve is by turning the handle a 1/4
turn (90 degrees). CW to close, CCW to open.

A. VALVE OPEN POSITlON

The handle is parallel with the pipeline.

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

The valve may be installed in any position on the

pipeline. Care should be taken to insure that actuator

misalignment does not occur or the valve may experience

premature failure. The actuator may require support to

avoid binding the valve stem.

The pipe ends must be correctly aligned and spaced

as to not induce stresses in the valve.

As shipped from the factory, Valves may contain non-

silicone lubricant. This is for break-in and may be

removed by solvent washing, if it is undesirable in a

particular application.

INSTALLATION OF THREADED END VALVES:

1. The use of a thread sealant is recommended; Use
conventional sealant, such as hemp core, Teflon, etc;

2. Do not tighten by applying torque to the opposite
end cap or other valve components. Apply a
wrench only to the hex/octagon nearest the valve

© 2011 Flow-Tek, Inc.

A Subsidiary of BRAY INTERNATIONAL, Inc.

Installation and Maintenance Manual

®

Series 5000 and 6000 Ball Valves

Date: August 2011 / Page 2 of 6

end being tightened. Tightening by using the valve
body, handle or the opposite end cap can seriously
damage the valve; Use a wrench on both the second
end cap and pipe to avoid applying torque to the
body through the bolting.

3. In some applications, threaded end valves may be
back-welded on site. Use caution. Do not overheat the
valve body. Confirm that the end cap bolt holes are
aligned with the body screw holes on both ends and
that the end caps are parallel and correctly spaced
to fit the valve body before re-assembly or back
welding. Make up both of the threaded connections
normally and then remove the body assembly as
described below for weld-end connections before
back welding the threaded connection.

4. Do not use the body screws to pull the pipe ends
together to correct misalignment.

INSTALLATION OF WELD-END VALVES

Insure that weld procedures are implemented that are
compatible with the materials used.

1. Tack weld the assembled valve to the pipe at four
points on both end caps.

2. With the valve in open position, (the valve is in the
open position when the handle is parallel to the axis
of the valve and pipe), loosen all body bolts, take
the body out.

then replace all bolts and cross tighten.

10. (See table 1. Tightening torques for end cap screws).

4. DISASSEMBLY & CLEANING PROCEDURES:

CAUTION: Line must be depressurized before disassembly.
Valve should be cycled after draining the system to relieve
any pressure trapped in the valve body cavity. Ball valves
can trap pressurized media when closed. Flush line with
the valve 1/2 open to remove hazardous media. If the
valve has been used to control hazardous media, it must
be decontaminated before disassembly.

WARNING: DO NOT attempt to remove packing
components or any other valve parts while line is under
pressure!

CAUTION: Properly support the valve before removing
or loosening any body bolts. The larger sizes are heavy
and may cause injury if allowed to swing or fall freely.

Remove the actuation air and power connections and
confirm that there is no stored energy in the actuation such
as compressed springs or trapped air before beginning.
Stored energy devices can cause serious injury if the
energy is released without warning.

DISASSEMBLY FOR STEM AND SEAL SERVICE:

1. It is not necessary to remove the flanges from the
pipeline. Removing the actuation and controls may
make service easier.

3. Turn the handle in the half open position. Remove the
seats and body gaskets.

4. Turn handle in closed position and remove ball.

5. Place all removed parts in a clean and secure place.

6. Replace the body and all bolts and tighten them slightly.
This operation is very important, so that the body and
end caps remain perfectly parallel, thus preventing any
leakage at the body joint after welding.

7. Finish welding both end caps onto the pipe. Use
temperature indicating crayons to insure that the
body temperature doesn’t exceed 200°F in the area

2. Remove one of the upper body bolts and loosen the
remaining bolts. The center body section containing the
ball and seals will swing out for service, leaving the end
caps in place on the pipe ends. See illustration below.

3. To completely remove the valve from the pipeline,
remove the remaining upper body bolt and the body
will lift free. Gently support the body in a vise to
complete the remainder of the disassembly. To avoid
damage to the seal surfaces, hold the body horizontally
across its diameter, not across the end faces.

4. Remove the seats and body seals.

of the neck or component/seal damage may occur.

8. When cool, remove the body, clean the end caps,
and reassemble per the instructions given below.

9. Place the bodies between the two end connections;

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

5. Remove the handle nut and handle. Remove the
gland nut.

6. To remove the ball, rotate the stem so the ball is fully

© 2011 Flow-Tek, Inc.

A Subsidiary of BRAY INTERNATIONAL, Inc.

Installation and Maintenance Manual

®

Series 5000 and 6000 Ball Valves

Date: August 2011 / Page 3 of 6

closed. Lift the ball from body, using a strap and lift
device if necessary.

NOTE: Extreme caution should be taken to avoid
damage to the ball.

7. The stem must be removed from inside the body - a
tap on the top of the stem should loosen it. The thrust
washer should come out with the stem. Then remove
the stem packing.

Disassembly for servicing seats and stem seals may be
performed without removing the end flanges from the
pipeline.

This feature allows the removal of the valve from service
without disturbing piping connections.

5. VISUAL INSPECTION:

Clean and inspect all metal parts for damage and wear.
It is not necessary to replace the ball and stem unless
the sealing surfaces have been damaged by abrasion
or corrosion. Replacement of all soft parts is strongly
recommended whenever the valve is disassembled for
reconditioning. This is the surest protection against
leakage. The replacement parts can he ordered in kit form.

NOTE: The valve may be assembled and operated dry
where no lubricants are allowed in the system; however,
a light lubrication of mating parts will aid in assembly
and reduce initial operating torque. Any lubricant used
must be compatible with the intended line fluid.

6. RE-ASSEMBLY:

Refer to the illustrations on page 4 and 5.

1. Hold the body horizontally in a vise firmly enough
that it will not move but do not crush it.

2. Put thrust washer (12) on valve stem (5) and slide
the stem into the stem hole from inside the valve
body (1);

3. Slide the stem packing components (14) onto the stem
until they are bottomed in the stem hole;

4. Install the packing gland nut (15) into the body over
the stem and packing. Tighten finger tight.

5. Turn the stem until the upper stem flat is perpendicular
to the valve centerline (closed, so that the ball can
fit onto the stem):

6. Install the ball (3) inside the valve body. The lower
stem flats will fit into the slot in the ball;

7. Turn the stem so that the ball is in the open position
(the ball will not fall out of the valve);

8. Install the seats (4) and body seals into the body
ends. Make sure the spherical curvature side of the
seat will face the ball;

9. Lift the valve into position between the flanges in the
pipeline. Use caution that the seal components do
not shift position or fall out.

10. Install the end cap bolts (9), lock washers (7) and
nuts (8). Alternately cross tighten all nuts gradually
up to the values indicated in Table 1. Using a torque
wrench is recommended.

11. Install and secure the handle (25) with the handle
washer (19) and handle nut (26).

12. Cycle the valve slowly several times. Cycling the
valve slowly will insure that the seats will align with
and conform to the ball. A fast turning motion may
damage the seats before they have a chance to
form the proper seal:

Refer to the instructions given in section 2, above, to
re-commission the valve after installation.

For automated installations, follow the instructions
provided with actuation instrumentation to correctly
set up and recalibrate the installation.

Table 1 - Tightening torques for end cap nuts

VALVE SIZE 1/4” 3/8” 1/2” 3/4” 1” 1 -1/4” 1-1/2” 2” 2-1/2” 3” 4”

NutTorque (lb-in)
(Lb-ft)

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

70 70 155 155 155 300 300

25 25 43 58 83 83

© 2011 Flow-Tek, Inc.

A Subsidiary of BRAY INTERNATIONAL, Inc.

COMPONENTS

Item Name Qty.

1 Body 1
2 End Cap 2
3 Ball 1
4 Seat 2
5 Stem 1
6 Body Seal 1
7 Washer *
8 Body Nut *
9 Body Bolt / Stud **
12 Thrust Washer 1
14 Stem Packing 1
15 Gland Nut 1
19 Handle Washer 1
23 Stop Set Sleeve 1
24 Stop Bolt 1
25 Handle 1
26 Handle Nut 2
28 Handle Sleeve 1
29 Locking Device 1

Number of Nuts & Lock Washers:

*

1/4”– 2” Valves ...... 4

2-1/2”– 3” Valves .... 8

4” Valves ................ 12

Number of Body Bolts or Studs:

**

1/4”– 2” .........4 (Bolts)

2-1/2”– 3” ........4 (Studs)

4” Valves ..........6 (Studs)

®

1/4” - 2” Valves

12

5

26

19

15

14

Installation and Maintenance Manual

Series 5000 and 6000 Ball Valves

Date: August 2011 / Page 4 of 6

28

25

29

24

23

7

2

6

4

8

1

3

4

6

2

9

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

© 2011 Flow-Tek, Inc.

A Subsidiary of BRAY INTERNATIONAL, Inc.

2 1/2” - 4” Valves

Installation and Maintenance Manual

®

Series 5000 and 6000 Ball Valves

Date: August 2011 / Page 5 of 6

NEED OTHER

EXPLODED

VIEWS

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

© 2011 Flow-Tek, Inc.

A Subsidiary of BRAY INTERNATIONAL, Inc.

Installation and Maintenance Manual

®

Series 5000 and 6000 Ball Valves

Date: August 2011 / Page 6 of 6

8. Short and Long Term Storage:

Short term:

1. Short term storage is defined as storage of
products and equipment to be used in the
construction of a project for periods of one to
three months.

2. Ball valves should remain in the original
shipping containers be placed on pallets
of wood or other suitable materials. End
protectors should remain on the valve ends to
prevent the entrance of dirt.

3. Valves should be stored in the open position
to protect the ball and seats.

4. Storage of ball valves can be in an open
uncovered area provided provisions are
made for inclement weather such as tarps or
sheeting. Valves with electric actuators shall be
stored under cover until ready for installation.

Long term:

1. Long term storage is storage of products and/
or equipment for periods of three months or
more.

2. Valves should be stored in the open position
to protect the ball and seats.

3. Ball valves should remain in the original
shipping containers placed on pallets of
wood or other suitable materials and stored
indoors. End protectors should remain on the
valve ends to prevent the entrance of dirt.
The storage environment should be dry and
not have severe swings in temperature and
humidity.

9. Safety Summary

1. Read completely and understand all
instructions provided prior to beginning
installation or maintenance.

2. Follow all instructions as described using the
correct tools for the job.

3. Before installing this equipment, confirm that
it is suitable for the intended service. The
identifications tags describe the maximum
allowable service conditions for this product.

4. Be sure that the installation is protected by
appropriate pressure control and safety
devices to ensure that acceptable limits are
not exceeded.

5. Remove actuation air and power connections
and confirm that there is no stored energy in
the actuation such as compressed springs or
trapped air before beginning. Stored energy
devices can cause serious injury if the energy
is released without warning.

6. Confirm that line pressure has been removed
and that there is no pressure trapped within
the valve prior to beginning service. Do not
attempt to remove any packing components or
other fittings before confirming that pressure
has been completely removed!

7. Do not begin service work without proper
tools and protective safety measures.

8. The work area should be clear of obstructions
and other safety hazards.

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

© 2011 Flow-Tek, Inc.